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Service Manual

Overview of electrical symbols 8.01.1 A 900 C-ZW EDC (F.D.) 37728-

Notes regarding the electrical system 8.02.1 A 900 C-ZW EDC (F.D.) 37728-

Arrangement of components 8.12.1 A 900 C-ZW EDC (F.D.) 37728-

Electical system with installation kits and 8.34.1 A 900 C-ZW EDC (F.D.) 37728-
wiring harnesses

Electical system with installation kits and 8.36.1 A 900 C-ZW EDC (F.D.) 51093-
wiring harnesses

Electical system with installation kits and 8.38.1 A 900 C-ZW EDC (F.D.) 63563-
wiring harnesses

Operating symbols on the operator's platform 8.44.1 A 900 C-ZW EDC (F.D.) 37728-

Data logger 8.50.1 A 900 C-ZW EDC (F.D.) 51093-

Operator ID code 8.52.1 A 900 C-ZW EDC (F.D.) 51093-

Electronically controlled working and travelling 8.60.1 A 900 C-ZW EDC (F.D.) 37728-
pedal

Calibration of the electric foot pedals 8.62.1 A 900 C-ZW EDC (F.D.) 37728-

ZW monitoring display (TDS01) 8.70.1 A 900 C-ZW EDC (F.D.) 37728-

Monitoring display from V.4.7.2 8.72.1 A 900 C-ZW EDC (F.D.) 37728-

Control panel 8.79.1 A 900 C-ZW EDC (F.D.) 37728-

Error code list 8.80.1 A 900 C-ZW EDC (F.D.) 37728-

Emergency actuation (emergency operation) 8.81.1 A 900 C-ZW EDC (F.D.) 37728-
LHB/en/Edition: 10/2013

Slip ring rotary connection 8.82.1 A 900 C-ZW EDC (F.D.) 37728-

Resistance measurement 8.90.1 A 900 C-ZW EDC (F.D.) 37728-

MJFCIFSS
MJFCIFSS
Service Manual

LHB/en/Edition: 10/2013
Service Manual Overview of electrical symbols
Overview of symbols

A new software package has been used for the drawing of the electrical diagrams of machines from
models A 900 C 24677 and A 904 C 30580 .
The symbols, their designation and meaning are shown in the table below for a better understanding
of the diagrams.

Input (assembly) Output (assembly)

NC contact, touch-sensitive NO contact, touch-sensitive

Speed sensor, 2-pin Angular speed encoder


Electrical accelerator pedal

Speed sensor, 2-pin Pressure switch, NC contact,


2-pin

Pressure switch changeover Pressure switch with 4-20 mA


contact current output
LHB/en/Edition: 11/2007

Pressure switch with 0-5 V Pressure switch with


voltage output switching output NC/NO
contact PNP

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Overview of electrical symbols Service Manual
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Level switch, 2-pin with Level switch, 3-pin with


switching output switching output (+)

Light switch with changing Inductive proximity switch NC


light, switching to dark contact PNP

Capacitive proximity switch Inclination sensor 4-20mA


NO contact NPN current output

Level switch, tank sensor Level switch, tank sensor


+ mechanical NC contact

Thermal NC contact Thermal NO contact with


monitoring

Detector with switching Angle sensor including S/A


output converter

Loudspeaker Main light with position light


LHB/en/Edition: 11/2007

Roof-mounted light Beacon

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Service Manual Overview of electrical symbols
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Rear light with brake/tail light Heating element


and indicator

Heating element with thermal Heater flange


switch (NC contact)

Cigarette lighter Semiconductor fuse


(poly-switch)

General fuse Automatic cut-out


Automatic protective power
switch

Battery Alternator
Generator

Lamp / general Horn

Buzzer Relay contact


Double NO contact
LHB/en/Edition: 11/2007

Relay contact Relay contact


NC contact NO contact

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Overview of electrical symbols Service Manual
Overview of symbols

Relay contact Contact mirror relay


Changeover contact

Electronic indicator relay Relay with 1 changeover


contact
Coil reset with diode

Coil (without reset) Coil with shut-down delay


(without reset)

Coil with switch-on delay Time relay


(without reset) (with drop-out delay)

Time relay
(with pick-up delay)

Coil with reset Coil with progress relay


Resistor (VDR) (surge relay)

Coil with suppressor diode Coil / inductivity


(reset with diode)
LHB/en/Edition: 11/2007

Starter DC motor with


blower

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Service Manual Overview of electrical symbols
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DC motor with blower, speed DC motor


adjustable

DC motor / pump DC motor / pump


Windscreen washer system

Windscreen wiper Servo motor

Slip ring contact Operating hour meter

Operating hour meter Speed meter

Backlit fuel indicator Backlit temperature indicator

Backlit clock Resistor


LHB/en/Edition: 11/2007

Glow plug Resistor, negative


temperature coefficient hot
conductor

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Potentiometer Resistor, positive


temperature coefficient cold
conductor

Resistor, varistor Variable resistor


(voltage-dependent resistor) General

Multi-position switch Battery main switch, 1-pin,


4 positions actuator removable in
position "0"

Battery main switch, 1-pin, Rotary switch with 3 positions


actuator removable in (NC-off-NO)
position "1"

Hot start switch

NC auxiliary contact NO auxiliary contact

Interval relay Steering column switch with


horn, indicator
LHB/en/Edition: 11/2007

Mechanical NC limit switch Mechanical NC/NO limit


switch

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Mechanical NO limit switch Mechanical changeover


contact limit switch for slip
ring

Mechanical limit switch Button 1 NC contact, 1 NO


2 NO contacts contact
Indicator light

Button NO contact / general Button NC contact / general

Hazard light switch with Ignition switch


search and function lighting (without pre-heating)

SWF switch with 2 SWF switch with 1


changeover contacts, lighting changeover contact, lighting
and actuation lock

DC/DC converter Diode


(direct current converter)

LED LED
flashing
LHB/en/Edition: 11/2007

Z diode Amplifier

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Amplifier with LED for input/ NPN transistor


output, fault

PNP transistor Aerial

Terminal (disconnectable) Potential bolt (screwed


connections)

Potential point Cable kit view for


(plug connections) "stripped"

M10 ground bolt (slave)


M10 ground bolt (master symbol)

Cable kit view for Socket contact


"wire end ferrule"

Socket connection Metering pump


with terminals
LHB/en/Edition: 11/2007

Valve Valve with reset (diode)

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Valve with reset Valve with reset


(interconnected Z diodes) (varistor)

Twisting of wires Revision note

Revision note Cable kit - note

Tightness symbol Cable kit - note

Cable kit - note Cable kit - note

Cable kit - note Cable kit - note

Standard plug connection Device plug


(plug-plug) (device/valve plug)
LHB/en/Edition: 11/2007

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Forced wiring Field, housing, assembly

Potential arrow target directly Potential arrow source


from fuse

Potential arrow target Potential arrow source

Potential arrow target Unassigned cross references


directly to earth Source documents

Unassigned cross references


Target documents

LHB/en/Edition: 11/2007

Fig. 1 General equipment

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Service Manual Overview of electrical symbols
Overview of symbols

Unit code Connecting pin 2 (-) supply


Location sign Connecting pin 3 (output)
Equipment code (EC) Colour of exposed wire
Engine oil pressure Output: switching contact can be PNP or
NPN
(current output, voltage output)
Function text Output: NO contact
Type of converter p=pressure>electric Technical data
unit
Connecting pin 1 (+) supply

Fig. 2 Master-slave relationship in relay

Slave (relay coil) Cross reference to slave on coordinate


K16
Cross reference to master symbol on Cross reference to master on coordinate
coordinate L16 L16
Cross reference to slave on coordinate NO contact (slave)
K17
Master symbol
LHB/en/Edition: 11/2007

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Fig. 3 Overview for the connection of the display (example)


LHB/en/Edition: 11/2007

Equipment code (EC) Module name


Physical address Input/output address
Cross reference to slave (input/output) Module number
Note re. (input/output) Pin name
Example Plug name
Cross reference to master Input/output address (for programmers /
software)

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Service Manual Notes regarding the electrical system
General notes regarding the electrical system

Risk of injury from sparks.


Avoid sparks and naked flames when charging batteries or working on them.
Always wear goggles and protective gloves.

Regularly inspect the electrical system of the machine for defects.


Identify the cause for blown fuses and broken incandescent lamps, eliminate it and replace the
fuse or the lamp.
Only use original fuses with the correct amperage.
Defects such as loose connections, chaffed cables or poorly fixed clamps must be replaced
without delay.
Do not work on powered components.
When carrying out work on medium or high voltage components, shut down the power supply and
connect the supply cable to the ground to discharge any residual energy.
Check all disconnected parts to ensure that they are fully de-energized, and then ground and
short-circuit them. Insulate adjacent powered parts.
Only qualified electricians should attempt carrying out work on high-voltage assemblies.
Before carrying out any work on the electrical system or carrying out electric arc welding work on
the machine, disconnect the batteries.

Risk of injury from sparks.


Disconnect the negative pole (-) first and reconnect it last.

When switched off (position 0, see Fig. 1), the battery main switch disconnects the electric contact
(vehicle mass) to all connected components.

After switching off the diesel engine, the engine control unit remains activated for approx.
LHB/en/Edition: 02/2009

40 seconds in order to save system data.


Do not interrupt the saving process of the engine control unit. Switching off the battery main switch
during saving might result in the loss of data so that the diesel engine cannot be restarted.
After switching off the diesel engine, wait for approx. 1 minute before switching off the battery
main switch to ensure that the saving process is properly completed.

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Notes regarding the electrical system Service Manual
Battery

Special care is required in connection with machines with built-in auxiliary heater.
Only switch off the battery main switch after the afterrun time of the auxiliary heater has lapsed.

Fig. 1 Battery main switch

Before carrying out any work on the electrical system or performing welding work on the machine,
set the battery main switch to position (off).
Before washing the machine, cover the electrical devices (in particular the alternator, generator,
cabling, electrical components and measurement transducers) so that they are protected against
LHB/en/Edition: 02/2009

splashing water.
When cleaning the engine with a water or steam jet, ensure that the measurement transducers
(e.g. oil pressure switches) are not exposed to a direct water or steam jet.
Otherwise, water might penetrate the devices causing corrosion of the contacts, leading to
measuring failures.
Oil pressure switches cannot be designed as water-tight units due to the need for diaphragm
ventilation.

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Service Manual Notes regarding the electrical system
Battery

The battery might discharge itself during prolonged standstills.


Prior to prolonged standstills, set the battery main switch to position (off).

To ensure that the batteries work properly at all times, keep them clean.
Regularly clean the pole heads and cable terminals and apply a thick layer of acid-proof grease,
see Fig. 2.

Kinked rubber hoses of the central gas release system lead to a higher risk of explosion!
The hydrogen produced in the battery may not collect in the battery box and must be released from
the enclosure through rubber hoses. When installing the hoses of the central gas release system,
ensure that they are not kinked.
Regularly check the hoses for damage, especially after installation of the battery, see Fig. 2.

The liquid level in the cells should be about 10 to 15 mm above the upper edge of the plate. If topping
up is necessary, add only distilled water.

Fig. 2 Battery care

From time to time, check the acid density using a battery tester .

If the battery tester shows a lower value, the battery is discharged to some degree and might need
to be recharged.
LHB/en/Edition: 02/2009

When connecting an external battery, there is a risk of increased gas production in older batteries.
When jumpstarting the machine, always wear goggles and protective gloves. Ensure that there
are no naked flames near the battery and prevent sparks in the vicinity of the discharged vehicle
battery. RISK OF EXPLOSION!
Use only jump leads with adequate cross-section. Strictly adhere to the proper jumpstart
procedures.

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Notes regarding the electrical system Service Manual
Slip ring body (optional equipment)

First connect the cable to the positive pole (+) of the discharged battery and then to the positive
pole (+) of the external battery.
Then connect the second cable to the negative pole (-) of the discharged battery and subsequently
to the negative pole (-) of the external battery.
Start the engine as described above.

Before disconnecting the jump lead, set the diesel engine of the jump-started machine to the
lower idle speed.
For safety reasons, switch off all large consumers such as working headlights, uppercarriage
illumination, etc. to prevent overvoltage. Otherwise, there is a risk of damage to the electronic
equipment.

First disconnect the cable from the negative pole (-) of the external battery and then from the
negative pole (-) of the discharged battery.
Then disconnect the second cable from the positive pole (+) of the external battery and
subsequently from the positive pole (+) of the discharged battery.
Test the electrical functions of the machine.
For instructions regarding battery care and maintenance, see chapter "Battery care".

Fig. 3 Slip ring body

Slip ring bodies are easily damaged by humidity, as oxide layers might form on the conducting
surfaces, impairing electrical conductivity. As a consequence, the electrical consumers in the
undercarriage are insufficiently supplied with power, which can result in malfunctions.
To prevent this, we recommend carrying out the following tasks every 500 operating hours:
Unscrew the lock nuts .
LHB/en/Edition: 02/2009

Remove the slip ring housing .


Remove any oxidation from the slip ring body (use cleaning spray, if necessary).
Replace damaged (corroded) fork terminals.
Apply Cramolin contact spray to all slip ring elements.
Replace the housing .
Secure the housing with the lock nuts and tighten them with the same torque.

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Service Manual Arrangement of components
Control elements

Fig. 1 Operator's platform

Radio Engine failure indicator light


Electronics / BST excavator control Hour meter
LHB/en/Edition: 11/2010

Emergency control Ignition switch


Printed circuit board ESP01 Signal switch / horn
Auxiliary board / kits Safety switch
Printed circuit board ESP02 Emergency start / emergency operation
switch
Signalling buzzer / warning Switch / high/low speed
Signalling buzzer / parking brake Switch / emergency operation
Emergency operation indicator light Voltage transformer

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Arrangement of components Service Manual
Control elements

Fig. 2 Operator's view: electrical control elements

Radio Magnet ON/OFF (optional equipment)


Display / ZW console Push button / turn grapple right
Keyboard ZW control console Push button / changeover grapple -
tamping pick
Cigarette lighter Travel direction switch
Monitoring display Steering column switch / turn signal - horn
Operating hour meter Switch / hazard light
LHB/en/Edition: 11/2010

Ignition switch Mini clock - auxiliary heater


Excavator keyboard Rocker switch / special function activation
Push button / turn grapple left 12 V socket (optional equipment)
Push button / turn grapple right Brake switch - railcar brake system
Push button / traction increase A/C control panel

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Service Manual Arrangement of components
H1 Monitoring display

Fig. 3 Monitoring display

Analog indicator Indicator light / flow indicator


Check display LED indicator / coolant temperature
Main screen Warning range / coolant temperature (red
LED)
Menu control screen LED indicator / fuel reserve
Indicator light / motor oil pressure Reserve indicator / fuel level
red LED
Indicator light / battery charging Screen button / BACK
Indicator light / travel direction indicator Screen button / DOWN
Indicator light / parking brake Screen button / UP
LHB/en/Edition: 11/2010

Indicator light / accumulator pressure Screen button / MENU and confirmation


(working brake) (OK)

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S2 Keyboard

Fig. 4 Control console

Display / motor speed Switch / special function 3


Changeover kit
Switch / work headlight Switch / special function 4
Switch / windscreen washer system Switch / beacon
Switch / windscreen wiper Switch / off-road gear
Switch / parking brake Switch / no function
LHB/en/Edition: 11/2010

Switch / slewing gear brake Switch / grapple operation


Switch / overload warning system Switch with LED / mode selection
Switch / additional function (e.g. rotator) Push button / step up speed step
Switch / low idle automatic Push button / step down speed step
Switch / creeper gear Switch / performance step: Super Finish
Switch / travel light (ZW light ON) Plug connection / control console
A 1001 printed circuit board

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S2 Keyboard

Switch / servo shutdown Plug connection / control console - screen


Switch / special function 1 Code plug / control console
Switch / special function 2 Plug-type connection / control console
A1100 printed circuit board

This is where switched functions are being stored when the machine is shut down. When the
electrical system is switched on again, the original state is restored (as before shutdown).
For information on keyboard repairs, please refer to .
LHB/en/Edition: 11/2010

Fig. 5 Rear of control console

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ZW system - control element

Fig. 6 Control console ZW system

ZW indicator light (ON) Front axle (lock)


Indicator light / automatic mode Rear axle (lock)
Indicator light (excavation position) Override (boom limitation)
Indicator light Automatic train stop (steering axle)
(boom limitation override)
Indicator light Automatic train stop (rigid axle)
LHB/en/Edition: 11/2010

(boom limitation override)


Rail gear (lift) Stroke limitation override
Rail gear (lowering) Kit-specific
(lock in automatic mode)
Automatic mode

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ZW system - control element

Fig. 7 Display ZW system

Angle of inclination Hydraulic pressure - rear rail


guide axle
Display / ZW console Railcar brake system air pressure
Key switch of ZW system Main brake line air pressure
Hydraulic pressure - front rail Travel speed
guide axle
LHB/en/Edition: 11/2010

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Arrangement of components Service Manual
Control console A (type 1033)

Fig. 8 Control console A (type 1033)

Ignition switch Windscreen wiper / washing system


cab roof
LHB/en/Edition: 11/2010

Magnet system Windscreen wiper / washing system


rear window
Quick change adapter SET/TEACH DATA (stroke / boom
limitation)
Oscillating axle automatic Continuous operation - accessory kits
P1
Central lubricating pump Continuous operation - closing cylinder
A1

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Service Manual Arrangement of components
Control console A (type 1384/1385)

Stroke limitation Changeover attachment/packing tool


Emergency brake Changeover foot pedal - pilot control
Horn lift&carry mode
Auxiliary headlight - counter weight Stroke limitation
Boom limitation Boom limitation
Tempomat preselection Warning buzzer / emergency hydraulics
Railcar brake Indicator light / changeover
attachment/packing tool
Changeover valve / exhaust gas system Power socket 12 V
24 V socket on stick
LHB/en/Edition: 11/2010

Fig. 9 Control console A (type 1384/1385)

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Control console A (type 1384/1385)

Stroke limitation 24 V socket on stick


Boom limitation Windscreen wiper / washing system
cab roof
Warning buzzer / emergency hydraulics Windscreen wiper / washing system
rear window
Ignition switch SET/TEACH DATA (stroke / boom
limitation)
Magnet system Continuous operation - accessory kits
P1
Quick change adapter Continuous operation - closing cylinder
A1
Oscillating axle automatic Changeover for packing tool (A)
Central lubricating pump Changeover attachment/packing tool
Stroke limitation Changeover control A1/A2 with AHS
pedal
Emergency brake Grapple open/close with LIKUFIX
Horn Switch S/L (static/lift) mode overload
shut-down
Auxiliary headlight - counter weight Switch L/C (lift&carry) overload shut-
down
Boom limitation Key switch (tandem/lift) overload shut-
down
Railcar brake Switch D/G (digging & grabbing) mode
Changeover valve / exhaust gas system Switch data logger
Key switch changeover block - electrical Power socket 12 V
bucket/grapple

LHB/en/Edition: 11/2010

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Service Manual Arrangement of components
Printed circuit board A 1001 (ESP-01)
LHB/en/Edition: 11/2010

Fig. 10 Printed circuit board A 1001 (ESP-01)

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Printed circuit board A 1001 (ESP-01)

Poly switch - cannot be replaced

Relay / windscreen wiper Relay / reserve


Relay / charge check Relay / emergency function
Relay / reserve

Additional pressure level LED green LED red LED yellow


Input signal Fault Output signal
Travel brake LED green LED red LED yellow
Input signal Fault Output signal
Slewing gear brake LED green LED red LED yellow
Input signal Fault Output signal
Solenoid valve pilot control LED green LED yellow LED red
Input signal Output signal Fault
Fast travel LED green LED yellow LED red
Input signal Output signal Fault
Windscreen washer LED green LED yellow LED red
system Input signal Output signal Fault
Heater fan, level 1 LED green LED yellow LED red
Input signal Output signal Fault
Heater fan, level 2 LED green LED yellow LED red
Input signal Output signal Fault
Headlight - uppercarriage LED green LED yellow LED red
Input signal Output signal Fault
Roof light LED green LED yellow LED red
Input signal Output signal Fault
Beacon LED green LED yellow LED red
Input signal Output signal Fault
Pressure cut-off valve LED green LED red LED yellow
Input signal Fault Output signal
Transistor / windscreen LED green
wiper Input signal
Sensors LED green
Input signal

Plug connection to A153 / 5-pin Plug connection with power supply S2 / 3-


pin
LHB/en/Edition: 11/2010

Plug connection to S2 / 37-pin Plug connection / 2-pin


Plug connection to A1100 / 10-pin Plug connection / 3-pin
Plug connection to E1 / 4-pin Plug connection / 6-pin
Plug connection / 8-pin Plug connection / 6-pin
Plug connection / 3-pin Plug connection to M3, M4, E2, E7, E9 /
10-pin

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Service Manual Arrangement of components
Printed circuit board A 1100 (ESP-02)

Plug connection / 6-pin Plug connection to grapple attachment -


rotating / UEC
Plug connection / 8-pin Plug connection to E52 / 2-pin
Plug connection to sensor B19L / 3-pin Plug connection / 2-pin
Plug connection with sensor B19R / 3-pin Plug connection - diagnosis / 9-pin
Plug connection to sensor B40 / 2-pin Plug connection service plug / 9-pin
Plug connection to sensor B41 / 2-pin Plug connection keyboard / 9-pin
Plug connection to safety lever / Plug connection (diagnosis) / 9-pin
4-pin
Plug connection to S1 / 4-pin Plug connection
Plug connection to S57 / 2-pin
LHB/en/Edition: 11/2010

Fig. 11 = plug-in plate, = printed circuit board A1100 (ESP-02)

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Printed circuit board A 1100 (ESP-02)

Parking light, tail light / left (2A) E52 (15A)


Parking light, tail light / right (2A) B60, X220/1 (7.5A)
V160, K330, K331 (7.5A) E21, E22, E23, E24 (7.5A)
V156, V158, X202/4 (15A) X214-1/1 (15A)
V151, V152, V154 (15A) X214-2/1 (15A)
V150, brake light / right and left (15A) E8 (7.5A)
Work headlight, roof light (15A) X215/1 (15A)
Solenoid valve pilot control, slewing gear S1 - terminal 30 (15A)
brake (7.5A)
M4 (7.5A) E7, X12/1 (7.5A)
M3, X16/1, Y22, Y23 (15A) E4 (7.5A)
X214-3 (15A) E3 (7.5A)
Amplifiers A 1001 (15A) Keyboard S2 / terminal 15 (2A)
A153 (15A) Keyboard S2 / terminal 30 (2A)

LED: signal ground / travelling valves LED: power supply X214-3/1


LED: ground / travelling valves LED: power supply amplifiers A1001
LED: relay actuation LED: power supply U16
travel light K332
LED: actuation of relay K334 LED: power supply E52
LED: actuation of relay K331 LED: power supply X214-2/1
LED: actuation of relay K330 LED: power supply E8
LED: actuation of relay K333 LED: LED power supply
power supply 160, K330, K331
LED: power supply terminal 15 LED: fuse F250
LED: power supply B60 LED: power supply sensor 24V
LED: power supply V156, V158, Y62, Y63 LED E18, E16
LED: power supply SF2, SF3, SF4 LED: E15, E17
LED: power supply E19, E20, SF1, Y55, LED: E3
Y66
LED: power supply E21, E22, E23, E24 LED: E4
LED: power supply X214-1/1 LED: power supply indicator unit
LED: power supply Y22, Y23, M3, E9, LED: power supply electronics
K302, X16/1
LED: power supply M4 LED: power supply terminal 30, X215/1
LED: power supply Y6, Y7, Y3, Y24 LED: power supply terminal 30 S1
LED: power supply E2, E1 LED: power supply terminal 30, E7, H9
LHB/en/Edition: 11/2010

Relay socket / kit Relay / kit


Relay socket / kit Relay / kit
Relay / travel light Relay / overload warning system -
switchable

Amplifier: kit SF1 Amplifier: kit

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Service Manual Arrangement of components
Printed circuit board A 1100 (ESP-02)

Amplifier: kit SF2 Amplifier: safety lever kit


Amplifier: kit SF3 Amplifier: travelling valves
Amplifier: kit SF4 Amplifier: kit
Amplifier: 1st gear Amplifier: parking light
Amplifier: oscillating axle Amplifier: indicator unit
Amplifier: servo kit Amplifier: brake light

Plug connection on A1100 / 4-pin Plug connection to BS K334 / 6-pin


Plug connection between S2 and A1100 / Plug connection to KS BST / 4-pin
25-pin
Plug connection to KS motor / 15-pin Plug connection to BS overload warning
device, switchable / 2-pin
Plug connection to KS revolving deck / Plug connection to BS optional equipment
15-pin / 3-pin
Plug connection to KS motor / 9-pin Terminal for flow limitation / 3-pin
Plug connection to KS revolving deck / Plug connection magnet system / 2-pin
15-pin
Plug connection to KS operator's platform Plug connection input signal / 2-pin
/ 6-pin
Plug connection to KS operator's platform Plug connection oscillating axle support
/ 12-pin automatic / 6-pin
Plug connection to E8 / 2-pin Plug connection analog signal 1 / 3-pin
Plug connection to KS BST / 3-pin Plug connection analog signal 2 / 3-pin
Plug connection to kit SF1 / 2-pin Plug connection frequency signal 1 / 3-pin
Plug connection to BS SF2 / 2-pin Plug connection frequency signal 2 / 3-pin
Plug connection to BS SF3 / 2-pin Plug connection hazard light / 2-pin
Plug connection to BS SF4 / 2-pin Plug connection / 3-pin
Plug connection to servo kit / 2-pin Plug connection Sub-D with CAN 2 bus
Plug connection to BS safety lever / Plug connection to KS console, right / 10-
2-pin pin
Plug connection to BS servo / 2-pin Plug connection to B33 / 3-pin
Plug connection to BS servo / 2-pin Plug connection to kit / 2-pin
Plug connection to BS servo / 2-pin Plug connection with fuses
F250 / 251 / 4-pin
Plug connection to BS terminal 15 / 2-pin Plug connection to KS revolving deck /
12-pin
Plug connection to BS terminal 15 / 2-pin Plug connection to KS motor / 2-pin
Plug connection to BS terminal 15 / 2-pin Plug connection to KS revolving deck
2-pin
Plug connection to BS terminal 30 / 2-pin Plug connection to KS revolving deck / 3-
LHB/en/Edition: 11/2010

pin
Plug connection to BS K333 / 6-pin

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Universal Earthmoving Controller (UEC)

Fig. 12 in undercarriage

Diagnostic plug Plug connection


ZW distribution box Plug connection
LHB/en/Edition: 11/2010

Electric cabinet in undercarriage Plug connection


UEC01 in undercarriage Plug connection
UEC01 in uppercarriage Plug connection
Inclination sensor Wire harness - front axle
Ground connection Wire harness - slip ring
Plug connection Wire harness - rear axle
Plug connection

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Service Manual Arrangement of components
Universal Earthmoving Controller (UEC)

Fig. 13 UEC in uppercarriage

In the event of a complete failure of the electrical system, the software version of the UEC is not
displayed. It can however be found on the adhesive label . If the software has been upgraded since
the machine was delivered, the current version number can be found on the inside of the cover of
the electric box .

Electric cabinet Power supply


Relay board Power supply
Cover Radiator ground connection
Adhesive label Revolving deck ground connection
UEC control system (uppercarriage) CAN terminal resistor
LHB/en/Edition: 11/2010

UEC optional equipment control UEC diagnostic plug / uppercarriage


to fuse box Travel signal plug

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Arrangement of components Service Manual
Relay board 2

Fig. 14 Relay board

20 A Rail guide terminal 30


10 A Uppercarriage electrics terminal 30
10 A ZW control console terminal 30
10 A ZW horn terminal 30
10 A UEC uppercarriage terminal 30
Reserve terminal 30*
10 A UEC options terminal 30
20 A Rail guide terminal 15
10 A Uppercarriage electrics terminal 15
10 A ZW control console terminal 15
15 A Rear working light terminal 15
10 A Uppercarriage UEC and right console
10 A Windscreen wipers, windscreen washer terminal 15
10 A UEC01 options terminal 15
15 A Railcar brake system
LHB/en/Edition: 11/2010

10 A Signalling light lifting mode


F394 10 A Data logger terminal 30 (1384 only)
F395 10 A Data logger terminal 15 (1384 only)
F398 10 A Heating air dryer railcar brake system terminal 15
Signal horn relay (air horn) terminal 15
Relay / horn
Relay switchover road light / rail light

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Service Manual Arrangement of components
Relay board 2

Relay switchover right road light / rail light


Relay brake light switch-off
Relay left parking light switch-off
Relay right parking light switch-off
Relay turn signal switch-off
Relay servo locking mechanism of outrigger control (only in model 1031)
Relay rear working light (on operator's cab or counter weight))
Relay roof screen wiper
Relay rear window wiper
Relay air dryer heating (railcar brake system)*
Relay Liebherr hydro magnet*
XF3_2 KL30 Connection / safety module XF3
XF3_3 KL30 Connection / safety module XF3
XF3_7 KL15 Connection / safety module XF3
ZW relay plate plug
ZW relay plate plug
ZW relay plate plug
ZW relay plate plug
ZW relay plate plug
ZW relay plate plug
ZW relay plate plug
ZW relay plate plug
ZW relay plate plug
ZW relay plate plug
ZW relay plate plug
ZW relay plate plug
LHB/en/Edition: 11/2010

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Arrangement of components Service Manual
Fuse and power switch cabinet

Fig. 15 Fuse and power switch cabinet


LHB/en/Edition: 11/2010

100 A Automatic cut-out / preheating system


50 A Automatic cut-out / main fuse
7.5 A Warning light system
7.5 A Heating and a/c system terminal 15
7.5 A Refuelling pump*
Reserve
Reserve

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Service Manual Arrangement of components
Fuse and power switch cabinet

20 A Refuelling pump*
15 A Reserve K66-2
20 A Heating and a/c system terminal 30
50 A Special equipment auxiliary headlight* and motor terminal 30
50 A Engine control terminal 30
7.5 A Emergency operation terminal 15
7.5 A Engine control terminal 30
7.5 A Engine control terminal 15
7.5 A Engine control, preheating monitoring
7.5 A not assigned
25 A Stick light
50 A Automatic cut-out terminal 15/terminal 30 main circuit
Relay, optional*
Fuel pre-heating*
Relay, optional*
Relay, optional*
Relay of emergency operation / speed control
Relay for starting engine emergency operation
Main relay terminal 15
Relay of pre-heating
Auxiliary heating
Relay stick light*
Main relay ZW operation terminal 15

Fig. 16 Fuse of emergency hydraulics


LHB/en/Edition: 11/2010

300A Emergency hydraulics

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Arrangement of components Service Manual
Fuse and power switch cabinet

Fig. 17 Diagnostic plug under passenger seat

UEC uppercarriage diagnostic plug (stroke and boom limitation)


X1308 Diagnostic plug / UEC undercarriage

Fig. 18 Warning signal (bell) on counter weight

Warning signal (bell)

LHB/en/Edition: 11/2010

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Service Manual Arrangement of components
D 934S/L A6 diesel engine

Fig. 19 D 934S/L A6 diesel engine

Engine control Starter


Transducer / coolant level Heating flange
Speed transducer (sensor) Magnetic coupling / a/c compressor
Alternator
LHB/en/Edition: 11/2010

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Arrangement of components Service Manual
Tank and control oil unit

13 Tank and control oil unit

Fig. 20 Hydraulic tank, fuel tank with control oil unit

B8 Transducer / hydraulic oil temperature Y7 Solenoid valve / slewing gear brake


B14 Transducer / hydraulic oil level Y50-1 Proportional solenoid valve /
power control P1
B39 Transducer / fuel level Y50-2 Proportional solenoid valve /
LHB/en/Edition: 11/2010

power control P2
H9 Horn Y66 Solenoid valve / oscillating axle support
Y3 Solenoid valve / pilot control pressure Y353 Proportional solenoid valve / travel
function

8.12.24
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Other components

Fig. 21 Slewing gear fine control

Pressure sensor / slewing gear fine control


Solenoid valve / slewing gear fine control
LHB/en/Edition: 11/2010

Fig. 22 HBGV block and solenoid valve on basic boom bearing block

Solenoid valve / 2nd gear or on-road gear


Solenoid valve / first gear

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Arrangement of components Service Manual
Other components

Fig. 23 Operator's platform from below

Pressure switch / accumulator pressure


Brake light switch
Solenoid valve / forward travel (with emergency actuation)
Solenoid valve / reverse travel (with emergency actuation)
Proportional solenoid valve / Super Finish pressure reduction - pilot control

Fig. 24 Foot pedals in operator's cab


LHB/en/Edition: 11/2010

Proximity switch / brake pedal


Electric foot pedal
Electric working pedal sensor / right
Electric working pedal sensor / left

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Service Manual Arrangement of components
Other components

Fig. 25 Proportional solenoid valve - fan control

Proportional solenoid valve - fan control

Fig. 26 Radiator area

Power and safety switch cabinet, see Fig. 15


LHB/en/Edition: 11/2010

Batteries
Battery main switch

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Arrangement of components Service Manual
Other components

Fig. 27 Angle sensor of the rail gear

Angle sensor (VL)


Angle sensor (HL)

Fig. 28 View: control valve block with auxiliary axles

Solenoid valve / turn grapple


Solenoid valve / turn grapple
LHB/en/Edition: 11/2010

Solenoid valve / separating plate

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Service Manual Arrangement of components
Other components

Fig. 29 Valve bar

Proportional solenoid valve / regulating cylinder (retracting)


Proportional solenoid valve / regulating cylinder (extending)
Proportional solenoid valve / closing cylinder (opening)
Proportional solenoid valve / closing cylinder (closing)
Proportional solenoid valve / attachment (closing)
Proportional solenoid valve / attachment (opening)

Fig. 30 Components in undercarriage


LHB/en/Edition: 11/2010

Pressure switch / foot brake Solenoid valve / creeper gear


Response pressure up to serial no.
51092 (5/4 bar), from serial no. 510923
(9/8 bar)

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Arrangement of components Service Manual
Other components

Fig. 31 Air conditioning components


LHB/en/Edition: 11/2010

Thermostat / a/c system Motor / control console air flap


Pressure switch of a/c system Motor / legroom and windscreen air flap
Temperature sensor / cabin Control unit / heating and air-
conditioning system
Temperature sensor / blow-out air Control device
Motor / evaporator blower Solenoid valve / a/c clutch
Motor / outdoor air flap Solenoid valve / heating system

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Service Manual Arrangement of components
Other components

Motor / rear panel air flap


LHB/en/Edition: 11/2010

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Arrangement of components Service Manual
Other components

LHB/en/Edition: 11/2010

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Service Manual Operating symbols on the operator's platform
Overview of symbols

S124 Mower rake kit in operation Right console


H329

S124 Mower rake kit ON Right console


H329

S395 Heating element Left console

S387 Separ water filter with monitoring Right console


system

S47 Quick change adapter Right console

S47 Industrial quick-change adapter Right console


LHB/en/Edition: 11/2007

S47 Quick-change equipment Right console

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Operating symbols on the operator's platform Service Manual
Overview of symbols

H341 Quick-change adapter powered Right console

S209 Topas quick-change adapter Right console


Retract telescopic grapple

S208 Topas quick-change adapter Right console


Extend telescopic grapple

S403 Stick cylinder shut-down Right console

H315 Automatic shut-off mechanism OFF Right console


S396

S291 Overriding of stroke limitation of basic Right console


boom

S466 Stick cylinder shut-down Right console


Height limitation for stick
LHB/en/Edition: 11/2007

S393 24 V stick plug on stick Right console

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Service Manual Operating symbols on the operator's platform
Overview of symbols

S364 Lowering without pressure Right console


Attachment lowering lock

S216 Industrial shut-down Right console

S291 Hydraulic boom adjustment Right console


Stroke limitation

S291 Stroke limitation Right console


H159

H320 Changeover ZETKO control Right console


Extending ZETKO

H320 Changeover ZETKO control Right console


Bending ZETKO

H322 Changeover bucket / attachment kit Right console


S405
LHB/en/Edition: 11/2007

S400 Additional pressure level Left console

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Operating symbols on the operator's platform Service Manual
Overview of symbols

S35 Servo control Right console

S419 Clutch Right console

S424 Drilling slide Right console


Push button / continuous operation
AHS

S422 Radio mute mode Right console

S452 Grapple rotation with rocker switch Right console

S447 Burning particle filter Right console


Full load simulation for particle filter

S462 Pulling unit UP Right console


LHB/en/Edition: 11/2007

S461 Pulling unit DOWN Right console

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Service Manual Operating symbols on the operator's platform
Overview of symbols

S453 Continuous operation of attachments Right console

S458 Continuous operation of closing Right console


cylinder

S338 Compressor of wagon brake system Right console


Pneumatic load hook

H297 Friction wheel operation Left console


Conversion of rail chassis

S401 Rail guide Right console

S484 Continuous operation attachments - Right console


release

H345 Fault in traverse potentiometer Right console


LHB/en/Edition: 11/2007

S200 Hydraulic operator's cab elevation Left console


Cab UP

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Operating symbols on the operator's platform Service Manual
Overview of symbols

S201 Hydraulic operator's cab elevation Left console


Cab DOWN

S202 Cab FORWARD Left console

S203 Cab BACK Left console

S394 Hydraulic operator's cab elevation Left console


Cab/ lift frame

S216 Engine shut-down Left console


Engine stop switching reversed

S218 Windscreen wiper Right console

S275 Work headlight Right console


LHB/en/Edition: 11/2007

S238 4-wheel steering Left console

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Service Manual Operating symbols on the operator's platform
Overview of symbols

S238 4-wheel steering Left console


Rear axle switched off

S239 4-wheel steering with dog-walk steering Left console


mode

H325 Steering changeover check Right console

S413 Steering changeover ON Left console

S321 Joystick control Right console

S247 LIEBHERR control Right console


H292 Changeover Euro - LIEBHERR

H158 Fuchs steering Right console


LHB/en/Edition: 11/2007

S45 Priority circuit Left console

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Operating symbols on the operator's platform Service Manual
Overview of symbols

H292 Special control changeover Right console

S204 Individual control right outrigger Left console


S205

S206 Individual control right outrigger Left console


S207

S435 Changeover travel / support Right console


H310 Outrigger symbol (blade at rear)

S356 Changeover valve in undercarriage Right console

S409 Support automatic Right console

H343 Outrigger monitoring system Right console


LHB/en/Edition: 11/2007

S335 Blade mirrored Right console

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Service Manual Operating symbols on the operator's platform
Overview of symbols

S335 Blade mirrored Left console

S469 swivel rotator Right console


S80 Tilt ditch cleaning bucket

S46 Magnet systems Right console

S356 Trailer coupling Left console

S210 Cold-start system Right console


Cold-start aid

S84 Central lubrication Right console

S84 Central lubrication system Right console


LHB/en/Edition: 11/2007

S359 Sorting grapple Right console


H347

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Operating symbols on the operator's platform Service Manual
Overview of symbols

S357 Lifting boom when closing grapple Right console

S356 Function of regulating cylinder Right console


ASU changeover valve

H295 Data transmission Right console

S374 Slewing ladder Left console

S26 Fuel pre-heating Right console


S213
S237

H298 Exhaust backpressure Right console

H300 Fill level of additive Right console


LHB/en/Edition: 11/2007

S379 Release button Right console

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Service Manual Operating symbols on the operator's platform
Overview of symbols

S445 Turning stick with changeover valve Right console


Flow reduction with button
LHB/en/Edition: 11/2007

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Operating symbols on the operator's platform Service Manual
Overview of symbols

LHB/en/Edition: 11/2007

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Service Manual Data logger
Function/design

The data logger records various data of the machine, (see “Logged files of data logger” on
page 5). The data on the memory card (CF2) can be read with a conventional card reader.
The data logger is installed in the right console behind the passenger seat. To protect the data
logger against unauthorised access, it is secured with a padlock.
The data logger does not have any control function and is only used for the recording of machine
data. In order to ensure continuous data logging, a memory card each must be inserted in the two
slots and of the data logger.
The logger is monitored with the button (LOG) in the right console. It indicates the operating
status of the data logger.

If the indicator light in the button is off, no data is being recorded. In this case, it is strictly
forbidden to operate the machine, (see “Operating statuses of data logger” on page 3).

Fig. 1 Electrical system of data logger


LHB/en/Edition: 09/2012

Memory card slot (CF1) Plug connection


Memory card slot (CF2) Data logger button
Data logger Plug connection
Plug connection Plug connection
Plug connection Plug connection
In/out module Plug connection

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Data logger Service Manual
Function/design

Plug connection Plug connection


Printed circuit board Plug connection
Fuse (10A) Plug connection
Fuse (10A) Plug connection
Ground connection / relay board Plug connection
CAN terminal resistor Plug connection

Fig. 2 Design of data logger

Memory card (slot CF1) Plug connection LAN1 (diagnosis)


Data logger software
Memory card (slot CF2) Plug connection LAN2
Data memory
LED indicator / memory card status Plug connection LAN3 (monitor
connection)
Operating status LED indicator Plug connection COM1 (device monitor)
LHB/en/Edition: 09/2012

Voltage supply LED indicator Plug connection COM2 (modem)


Cover for card slot Plug connection COM3
Bleeder screw Plug connection COM4 (diagnosis)
Plug connection / power supply Data logger
(A190.PWR.X)
Plug connection / CAN connection
(A190.CAN.X)

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Service Manual Data logger
Function/design

Switch on the ignition.


The indicator light in the switch The data logger works properly.
is on in green. The machine is ready for operation.

The indicator light in the switch An overload occurred since the last
flashes. reset. Connect the service plug, see Fig.
9, and actuate the switch . If the
system works properly, the indicator
light is on in green.
(see “Resetting data logger” on page 8).
The indicator light in the switch No data is being logged. In this case, it
is off. is to operate the machine.
Observe the error messages, see group
8.80.

Tab. 1 Operating statuses of data logger

Fig. 3 Memory cards

CF1 memory card with software for data logger, information on the software version and ID
number
Memory card (slot CF2) for logged data
LHB/en/Edition: 09/2012

When handing over the machine to a new owner, pass on the key. It is the responsibility of the
machine owner to manage access to the key according to standard RIS1530, version 2.

Remove the padlock and open the cover .

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Data logger Service Manual
Function/design

Unscrew the cover of the data logger , (see “Design of data logger” on page 2).
The memory card is now accessible and can be removed to read out the data. The memory card
remains inserted.

The LEDs indicate the operating status of the memory card and the communication status between
the memory card and the control system.

Fig. 4 Operating status LED indicators

LED indicators: memory card


– LED indicates whether the memory card is inserted.
– LED is on or flickers when the memory card communicates with the control system.
– LED indicates whether the memory card is inserted.
– LED is on or flickers when the memory card communicates with the control system.
LED indicators: control

Row A, green (LED 1-3 LAN) lit Network connection established


Row A, green (LED 4) flashing Control system works without errors
Row B, yellow (LED 1-3 LAN) flickering Network active
Row B, yellow (LED 4) flashing Control system operating properly
Row C, red (LED 1-4 CAN) flashing Error message on CAN bus
Row C, red (LED 1-4 CAN) lit CAN bus timeout
Row D, green (LED 1-4 CAN) flashing CAN bus active
rapidly

Tab. 2 LED control indicator


LHB/en/Edition: 09/2012

The data logger logs the data listed in the table below over a period of 100 operating hours. After
100 operating hours have lapsed, the oldest recorded data is overwritten with new data. This
ensures that the logger always stores all data of the last 100 operating hours. However, less data
is available if data has been deleted.

1 Datum / Uhrzeit date / time

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Service Manual Data logger
Function/design

2 Zähler counter
3 Fahreridentifkation-Code personal number
4 Fahreridentifkation-Code personal number OK
5 Überlastabschaltung eingeschaltet RCI on
6 ZW ein rail-mode on
7 SWL zulässige max. Last (t) safe working load - SWL (t)
8 Last am Haken (t) load (t)
9 Radius (m) radius (m)
10 Höhe (vorderer Stielbolzen) (m) height (m)
11 Winkel (Unterwagen-Oberwagen (Winkel) slew angle (degree)
12 Überhöhung in mm cant (mm)
13 Überhöhung (0=Winkel, 1=mm) cant unit (==degree; 1=mm)
14 Geschwindigkeit speed
15 Anzeige der Geschwindigkeit (0=km/h; 1=mph) speed unit (0=km/h; 1=mph)
16 UL-Vorwarnung RCI-audible warning
17 UL-Abschaltung RCI-cutoff
18 UL-Überbrückung betätigt RCI-by-pass active
19 Pendelachse zu axle locked
20 Static Lifting mode ein S/L-mode on
21 Lift and Carry ein L/C-mode on
22 Digging mode D/G-mode on
23 Tandem Lift ein T/L-mode on
24 Backward stability ein backward stability on
25 Sicherheitshebel safety lever
26 Abschaltung Hub durch die backward stability stop boom due to backward stability (bs)
27 Abschaltung Drehwerk durch die backward stop slewing gear due to backward stability (bs)
stability
28 Berechnete Radlast calculated wheel load
29 Nothydraulik aktiv emergency hydraulic on
30 Schienenachsen senken lowering rail gear
31 Schienenachsen heben lifting rail gear
32 Hinterachse gesperrt Rear axle locked
33 Vorderachse gesperrt Front axle locked
34 Regeln in Automatik control automatic active
35 Automatikbetrieb aktiv automatic
36 Gefahr des Traktionsverlustes E964 traction lose E964
37 Automatik gesperrt automatic locked
38 Quittierung Kontrollleuchte Datenlogger Confirmation control lamp
LHB/en/Edition: 09/2012

39 Service-Mode (Servicestecker gesteckt) service-mode


40 Not-stop betätigt emergency stop ZWU pressed
41 Position Lenkachse (in Promille) angle steering axle (per mill)
42 Position Starrachse (in Promille) angle rigid axle (per mill)

Tab. 3 Logged files of data logger

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Data logger Service Manual
Function/design

Fig. 5 Reading data logger

The recorded data is stored on the memory card (CF2/128MB). The data is stored in several
directories and files.

The recorded data is available in text format and can thus be analysed by means of standard office
applications such as MS Excel.

When reading out data, note that the reading date does not correspond to the recording date, (see
Fig. 6 on page 6).

Shut down the machine.


Connect a conventional card reader to a PC.
Carefully remove the memory card (CF2) from the data logger.
Insert the memory card into the card reader .
Copy the data from the memory card through the card reader . Do not delete the data from
the memory card.
Transfer the data to the connected PC.

LHB/en/Edition: 09/2012

Fig. 6 Reading data from logger

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Service Manual Data logger
Function/design

Import data to the desired application.

Fig. 7 Data imported to txt editor


LHB/en/Edition: 09/2012

Fig. 8 Data imported to Excel

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Data logger Service Manual
Function/design

Fig. 9 Reading data through interface

Connect the SCULI dongle.


Connect the PC to the interface on the data logger .
Establish a connection by means of the SCULI software diagnostics.
Retrieve the data with the software.

After reading the data, reset the status indicator (indicator light in button ) of the data logger by
pressing the button .
The service plug is connected.
Press the button .
The data logger status indicator is reset and the indicator light is lit in green, provided that the
device works properly.

LHB/en/Edition: 09/2012

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Service Manual Operator ID code
Preliminary settings (storing operator code)

Up to 10 operator ID codes can be stored in the menu. These codes must be entered through the
excavator keyboard (BBT).

Fig. 1 Entering operator ID code

Connect the service plug .


Connect a PC to the plug connection (BBT) on the printed circuit board .
Establish a connection and start Likom with .
A connection to the BBT is established and the input screen is displayed.
LHB/en/Edition: 11/2010

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Operator ID code Service Manual
Preliminary settings (storing operator code)

Fig. 2 Starting Likom and entering command

Enter command and conform with the ENTER button.


The operator ID code menu is displayed.

If less than ten operator ID codes are to be assigned, enter the last operator ID code in all blank
fields.
Each code change must be saved separately with . To exit the program, press (see arrow).

LHB/en/Edition: 11/2010

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Service Manual Operator ID code
Preliminary settings (storing operator code)

Fig. 3 Entering operator ID codes

Enter the 8-digit operator ID codes.


Save entry with and exit program with .

Fig. 4 Activating menu


LHB/en/Edition: 11/2010

Connect the service plug.


In menu , select submenu and confirm with the "Menu" button.
Using the UP/DOWN arrow buttons, select submenu and set from to ,
using the "Menu" button.
Exit the submenu by pressing the button.
The menu is activated.

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Operator ID code Service Manual
Preliminary settings (storing operator code)

Fig. 5 Code entry

Switch on ignition (contact position 1).


The menu for the code input is displayed.
Enter your personal 8-digit operator ID code, using the numerical keypad of the excavator
keyboard (BBT) and confirm with the "Menu" button.
If a correct ID code has been entered, message is displayed on the menu screen.
The machine is only released for operating if a correct ID code has been entered. The machine can
now be started.
If an incorrect ID code has been entered, message is displayed on the menu screen.
In this case:
Switch off the ignition and switch it on again.
Re-enter the ID code.
The number of code input attempts is not limited!
LHB/en/Edition: 11/2010

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Service Manual Electronically controlled working and travelling pedal
Function/design

The Liebherr rail-road excavators are equipped with an electro hydraulic travel drive and the
associated components as well as with electronic working pedal sensors.
The direction and speed of travel and the working pedal functions the are controlled electronically,
while the travel drive is controlled hydraulically.
The UEC optional control system ( ) controls the travelling pedal sensor as well as the
proportional solenoid valve . It also controls the working pedal sensors and with the
accessory kit functions.
The electronically controlled working and travelling pedals consist of the following main components:
– Travelling pedal sensor on the pedal / operator's platform
– Working pedal sensors and on the pedal / operator's platform
– Switch for travel direction and switch for the storage of the travel velocity
– Proportional solenoid valve on the control oil unit
LHB/en/Edition: 12/2008

Fig. 1 Working and travelling pedal sensor

travelling pedal sensor Plug connection


Working pedal sensor, right Plug connection

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Electronically controlled working and travelling pedal Service Manual
Functional description

Working pedal sensor, left Plug connection

(see Fig. 6 on page 6)

Fig. 2 Electric travel

Preselect the direction of travel with the switch . Depending on the position of the switch ,
(forward travel) or (reverse travel) is powered (the direction of travel is indicated on the display).
The proportional solenoid valve (pressure reducing valve) is powered through the UEC optional
control system ( ), whereby the current is determined by the pivot angle detected by the travelling
pedal sensor .
The resulting control oil pressure acts through the connection of the control oil unit and through
the actuated solenoid valve on the spool of the compact control block . The spool
is moved up or down, in proportion to the control pressure, thus feeding pressurised hydraulic oil
from the working pump to the regulating travel motor The regulating travel motor is pressurised and
drives the machine through the transmission the drive shafts and the axles.

The automotive travel function can be switched on or off in the menu. The default setting for automatic
travel is .
LHB/en/Edition: 12/2008

If the switch is not actuated, automatic travel is controlled by the UEC optional control system
( ). In this mode, the travelling pedal sensor also controls the diesel engine speed,
depending on the pivot angle of the pedal.
Advantages for travel in normal road traffic: If required, semi-speed and idling speed operation can
be controlled with the travelling pedal sensor and must thus not be constantly corrected with
the speed buttons.

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Service Manual Electronically controlled working and travelling pedal
Functional description

"Tempomat" operation is activated with the switch (right console). When this function is on, the
indicator light in the switch is lit.
When the desired speed is reached, it can be stored by briefly pressing . The current value of
the travelling pedal sensor is stored in the UEC optional control system ( ).
Both Tempomat and normal mode travel ( on) is possible in both directions of travel. In normal
on-road travel mode ( off), the Tempomat function is only available for forward travel.
The operator can now lift the foot from the travelling pedal while the machine continues to travel
at the set speed. The proportional solenoid valve is powered with a constant current from the
UEC optional control system ( ).
For safety reasons, the following events automatically deactivate the Tempomat:
– The switch is pressed again (indicator light in the switch is off).
– The travelling pedal sensor records a value that is above the saved limit.
– The direction of travel is changed.
– The wagon brake system is actuated.
– An emergency brake manoeuvre is carried out.
– The safety lever is tilted up or the servo control is switched off.
– An kit that is also controlled with the push button is switched on.
The stored value is thereby deleted.

Press the switch .


The indicator light in the switch is on.
Tempomat operation is preselected.
Press down the travelling pedal until the desired speed is reached.

Fig. 3 Right pilot control unit

Press the push button .


Release the travelling pedal sensor
The travel speed is stored.
The machine continues to travel at the current speed, provided that the road conditions are
suitable.
The screen symbols for "forward travel" and "reverse travel" are shown with a sign for
LHB/en/Edition: 12/2008

Tempomat.
Press the push button again or actuate the brake to deactivate the set travel speed.
The set travel speed is deleted, and the vehicle velocity must again be controlled with the
travelling pedal.

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Electronically controlled working and travelling pedal Service Manual
Functional description

The travelling pedal sensor generates a voltage signal that is proportional to the actual pedal
path and that transmitted to the central control unit . Each incoming voltage signal is assigned
an output current to the proportional solenoid valve . This current is determined by means of
characteristics stored in the UEC optional control unit ( ).
The travelling pedal sensor is equipped with 2 analog outputs. The two analog outputs of the
travelling pedal sensor generate negative-sequence voltage signals, which are read,
processed, constantly compared with each other and assessed for plausibility by the UEC optional
control system ( ). If an error occurs at the travelling pedal sensor or in the cabling to the
travelling pedal sensor , the respective error code signals are generated. For details, see group
8.80.
If the UEC optional control system ( ) detects a signal from the travelling pedal sensor the
speed is set to the speed step preselected in the BBT.
To check the travelling pedal sensor , measure the voltage when the pedal is at the maximum/
minimum position and compare it with the diagram, see Fig. 4.

The travelling pedal sensor is calibrated in a high-precision procedure by the manufacturer.


Dismantling the travelling pedal sensor results in incorrect output signals, as the calibration is
interfered with.
In the event of a fault at the travelling pedal sensor , do not attempt to repair the device but
always replace it with a new unit.

Fig. 4 Functional diagram (for 25°C)

LHB/en/Edition: 12/2008

Fig. 5 Electric working pedal sensors

The electrical inputs are connected to the right working pedal sensor and the left working pedal
sensor . Depending on the activation (SF2 OFF/ON, SF3 OFF/ON or vertical-horizontal), on-
road travel, the attachment or the horizontal adjustment equipment is actuated.

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Service Manual Electronically controlled working and travelling pedal
Functional description

The UEC optional control system ( ) controls the listed proportional solenoid valves, depending
on the actual actuation.

Working pedal sensor right Y481 Boom UP


Y484 Cylinder movement / attachment
Y481 Horizontal boom to right
Working pedal sensor left Y480 Boom DOWN
Y485 Cylinder movement / attachment
Y480 Horizontal boom to left

If the continuous oil attachment (P1-S453) is activated, the road travel or vertical-horizontal
adjustment equipment functions are again released for the working pedals.
The continuous mode function is reset with the safety lever S7.

Control oil unit Solenoid valve / reverse travel


Control block Connection at control block
Spool (travel) Connection at control block
UEC optional control system Proportional solenoid valve / travel
function
travelling pedal sensor Proportional solenoid valve
regulating cylinder (retracting)
Working pedal sensor, right Proportional solenoid valve
regulating cylinder (extending)
Working pedal sensor, left Proportional solenoid valve
closing cylinder (open A2)
Push button Proportional solenoid valve
closing cylinder (close A1)
Rocker switch / travel direction Proportional solenoid valve
attachment (close P2)
Switch / Tempomat function Proportional solenoid valve
attachment (open P1)
Solenoid valve / forward travel

Electrical outputs Electrical inputs


LHB/en/Edition: 12/2008

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MJFCIFSS
Electronically controlled working and travelling pedal Service Manual
Functional description

LHB/en/Edition: 12/2008

Fig. 6 Functional diagram

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MJFCIFSS
Service Manual Electronically controlled working and travelling pedal
Maintenance and repair

Regularly clean the travelling and the working pedal sensors and the electrical connections.

For functional reasons, the pedals cannot be repaired. If necessary, always replace the entire pedal.
The pedals must be calibrated during commissioning of the machine or after they have been
exchanged. Always calibrate all 3 pedal sensors (travelling pedal sensor and the two
accessory kit pedal sensors ) together, see group 8.62.
LHB/en/Edition: 12/2008

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MJFCIFSS
Electronically controlled working and travelling pedal Service Manual
Maintenance and repair

LHB/en/Edition: 12/2008

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Service Manual Calibration of the electric foot pedals
Purpose of calibration

The pedals must be calibrated during commissioning of the machine and after they have been
replaced. Always calibrate all 3 foot pedals (travel pedal and 2 attachment kit pedals) together.

Fig. 1 Calibration menu

Insert the service plug and switch on the ignition.


In the service menu, select and confirm with the ENTER key.
Using the arrow keys, select the submenu and confirm with the ENTER key.
Using the arrow keys, select the submenu and confirm with the ENTER key.
Using the arrow keys, select the submenu and confirm with the ENTER key.
In the field , set the value to 1, using the arrow keys and confirm with the ENTER key.

Fig. 2 Activating calibration

Fully press down the travel pedal , the left attachment pedal and the right attachment pedal
one after the other. After calibration has been activated, you must always actuate all three pedals
one after the other.
After calibration has been completed, switch off the ignition.
Exit the calibration mode.
LHB/en/Edition: 04/2009

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Calibration of the electric foot pedals Service Manual
Maintenance and repair

Fig. 3 Travel pedal and attachment pedals

Regularly clean the pedals and the electrical connections.

For functional reasons, the pedals cannot be repaired. If necessary, always replace the entire pedal.

LHB/en/Edition: 04/2009

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Service Manual ZW monitoring display (TDS01)
Function/design

From TDS01 version 2.0, the ZW monitoring display has been equipped with a service menu
facilitating diagnostics. Without service plug, only the software version can be viewed. With service
plug, the parameter values, the internal variables as well as the I/O values can be viewed and
adjusted, if necessary.
It is thus possible to call up the values of the rail guide system and to set the parameters for the
various configurations without the need for a laptop.
The program includes three different service menus:
– i-i/O
– i-parameters
– i-variables
The control buttons of the monitoring display are shown as graphic icons. The system is operated
with the keys F1 to F4.

F1 = BACK
F2/F3 = UP/DOWN
F4 = MENU

Fig. 1 ZW monitoring display


LHB/en/Edition: 05/2010

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ZW monitoring display (TDS01) Service Manual
Checking of parameters, inputs and outputs

If the ignition is started without connected service plug and the key is pressed, only the software
version is shown on the monitoring display.

Connect the service plug.

Fig. 2 Connecting the service plug

Press and hold the key and start the ignition.


The software version of the monitoring display (TDS01) is shown.
Keep the key pressed down.
The service menus are displayed.

In the i-i/O service menu, you can view the input and output values of the control system. These
values are converted by the UEC control system into effective values in mA and bar. For details, see
Tab. 1.
Press the F2/F3 (UP/DOWN) keys to select the i-i/O service menu and confirm by pressing the
menu key.
The I/O values are displayed.
Compare the I/O values with those in the table, see Tab. 1.
Use key F4 to page through the menu pages 1 to 9.
To exit the menu, press key F1 (BACK).
LHB/en/Edition: 05/2010

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Service Manual ZW monitoring display (TDS01)
Checking of parameters, inputs and outputs

Fig. 3 i-i/O service menu

36 32 X2.7 DIN (9) not assigned


37 32 X2.8 Foot brake pressure switch B325
38 32 X2.9 DIN (11) not assigned
39 32 X2.10 DIN (12) not assigned
40 32 X2.11 DIN (13) not assigned
41 32 X2.12 DIN (14) not assigned
42 32 X2.13 DIN (15) not assigned
43 32 X2.14 DIN (16) not assigned
44 32 X2.15 DIN (17) not assigned
92 32 X1:16 Resistance measurement input 1 not assigned
93 32 X1:17 Resistance measurement input 2 not assigned
94 32 X1.18 Resistance measurement input 3 not assigned
95 32 X1.19 Resistance measurement input 4 not assigned
96 32 X1.20 Resistance measurement input 5 not assigned
100 32 X1.1 Terminal 30+24V power supply control
101 32 X1.2 UB 0 + 24V / terminal 15 - power supply control; bridge
102 32 X2.37 UB 1 + 24V / terminal 15 - power supply
outputs
103 32 X2.38 UB 2 + 24V / terminal 15 - power supply
outputs
104 32 X2.39 UB 3 + 24V / terminal 15 - power supply
outputs
105 32 X2.40 UB 4 + 24V / terminal 15 - power supply
LHB/en/Edition: 05/2010

outputs
107 32 X1.11 OUT+28; overvoltage protection output, supply
External sensors
108 32 X1.39 DIN (1) not assigned
109 32 X1:40 DIN (2); emergency-stop input; 0V/24V
110 32 X2.1 DIN (3); outrigger support, front right, pressure switch B310
111 32 X2.2 DIN (4); outrigger support, front left, pressure switch B311
112 32 X2.3 DIN (5); outrigger support, rear right, pressure switch B312

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ZW monitoring display (TDS01) Service Manual
Checking of parameters, inputs and outputs

113 32 X2.4 DIN (5); outrigger support, rear left, pressure switch B313
114 32 X2.5 DIN (7) not assigned
115 32 X2.6 DIN (8) not assigned
126 32 X1.31 Pressure sensor railcar brake system accumulator pressure
B320
127 32 X1.32 Angle sensor, front B401 0-5V
128 32 X1.33 Pressure sensor railcar brake system operating pressure
B321 0-10V
129 32 X1.34 Angle sensor, rear B402 0-5 V
130 32 X1.25 Pressure sensor rail, front right B329 1-5V
131 32 X1.26 Pressure sensor rail, front left B330 1-5V
132 32 X1.27 Pressure sensor rail, rear right B331 1-5V
133 32 X1.28 Pressure sensor rail, rear left B332 1-5V
134 32 X1.29 Pressure sensor ZW pump B322 1-5V
142 32 X2.36 PWM nominal output 1; Y430 ZW pump
143 32 X2.35 PWM nominal output 2; Y395 front bottom to P
144 32 X2.34 PWM nominal output 3; Y395 rear bottom to P
145 32 X2.33 PWM nominal output 4; Y496 rear axle pressure regulation
146 32 X2.32 PWM nominal output 5; Y398 front ring to P
147 32 X2.31 PWM nominal output 6; Y399 front bottom to T
148 32 X2.30 PWM nominal output 7; Y400 rear bottom to T
149 32 X2.29 PWM nominal output 8; Y401 rear ring to P
150 32 X2.28 PWM nominal output 9; Y215 release outrigger front left
151 32 X2.27 PWM nominal output 10; Y495 front axle pressure
regulation
154 32 X2.17 Differential lock
156 32 X2.19 Bridge +; Y216 release front right
157 32 X2.18 BRIDGE - not assigned
158 32 X2.26 Nominal output 11; Y402 front axle release
159 32 X2.25 Nominal output 12; Y403 rear axle release
160 32 X2.24 Nominal output 13, Y325-2 rear axle
emergency lowering
161 32 X2.23 Nominal output 14, Y325-1 front axle
emergency lowering
162 32 X2.22 Nominal output 15; Y350 emergency valve railcar brake
system
163 32 2.21 Nominal output 16; Y217 outrigger rear left release
LHB/en/Edition: 05/2010

164 32 2.20 Nominal output 17; Y218 outrigger rear right release
165 32 2.16 IOut1 not assigned
170 32 1.35 FIN(1); B259 speed sensor gearbox
171 32 X1.36 FIN (2) not assigned
172 32 X1.37 FIN (3) not assigned
173 32 X1.38 FIN (4) not assigned

Tab. 1 I/O values

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Service Manual ZW monitoring display (TDS01)
Checking of parameters, inputs and outputs

Call up the i-parameters service menu to view and adjust the parameter values of the rail guide
system. In this menu, you can also activate and deactivate various configurations and modes by
adjusting the relevant parameter values. This menu has been designed to assist mechanics in
identifying faults and errors.
Changes made in this menu must conform to the relevant adjustment instructions of the accessory
kits. Only 9 values can actually be adjusted (marked in the table with ) while all other settings are
protected. These values can be temporarily adjusted for testing and troubleshooting purposes. The
new settings can however not be saved.
If the ignition is switched off, the default values are applied. For details, see Tab. 2.
Press the F2/F3 (UP/DOWN) keys to select the i-parameters service menu and confirm by
pressing the menu key.
The parameter values are displayed.
Compare the parameter values with those in the table, see Tab. 2.
Use key F4 to page through the menu pages 1 to 10.
To exit the menu, press key F1 (BACK).

Fig. 4 i-parameters service menu

EP1 32 Minimum current for lowering (actuation of valves) 390 150 450
EP2 32 Maximum current for lowering (end position of valves) 600 300 700
EP3 32 Minimum pressure front axle in 1/10 bar 350 0 1200
EP4 32 Minimum pressure rear axle in 1/10 bar 350 0 1200
EP5 32 Window for minimum pressure adjustment in 1/10 bar 70 0 400
EP6 32 P amplification for lifting, position controller 50 0 1000
EP7 32 Switch-on threshold of accumulator charging function 1000 10 1000
LHB/en/Edition: 05/2010

EP8 32 Switch-off threshold of accumulator charging function 1300 500 2000


EP9 32 P amplification for lowering, position controller 25 0 1000
EP10 32 Window for position controller ON/OFF 250 ± 10 digital 10 0 30
value
EP11 32 Level sensor front travel gear up 100%. Digital value from 400 70 430
which "travel gear 100% up" is displayed.
EP12 32 Level sensor front travel gear down 0%. Digital value from 110 70 430
which "travel gear 0% down" is displayed.

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ZW monitoring display (TDS01) Service Manual
Checking of parameters, inputs and outputs

EP13 32 Reserve 0 0 0
EP14 32 Reserve 0 0 0
EP15 32 Level sensor rear travel gear up 100%. Digital value from 400 70 430
which "travel gear 100% up" is displayed.
EP16 32 Level sensor rear travel gear down 0%. Digital value from 110 70 430
which "travel gear 0% down" is displayed.
EP17 32 Reserve 0 0 0
EP18 32 Minimum current ring side to P 420 150 450
EP19 32 Maximum current ring side to P 650 300 700
EP20 32 Minimum current for lifting (bottom to T) 420 150 450
EP21 32 Maximum current for lifting (bottom to T) 550 300 700
EP22 32 Reserve 0 0 0
EP23 32 Reserve 0 0 0
EP24 32 Reserve 0 0 0
EP25 32 P amplification parallel lifting pressure value 15 0 500
EP26 32 P amplification minimum pressure controller 100 1 300
EP27 32 I amplification minimum pressure controller (reserve) 0 200
EP28 32 I-max for minimum pressure controller in 1/1000 1000 0 1000
EP29 32 P amplification for parallel lifting 8 0 1000
EP30 32 Data log reserve 0 0 0
EP31 32 Current ZW pump stand-by 800 0 900
EP32 32 Current ZW pump automatic 300 0 900
EP33 32 Current ZW pump maximum pressure 100 0 900
EP34 32 Current ZW pump fan performance 0% 800 0 900
EP35 32 Current ZW pump fan performance 100% 400 0 900
EP36 32 Speed-controlled reduction I lifting 550 0 900
EP37 32 Lifting value in 1/1000 for lifting in automatic mode 20 0 100
Shift value for traction increase
EP38 32 Total axle transmission ratio, e.g. 16.00*1.19=1904 1904 1000 4000 X
Axle-dependent factor for speed indication
EP39 32 Current ZW pump for maximum pressure in mA 100 100 1000
EP40 32 Current ZW pump for minimum pressure in mA 900 100 1000
EP41 32 Correction speedometer for friction wheel in % 187 1 2000 X
Axle-dependent factor for speed indication
EP42 32 Undercarriage inclination for overload available = 1 1 0 1 X
1 With inclination sensor, 0 Without inclination sensor
EP43 32 Warning threshold rail pressure 1/10 bar 150 100 230 X
Warning threshold for buzzer activation
LHB/en/Edition: 05/2010

EP44 32 Pressure limit for pressure increase in auto mode 1/10 bar 1200 800 2000
ZW pump to maximum value 100 mA
EP45 32 Current factor for parallel lifting 900 500 1000
EP46 32 Locking during swivelling 0 0 3 X
0 OFF, 1 front axle, 2 rear axle, 3 both axles
EP47 32 Window for locking in 1/10 degrees 100 30 500 X
Angle left/right when locking is activated

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Service Manual ZW monitoring display (TDS01)
Checking of parameters, inputs and outputs

EP48 32 Special function locking -1, pressure control -2 0 0 5 X


0 no special function, 1 locking during swivelling in
automatic mode, 2 pressure control
EP49 32 Potentiometer limit for pressure control limitation of 0 500 400 X
maximum lowering depth with pressure control by means of
potentiometers
EP50 32 Angle for activation of pressure control (not used) 100 0 500
EP51 32 Type of hydraulic block 0 hydraulic block for position control, 0 0 1 X
1 hydraulic block for pressure control, switchable
(not used)
EP52 32 Differential lock ON/OFF 0 0 1 X
0 no differential lock, 1 axles with differential lock
EP53 32 Level limit for release of differential lock 420 0 500 X
Level limit from which differential lock switching is released
EP54 32 Speed limit for differential lock release 30 0 350 X
from 3 km/h, the differential lock cannot be switched
EP55 32 Gauge of rail axles 1505 0 2000 X
Required to indicate banking height in mm (1435 mm +70
mm)
EP56 32 Display of banking in mm or degrees 0 0 1 X
0 display of banking in degrees, 1 display of banking in mm
EP57 32 Correction factor for automatic level control front axle 90 0 500 X
For type 1033 only; electrical automatic level control,
potentiometer in neutral position
EP58 32 Correction factor for rear axle automatic level control 90 0 500 X
For type 1033 only; electrical automatic level control,
potentiometer in neutral position
EP59 32 Upper level limit at friction wheel; type 1033 only 290 0 500 X
EP60 32 Lower level limit at rail; type 1033 only 720 0 900 X
EP61 32 Nominal automatic level; type 1033 only 250 0 500 X
EP62 32 Right switching angle ultrasonic obstacle warning 600 0 3600 X
Kit setup, value in 1/10 degrees (60°)
EP63 32 Switching angle left ultrasonic obstacle warning system 450 0 3600 X
Kit setup, value in 1/10 degrees (45°)
EP64 32 Release of function lock upon Prio 1 error 0 0 1 X
0 error handling for operation, 1 function lock deactivated,
technician mode
EP65 32 Hydraulic railcar brake ON/OFF 0 0 1 X
0 hydraulic railcar brake off, 1 hydraulic railcar brake on
EP66 32 Override of rail axle lock with SF 0 0 5 X
0= override off; 1= override on, type 1033 only
EP67 32 Activation of railcar brake system 2 air circuit 0 0 5 X
LHB/en/Edition: 05/2010

EP68 32 Railcar brake system 2 accumulator pressure monitoring 70 0 110 X


circuit
EP69 32 Current ZW pump 3 road travel axle 0 0 0 X
EP70 32 Emergency lowering in manual mode 0 0 1 X
In manual mode, the machine is lowered with emergency
lowering when the foot pedal is actuated
EP71 32 Changeover of ZW display to km 0 0 5 X
EP72 32 not assigned 0 0 0

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ZW monitoring display (TDS01) Service Manual
Checking of parameters, inputs and outputs

EP73 32 not assigned 0 0 0


EP74 32 not assigned 0 0 0
EP75 32 not assigned 0 0 0
EP76 32 not assigned 0 0 0
EP77 32 not assigned 0 0 0
EP78 32 not assigned 0 0 0
EP79 32 not assigned 0 0 0
EP80 32 not assigned 0 0 0

Tab. 2 Variables

Call up the i-variables service menu to view measurements, current values, internal values and
variables. This menu has been designed to assist mechanics in identifying faults and errors. For
details, see Tab. 3.
Press the F2/F3 (UP/DOWN) keys to select the i-variables service menu and confirm by pressing
the menu key.
The i-variables are displayed.
Compare the i-variables with those in the table, see Tab. 3.
Use key F4 to page through the menu pages 1 to 12.
To exit the menu, press key F1 (BACK).

Fig. 5 i-variables service menu


LHB/en/Edition: 05/2010

IV 1 32 Diesel engine operating hours


IV 2 32 Diesel engine operating minutes and seconds
IV 3 32 ZW mode operating hours
IV 4 32 ZW mode operating minutes and seconds
IV 5 32 Automatic ZW mode operating hours
IV 6 32 Automatic ZW mode operating minutes and seconds
IV7 32 ZW pump operating hours at Pmax

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Service Manual ZW monitoring display (TDS01)
Checking of parameters, inputs and outputs

IV8 32 ZW pump operating minutes and seconds at Pmax


IV9 32 not assigned
IV10 32 not assigned

IV50 32 Emergency lowering at rear activated (type 1033 only)


IV51 32 Emergency lowering at front activated (type 1033 only)
IV52 32 Nominal rail level front axle
IV53 32 Nominal rail level rear axle
IV54 32 Control variable front axle
IV55 32 PRessure difference for parallel lifting (type 1033 only)
IV56 32 Rear axle pressure / filtered average
IV57 32 Rail guide system
IV58 32 Parallel lifting end value (type 1033 only)
IV59 32 Lift-out activated
IV60 32 Front axle pressure / filtered average
IV61 32 Pressure rail guide system front left 1/10
IV62 32 Pressure rail guide system front right 1/10
IV63 32 Pressure rail guide system rear left 1/10
IV64 32 Pressure rail guide system rear right 1/10
IV65 32 ZW pump pressure 1/10
IV66 32 I actual ZW pump current in mA
IV67 32 I actual front bottom to P
IV68 32 I actual rear bottom to P
IV69 32 I actual rear released
IV70 32 I actual front activated lifting
IV71 32 I actual front bottom to tank
IV72 32 I actual rear bottom to tank
IV73 32 I actual rear activated lifting
IV74 32 not assigned
IV75 32 not assigned
IV76 32 not assigned
IV77 32 not assigned
IV78 32 not assigned
IV79 32 not assigned
IV80 32 not assigned
IV81 32 Pressure filtered front left 1/10
IV82 32 Pressure filtered front right 1/10
IV83 32 Pressure filtered rear left 1/10
LHB/en/Edition: 05/2010

IV84 32 Pressure filtered rear right 1/10


IV85 32 Pressure filtered ZW pump 1/10
IV86 32 Front control (type 1033 only)
IV87 32 Rear control (type 1033 only)
IV88 32 Front parallel lowering (type 1033 only)
IV89 32 Rear parallel lowering (type 1033 only)
IV90 32 Inclination angle undercarriage filtered

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ZW monitoring display (TDS01) Service Manual
Checking of parameters, inputs and outputs

IV91 32 Level front in 1/1000


IV92 32 Inclination angle undercarriage in 1/10
IV93 32 Level rear in 1/1000
IV94 32 Friction wheel activated = 1
IV95 32 1=foot pedal pressure actuated
IV96 32 Pump block 1 = pressure = 2 = recirculation
IV97 32 Fan nominal value from BBT
IV98 32 Speed step from BBT
IV99 32 Rear axle pressure (average value)
IV100 32 Front axle pressure (average value)
IV101 32 Maximum ZW pressure
IV102 32 Pressure increase in automatic mode activated
IV103 32 Parallel lowering integer (type 1033 only)
IV104 32 Uppercarriage turning angle
IV105 32 Locking angle (locking during swivelling)
IV106 32 I nominal ZW pump current in mA
IV107 32 I nominal front bottom to P
IV108 32 I nominal rear bottom to P
IV109 32 I nominal rear released
IV110 32 I nominal front active lifting
IV111 32 I nominal front bottom to tank
IV112 32 I nominal rear bottom to tank
IV113 32 I nominal rear active lifting
IV114 32 Outrigger release (type 1033 only)
IV115 32 Pressure control front axle (type 1033 only)
IV116 32 Indicator light swivelling (type 1033 only)
IV117 32 Bit locking upon swivelling activated (type 1033 only)
IV118 32 Bit pressure control activated (type 1033 only)
IV119 32 Bit top-up with pressure control of front axle activated
(type 1033 only)
IV120 32 Bit top-up with pressure control of rear axle activated
(type 1033 only)
IV121 32 Bit ZW operation activated
IV122 32 Bit differential lock activated (type 1033 only)
IV123 32 Pressure switch differential lock front axle (type 1033 only)
IV124 32 Pressure switch differential lock rear axle (type 1033 only)
IV125 32 Release of differential lock level (type 1033 only)
IV126 32 Inclination undercarriage sensor in mm
LHB/en/Edition: 05/2010

IV127 32 Inclination undercarriage sensor in degrees


IV128 32 Info bit from BST diesel engine running
IV129 32 Speed in 1/10 km/h
IV130 32 Stop valve front axle Y402
IV131 32 Stop valve rear axle Y403
IV132 32 Rail level front axle (type 1033 only)
IV133 32 Rail level rear axle (type 1033 only)

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Service Manual ZW monitoring display (TDS01)
Checking of parameters, inputs and outputs

IV134 32 Air pressure main brake line B321


IV135 32 Air pressure accumulator B320
IV136 32 Railcar brake on
IV137 32 Switching angle right ultrasonic obstacle warning
IV138 32 Switching angle left ultrasonic obstacle warning
IV139 32 Release ultrasound front axle
IV140 32 Release ultrasound rear axle
IV141 32 Travelling signal forward
IV142 32 Travelling signal reverse
IV143 32 not assigned
IV144 32 not assigned
IV145 32 not assigned
IV146 32 not assigned
IV147 32 Total km counter
IV148 32 Daily km counter
IV149 32 Monitoring display key test byte 1
IV150 32 Monitoring display key test byte 2

Tab. 3 IV internal variables


LHB/en/Edition: 05/2010

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ZW monitoring display (TDS01) Service Manual
Checking of parameters, inputs and outputs

LHB/en/Edition: 05/2010

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MJFCIFSS
Service Manual Monitoring display from V.4.7.2

Fig. 1 Monitoring display

Analogue indicator Indicator lamp - steering


Check display Temperature indicator - cooling water
Main screen Temperature indicator - cooling water
critical range
Screen menu control Fuel gauge
Indicator light - motor oil pressure Indicator: critical fuel level
Indicator light: battery BACK button
Direction indicator LED DOWN button
Indicator light: parking brake UP button
Indicator light: accumulator pressure MENU button
LHB/en/Edition: 12/2007

Working brake

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Monitoring display from V.4.7.2 Service Manual
Ranges of analogue indicator and check display

Display must be in green range during operation.


In the event of overheating (beyond 98°C), the red LEDs at the bottom of the display flash.
At the same time, the buzzer sounds an overheat alarm. A warning symbol appears on the LCD
screen. The system stores the error code .
Stop all works immediately.
Let engine continue in high idle (no load) for about 3 to 5 minutes.
The alarm message remains displayed for more than 60 seconds.
Set engine into low idle gear.
Switch off the engine.
Find and eliminate cause.

The LEDs lighting up on the analogue indicator show how much fuel is left in the tank.
When red LEDs light up, fuel remaining in the tank amounts to 10 - 20 %, i.e. about 50 litres
(depending on type of machine).

The indicator light lights up, if the oil pressure in the engine falls below a certain pre-set value
during operation (depends on current rpm).
Low oil pressure sets off an acoustic alarm in the operator's cab (buzzer), and the system stores the
incident under error code .
Immediately switch the engine to low idle gear.
Shut down engine immediately.

Indicator light lights up as soon as the starter button is in contact position.


The indicator light goes out as soon as the engine is started.
During operation, the indicator light lights up, if the V-belt of the alternator or the electrical charging
system are defective.
Immediately switch the engine to low idle gear.
LHB/en/Edition: 12/2007

Let engine run in low idle for about 20 seconds.


Switch off the engine.
Find and eliminate cause.

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Service Manual Monitoring display from V.4.7.2
Ranges of analogue indicator and check display

Light starts to flash whenever the direction indicator switch or hazard light have been actuated.

The indicator lamp lights up as soon as the parking brake has been engaged and/or the release
pressure of the parking brake has been undercut.

The indicator light lights up, if the accumulator pressure is too low. The brake may not be
functional any more.
Whenever this light is on, the occurrence is stored under error code . The buzzer gives two short
signals.
Shut down machine.
Set engine into low idle gear.
Move the safety lever to the top.
Check the brake system.

If there is insufficient accumulator charge pressure, the brake does not work properly.
In the event of a malfunction, move the machine from the danger area.

The indicator light lights up, if the oil flow going to the steering Servostat is insufficient.
Whenever this light is on, the occurrence is stored under error code . The buzzer gives two short
signals.
Immediately switch the engine to low idle gear.
Let engine continue in low idle for about 2 to 3 minutes.
Switch off the engine.
Check the steering pump and system.

If the oil flow rate to the steering Servostat is too low, the steering becomes stiff and can only be
operated with great force.
In the event of a malfunction, move the machine from the danger area and halt it there.
LHB/en/Edition: 12/2007

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Monitoring display from V.4.7.2 Service Manual
Menu control for screen

Fig. 2 LCD screen

The display has four buttons for operation:

Fig. 3 Menu control for screen

* Switching between main and submenus


Use these buttons to move from operator's menu to submenus (and back) or browse among pages.
LHB/en/Edition: 12/2007

Simultaneously press buttons MENU and (more contrast) or (less contrast).


The value set at this point is stored in the system.
Setting brightness of main screen
Simultaneously press buttons BACK and (brighter) or (darker).
The value set at this point is stored in the system.

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Service Manual Monitoring display from V.4.7.2
Main screen

There is a light sensor at the top left of the monitoring display. It controls the brightness of the main
screen with respect to the ambient brightness. Automatic brightness control is based on the basic
setting entered with the buttons. The display will be dimmed when the environment gets darker.

Switch off ignition.


Simultaneously press and hold buttons .
Switch on the ignition again.
Do not release the buttons before end of autocheck.

The main screen appears after the machine has been switched on and will remain visible until you
press and change to the menu selection screen.

Fig. 4 Main screen

Wire error Symbols / time


Information Total operating counter, daily counter
Current tool (Tool Control)

(see “Main screen” on page 5)


LHB/en/Edition: 12/2007

The time is displayed in the upper part of the screen. To the left, you see error messages and warning
symbols. If the system needs to display more than 2 symbols, the clock is hidden. If there is reason
to show more than 2 symbols, they will wander and disappear to the left, one symbol every 10
seconds.
For a list of the symbols shown in the SY field, refer to group 8.80.

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Monitoring display from V.4.7.2 Service Manual
Error messages - menu control

Display window EC shows the error codes of current electrical faults in the electronics of the
excavator (faults in the lines, sensors etc.). Up to seven error codes can be shown at any one time.
If there are more than seven faults, an arrow appears besides the error code window, showing where
else in the list error codes occurred. The total is shown at the bottom of the EC field.
Press buttons and/or
to scroll up or down through the error code window.
The possible error codes are listed in group 8.80.

The field INF (bottom right in the main screen) is for the display of temporary information, also in
graphic form. If there is reason to show more than three symbols, they move across the screen and
disappear to the left, one symbol every 10 seconds.
Displayed information comes in the form of graphics or text, indicating e.g. a function launched (pre-
heating etc.), important pointers and reminders (scheduled service check) and/or dangers (overload
etc.).
The possible instruction signs are listed in group 8.80.

This field, to the bottom right, displays machine operating hours, the daily operating hours counter
and the attachment selected.
The open-end spanner may appear when the ignition is engaged. It indicates that the next scheduled
service check is due.
The display usually showing the daily operating hours now shows the hours of the current service
interval. The service check symbol disappears after about 8 seconds.
The symbols next to item 1 show that there is a distinction between the Super Finish function and
accessory kit operation:

Fig. 5 Symbols in field TI

– Full circle (Super Finish not active; kit not active).


– Semi circle (kit operation activated with button ).
– Symbol Finish without operation of kits).
– Symbol with semi circle (Super Finish is and kit operation is ).
LHB/en/Edition: 12/2007

As soon as a fault condition displayed in field is confirmed as , the display returns to the main
screen window. The corresponding error output is active.
Depending on the actual occurrence (importance), there may be an acoustic signal at the same time
(buzzer), either continuously or in recurring intervals.
The symbol indicates a possibility to reset the buzzer (button ).
The possible error codes are listed in group 8.80.

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Service Manual Monitoring display from V.4.7.2
On-road travel symbols on main screen

If the error indicated is not eliminated immediately, there is a danger people get hurt or equipment
gets damaged.
Make sure all faults are dealt with without delay.
To switch of buzzer, press BACK.
The error message is acknowledged and stored.

When travelling on public roads, you must conform to the relevant statutory regulations.
Before undertaking a journey, inform yourself of the local regulations.
Find out whether your machine is approved and registered for travel on public roads.
Always strictly adhere to the regulations.

Fig. 6 On-road travel, position of working attachment, optimised centre of gravity for type 1031

The total weight of the machine is distributed unevenly onto the axles, depending on the respective
position of the uppercarriage and the working attachment.
Sometimes, the permissible maximum axle load for travel on public roads is laid down in the national
regulations.
The weight of the rear axle of type 1031 (machine with outrigger support) might exceed 12 t, provided
that the working attachment is moved as closely as possible to the uppercarriage.
The following instructions are based on a . In order to keep
the load of the rear axle below this limit, the centre of gravity must be moved forward.
LHB/en/Edition: 12/2007

facilitate the adjustment.


Description of symbols:

This symbol is displayed, if the slewing boom is positioned in such a way that the rear
axle load is within the limits.

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Monitoring display from V.4.7.2 Service Manual
Output of information via menus in LCD screen

This symbol is displayed, if the are positioned in such


a way that the rear axle load is within the limits.

The servo control is switched on.


The uppercarriage is aligned in travel direction: steering (oscillating) axle at the front.
Move the slewing boom to its top position and lower it slowly.
Position the slewing boom in such a way that the "Slewing boom position correct" symbol is
displayed, see Fig. 6.
The symbol appears for approx. 20 seconds.
Slowly adjust the position of the boom until the "Boom / slewing boom position correct" is
displayed, see Fig. 6.
The symbol appears for approx. 20 seconds.
Position the stick in a vertical position.

Display DISP 02
Keypad BBT-02
Excavator control BST-EHR / UEC

Fig. 7 Menu selection "Reset hours" - operator's menu

Press the button on the main screen.


The list of available menus is displayed, see Fig. 7
LHB/en/Edition: 12/2007

To select a menu, press the buttons and/or .


The preceding and/or next operator's menu appears against a black background.
The selected menu appears in inverse graphics. (The example shows the menu
.)
Press the button again.
The sub-menu of the selected function appears.
Press the button
to exit the function.

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Service Manual Monitoring display from V.4.7.2
Level 1 for operators (no dongle required for access)

Execution of the various functions requires authorisations (service level), which are organised in
various levels. This sort of organisation allows to limit access to certain functions that require a certain
degree of knowledge to those persons who know the machine and components.

The first level can be accessed by everybody. For levels 2 and 3, personnel need a dongle for
or for amplifier board containing the appropriate coding,

Resetting the clock counting daily operating hours

Working speed in mode SF


– Slewing gear fine control
– Grapple fine control

Confirming scheduled service check

Tool Control. Selection of flow control depending on


attachment used (e.g. hammer).

Information regarding operating hours

Information regarding electrical inputs/outputs

Errors (operating errors and electrical system errors)


LHB/en/Edition: 12/2007

Stroke and boom limitation

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Monitoring display from V.4.7.2 Service Manual
Levels 2 and 3 for mechanics and inspectors

Adjusting the time settings

Automatic central lubrication system mode (optional


equipment)

Purge mode
Starting diesel engine in PURGE mode
(only displayed if diesel engine is off)

Tab. 1 Overview - menu items

– All the functionalities pertaining to level 1 plus


information concerning diesel engine.
– Menu of data stored (hours, errors etc.)
– setting parameters and errors via the serial
interface of the BBT.
– Setting external flow limitations of consumers
(hammer, grapple etc.)
– Pre-setting values for performance test
– Defining error code suppression and
individual excavator functions
– Erasing test error memories
for mechanics ( required for access)

– All the functions of level 2.


– Setting additional device-specific parameters
– Erasing additional error memories
– Releasing additional device-specific menu
items (e.g. immobiliser)
LHB/en/Edition: 12/2007

for inspectors ( required for access)

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Service Manual Monitoring display from V.4.7.2
Menu control

The description below refers to the menu control of the basic model. For ZW-specific menus, refer
to the service manual, (see “ZW-specific menu control” on page 11).

set data set ctrl.1.1 Group 3.42 Adjustment protocol


Group 3.47 Testing and adjusting tasks
set data set A 900 ZW Group 16.10 Option control
set data set o-ctrl Group 3.42 Adjustment protocol
Group 3.47 Testing and adjusting tasks
Group 8.62 Calibration of pedals
Group 16.10 Option control
set grease Group 18.54 Automatic lubrication system
i-HBG-SBG Group 16.50 Stroke and boom limitation
Group 16.52 Parameter adjustment

Tab. 2 ZW-specific menu control


LHB/en/Edition: 12/2007

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Monitoring display from V.4.7.2 Service Manual
Menu control

LHB/en/Edition: 12/2007

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Service Manual Control panel
Coding plug

Fig. 1 Connections between coding plug and keyboard

Control panel Coding plug


Microprocessor EEPROM memory for operational data
Connection plug Coding of machine type
Indication display

The control panel of the machine (called from now on) has a coding plug on connection plug
LHB/en/Edition: 04/2007

. Its purpose is as follows:

15-pin plug detects the type of machine, thanks to the hardware coding. In the absence of a valid
coding plug, the keyboard is not operational.

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Control panel Service Manual
Replacing control panel

The coding plug stores current machine data in a data memory (serial EEPROM), as listed below.
Thanks to this method, it is possible to exchange keyboards and re-enter data from the plug into the
new keyboard.
Data stored:
– Type of equipment, serial number and settings in menu
– Current operating hour
– Current operating times (screen )
– Current settings of flow limitation (internal and external values)
– Currently selected flow limitation options
– Error memory for water level )
– Error memory for water temperature
– Error memory for hydraulic oil
– Error memory for hydraulic oil temperature
– Error memory for motor oil pressure
– Confirmed service intervals / service checks
Transfer of data from the keyboard to the coding plug for storage is carried out
– automatically, every 30 minutes approx.
– It is possible, in addition, to force a copy of the data stored pressing buttons and
(see following paragraph) in order to save data to the plug, e.g. before you exchange the .

Fig. 2 Printed circuit board , service plug and parameters in display

Before you replace the panel, you should read the most important parameters of the keyboard in
LHB/en/Edition: 04/2007

the display and write them down (i.e. serial no., operating hours, flow limitations, number of
operating errors E5xx in error memory etc. See menus , and ).
Before you replace the , check the data in the coding plug.
Switch off ignition. Insert green service plug into of board ( ) (see Fig. 2).

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Service Manual Control panel
Secure data in coding plug.

Fig. 3 Checking keyboard data

Switch off ignition. Insert service plug. Press and hold buttons and . Hold buttons
and, simultaneously, turn key on position.
The keyboard will now check its data against the data stored in the plug.
If the data is okay, the display will show the message .
If the keyboard and plug data do not match, the keyboard data will be automatically copied to
the plug. (LEDs of speed adjustment flash running signal).
Finally, a message will appear.
LHB/en/Edition: 04/2007

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MJFCIFSS
Control panel Service Manual
Replacing keyboard S2

Fig. 4 rear view

Be sure to switch off main power switch before you disconnect the connection plug.
Remove connection plugs from keyboard you want to remove. Plug into new keyboard. Plug in
correctly. Secure. (see Fig. 4)
Automatic transfer of data from coding plug to new keyboard
– As soon as the control is launched (self-check), the data in the EEPROM are automatically
checked. The data stored will then be automatically transferred from the plug to the new keyboard.
– Data transfer is indicated by running light signal of the speed adjustment LEDs on the keyboard.
– When finished, all the important data listed and essential for operation are available in the new
keyboard.
Checking transferred data in the new BBT:
– Call up display menu and compare data indicated with data you wrote down before replacement. LHB/en/Edition: 04/2007

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Service Manual Control panel
Replacing glow bulbs of backlit keyboard

Fig. 5 Layout of glow bulbs in operator keyboard

– The backlit keyboard has six glow bulbs ( ) underneath upper part of keyboard.
– New keyboards are always supplied with two spares.

Remove keyboard from right-hand control desk.


Remove four M3 Philips screws in the sides of the keyboard housing. Lift off upper part of
keyboard.
For safety reasons: Do not disconnect plug connection ( ) see Fig. 5 between top and bottom
parts of keyboard.
Pull out old bulb ( ) from socket.
Pull spare ( ), see Fig. 5, from socket. Or insert spare bulb ID no. 6004408 (see ET spare parts
catalogue) into socket.
LHB/en/Edition: 04/2007

Replace upper part of keyboard. Replace four lateral M3 Philips screws.


Replace keyboard into control desk.

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Control panel Service Manual
Replacing glow bulbs of backlit keyboard

LHB/en/Edition: 04/2007

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Service Manual Error code list
Error code list

Malfunctions and errors are indicated by indicator lights or symbols on the monitoring display. In
certain cases, an acoustic warning signal is generated. Additional information that facilitates the
elimination of the problem is provided by error codes.
Malfunctions and errors are frequently caused by incorrect operation of the machine or improper
maintenance.
Each time you encounter a malfunction, read the relevant chapter in the operator's manual and/
or refer to the respective subgroup in the service manual.
Check the basic settings of the machine.
Identify the cause of the malfunction or error and eliminate it.

Fig. 1 LIEBHERR customer service

E 002 Engine oil pressure not monitored Pressure switch, short circuit, earth Check engine oil level,
E 003 Pressure switch B5 (X154/14) contact or wire break check pressure switch; replace, if
necessary
E 004 Coolant temperature not monitored Water level sensor, short circuit, Check cooling water level,
Water level sensor B3 (X135/13) earth contact or wire break check water level sensor; replace, if
E 005
necessary
E 006
E 007 Coolant temperature not monitored Temperature sensor, short circuit, Check cooler for dirt, check
E 008 Water temperature sensor earth contact or wire break temperature sensor; replace if
B2 (X135/40) necessary
E 009
E 010 Hydraulic oil level not monitored Hydraulic oil level sensor, short Check hydraulic oil level, check
E 011 Hydraulic oil level sensor circuit, earth contact or wire break hydraulic oil level sensor; replace, if
B14 (X135/31) necessary
E 012
LHB/en/Edition: 09/2012

E 013 Hydraulic oil temperature not Hydraulic oil temperature sensor, Check cooler for dirt, check hydraulic
E 014 monitored short circuit, earth contact or wire oil temperature sensor; replace if
Hydraulic oil temperature sensor break necessary
E 015 B8 (X135/21)
E 016 Pump distributor gear (if installed): Temperature sensor, short circuit, Check plug and cable connections,
E 017 gear oil temperature not monitored earth contact or wire break check temperature sensor; replace, if
Transmission temperature sensor necessary
E 018 B15 (X135/35)

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Error code list Service Manual
Error code list

E 022 Diesel engine speed not monitored; Speed sensor, short circuit, earth Switch diesel engine and hydraulic
diesel engine speed cannot be contact or wire break pump to emergency mode, see
E 023
changed through keyboard; reduced group 8.81 "Emergency operation"
E 024 hydraulic power Check speed sensor; replace, if
Diesel engine speed sensor necessary
B12 (X135/1)
E 027 Insufficient hydraulic power Cable defect at the amplifier for the Switch hydraulic pump to emergency
Power regulator solenoid performance regulation of the mode, see group 8.81 "Emergency
Y50 (X135/9 hydraulic pump operation"
E 030 Proportional solenoid valve Y451 Cable break at proportional solenoid Check solenoid valve Y347; replace,
(X135/8) not monitored; proportional valve Y514 if necessary
pressure control is not possible Check plug and cable connections;
E 033 Maximum fan speed Fan control, cable defective Check solenoid valve Y347; replace,
Fan control regulator solenoid if necessary
Y347 (EV5 X135/5) check fan control
E 036 Flow reduction for hydraulic Cable defect at the amplifier for the Do not operate flow-reduced
attachments is not working properly flow regulation of the hydraulic pump attachments, check solenoid valve
Flow reduction regulating solenoid Y51; replace, if necessary
Y51 (EV1 X135/7)
E 039 Flow reduction for hydraulic Cable defect at the amplifier for the Do not operate flow-reduced
attachments is not working properly flow regulation of the second attachments, check solenoid valve
Flow reduction regulating solenoid hydraulic pump Y52; replace, if necessary
Y52 (EV2 X135/6)
E 042 Slewing gear fine control not working Cable defect at valve Check solenoid valves; replace, if
Y451 (A 900 C - A 904 C) necessary
Monitoring of hydraulic oil cooling not Cable defect at valve Check plug and cable connections;
(EV3X135/25)
working Y53 (A 914C - A 924 C)
No power reduction at slewing gear Cable defect at valve
Y103 (A 934 C - A 954 C)
Performance regulation of hydraulic Wire break at valve
pump not working properly
E 045 Insufficient pressure for attachment Tool Control, cable defect at Check pressure control valve Y429;
pressure control valve Y414 (EV6) replace, if necessary
E 046 Separating plate over S38(SF3) can Wire break at solenoid valve Y431 Check plug and cable connections;
now longer the activated if necessary, replace solenoid valve
No kit operation Y431
E 053 Stick cannot be moved Angle sensor, short circuit, earth Check potentiometer; replace, if
E 054 Potentiometer B317 (X1/5) contact or wire break necessary Check plug and cable
E 055 connections
E 056 Fine control of slewing gear not Pressure sensor, earth contact or Check pressure switch at left servo
responding wire break control unit; replace, if necessary
E 057
Pressure sensor B335 (X1/21)
E 058
E 063 Engine power reduced Temperature sensor of intercooling Check temperature sensor; replace,
E 065 (XA/50) air, earth contact or short to plus if necessary

E 070 not assigned


E 072 No information re. intercooling air Intercooling pressure sensor, short Check intercooling air pressure
available circuit or wire break sensor; replace, if necessary
LHB/en/Edition: 09/2012

E 073
(XA/47)
E 074 Diesel engine cannot be started Starter, earth contact or wire break Check starter; replace, if necessary
E 075 Starter start terminal 15 (XA/29) Check plug and cable connections

E 078 - PLD hardware failure Check plug and cable connections;


E 079 PLD software error check software

E 081 In the event of a failure of both speed Speed sensor Speed1 Check speed sensor; replace, if
E 082 sensors, the engine cannot be Speed sensor Speed2 necessary
started

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Service Manual Error code list
Error code list

E 084 Failure of pre-heating and after- Cold-starting aid, short circuit, Check engine control unit, heater
heating function malfunction or wire beak flange, cable harness
E 085
E 086
E 087 Error is displayed Speed difference between Speed1 Check speed sensor; replace, if
and Speed2 necessary
E 088 Engine power reduced Fault in ambient air pressure sensor Check cabling and sensor; replace, if
necessary
E 089 Machine cannot be started Cable defect, water in fuel filter Check cabling between engine
control unit and sensor, dewater fuel
filter
E 090 Fuel temperature is not transmitted, Fuel temperature sensor, earth Check cabling between engine
engine performance is reduced contact, wire break or short to plus control unit and sensor; replace, if
E 091
(XA/52) necessary
E 098 Error is displayed Fault in cable connection D+ to PLD Check alternator and cabling to
(XA/64) electronics alternator; replace alternator, if
necessary
E 099 Alternator defective
E 100 Error is displayed Speed signal Speed1 Check speed sensor, cabling to
E 101 Speed signal Speed2 engine control unit; replace, if
necessary
E 102 Engine cannot be started Crank shaft synchronisation failed Check ignition (on/off) and speed
sensor; replace, if necessary
E 103 Error is displayed Speed sensor of cam shaft defective Check cabling to speed transducer,
E 104 No speed signal from cam shaft speed sensor; replace, if necessary

E 105 Engine cannot be started Cam shaft synchronisation failed Check speed sensor; replace, if
necessary
E 109 Error is displayed CAN1 hardware failure Check cabling, plugs and CAN
E 110 No CAN1 data (timeout) assemblies

E 111 Error is displayed Injector A1 defective Check cabling, plug and engine
control unit
E 112 Error is displayed Injector A1 BIP fault
E 113 Error is displayed Injector A2 defective
E 114 Error is displayed Injector A2 BIP fault
E 115 Error is displayed Injector A3 BIP defective
E 116 Error is displayed Injector A3 BIP fault
E 117 Error is displayed Injector A4 BIP defective
E 118 Error is displayed Injector A4 BIP fault
E 119 Error is displayed Injector B1 BIP defective Check cabling, plug and engine
E 120 Error is displayed Injector B1 BIP fault control unit

E 121 Error is displayed Injector B2 BIP defective


E 122 Error is displayed Injector B2 BIP defective
E 123 Error is displayed Injector B3 BIP defective
E 124 Error is displayed Injector B3 BIP defective
E 125 Error is displayed Injector B4 BIP defective
LHB/en/Edition: 09/2012

E 126 Error is displayed Injector B4 BIP defective


E 127 Error is displayed Bank1 parameters missing
E 128 Error is displayed Bank2 parameters missing
E 135 Error is displayed 5V reference 1 defective Check cabling, plug and engine
E 136 Error is displayed 5V reference 2 defective control unit

E 137 Error is displayed 5V reference 3 defective


E 138 Error is displayed 5V reference 4 defective

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Error code list Service Manual
Error code list

E 150 Servo pressure is not measured Wire break Check plug and cable connections;
B359 Current at pressure sensor B359 check pressure sensor B359;
<3mA replace, if necessary
E 151 Servo pressure is not measured Short circuit Check plug and cable connections;
B359 Current at pressure sensor B359 check pressure sensor B359;
>21mA replace, if necessary
E 302 Input through keyboard not possible No code plug
(X42)
E 303 Engine speed cannot be adjusted No CAN bus connection between Switch diesel engine and hydraulic
through the keyboard, hydraulic keyboard and control system (BST) pump to emergency mode, see
performance is reduced (Message might appear even if BST group 8.81 "Emergency operation"
Reduced hydraulic power in PLD excavator control is not operational, Y50 emergency operation of working
machines e.g. no power supply, etc.) pumps Y50 (only in PLD machines)
E 305 Malfunctions, e.g. of travel brake, No CAN bus connection between Switch control to emergency mode,
slewing gear brake, servo control keyboard and ESP01 printed circuit see group 8.81 "Emergency
board (message is also displayed, if operation"
ESP01 is not ready for operation) Check cable and plug connections
E 306 Malfunctions, e.g. in travel direction No CAN bus connection between Check cable and plug connections
switch, gear shifting system, keyboard and ESP02 printed circuit
oscillating axle locking mechanism, board (message is also displayed, if
accessory kits ESP02 is not ready for operation)
E 307 Throttle control not possible No CAN bus connection between Check cable and plug connections
PLD electronics A700 keyboard and PLD diesel engine
regulating unit (message is also
displayed, if PLD regulator is not
ready for operation)
E 308 No or incorrect display No CAN bus connection of keyboard Check cable and plug connections
to display, or keyboard defective Check software versions
E 309 Software incompatibility between
keyboard and display
E 311 The ZW control panel and/or the No CAN bus connection between Check cable and plug connections
main screen remain blank control system / ZW control panel, or
fault at ZW control panel
E 312 Control system failure No CAN bus connection between Check cable and plug connections
BBT and option control system
E 314 Diesel engine switches to Timeout of PLD
emergency mode
E 315 Machine cannot be moved, travel No CAN bus connection between Check cable and plug connections
function remains available UEC stroke limitation and UEC
undercarriage
E 317 Tool management not working No CAN bus connection to control Check cable and plug connections
system
E 318 Proportional control not working No CAN bus connection to control Check cable and plug connections
system (A180)
E 319 Engine speed cannot be adjusted Hardware coding does not match Switch diesel engine and hydraulic
through the keyboard, hydraulic software coding pump to emergency mode, check
E 321 performance reduced No known machine type received software versions
Code plug X42
from keyboard
LHB/en/Edition: 09/2012

Hardware coding X44


E 322 Unknown hardware coding
E 361 Overload shut-off not working No communication with control Check cables and plug connections,
(ESX-LT-A191) check fuse F394
E 362 Data logger not working No communication with data logger Check cables and plug connections,
check fuses F394 and F395
E 363 Data cannot be saved Indicator light in switch S525 is off; Check memory card and data logger
memory card defective or no memory
card inserted in slot CF1

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Service Manual Error code list
Error code list

E 442 Failure of idle automatic at left servo Handle sensor, short circuit, earth Deactivate idle automatic, check
control unit, engine remains at lower contact or wire break handle sensor; replace, if necessary
E 443
speed; handle sensor B19L
E 445 Failure of idle automatic at right Handle sensor, short circuit, earth Deactivate idle automatic S20,
E 446 servo control unit, engine remains at contact or wire break check handle sensor; replace, if
lower speed; handle sensor B19R necessary

E 447 Pressure for regulating travel motor Ground connection, wire break Check cable and plug connections
not monitored Cable fault at pressure sensor B144, Check pressure sensor; replace, if
current <3mA or >21mA necessary
E 450 Engine speed reduction at lowering Pressure sensor, short circuit, earth Check pressure sensor; replace, if
of attachment (pressure-free contact or wire break necessary
lowering)
Pressure sensor B145
E 454 Speed sensor for slewing gear Slewing gear speed sensor, slewing Check speed sensor; replace, if
mechanism without function; non- gear, short circuit, earth contact or necessary
E 455
compliance results in damage to wire break
slewing gear brake
Speed sensor B53
E 456 Incorrect fuel level indication Fuel sensor, short circuit, earth Visually check fuel level, check tank
Tank sensor B39 contact or wire break sensor; replace, if necessary
E 458

E 901 Overload warning system generates Pressure sensor in hoist cylinder Check pressure sensor; replace, if
warning signal and shuts down defective necessary
working attachment Pressure sensor B335
A141.X1.31
E 902 Reduced payload Failure of angle sensor B384 at Check cable and plug connections
horizontally adjustable boom Do not execute any work that
requires horizontal boom adjustment
Check angle sensor; replace, if
necessary
E 903 Failure of overload warning system Pressure sensor B318 of hoist Do not execute any work that
A141.X1.33 cylinder 1 faulty requires overload warning; check
E 904 Failure of overload warning system Pressure sensor B319 of hoist pressure sensor; replace, if
necessary
A141.X1.34 cylinder 2 faulty
E 905 Failure of overload warning system Failure of angle sensor of basic Do not execute any work that
and stroke limitation A141.X1.25 boom requires overload warning or stroke
limitation; check angle sensor;
E 906 Failure of overload warning system Angle sensor of boom faulty
and stroke limitation A141.X1.26 replace, if necessary

E 907 Failure of overload warning system Angle sensor of stick faulty


and stroke limitation A141.X1.27
E 908 Failure of overload warning system Failure of angle sensor of stick
and stroke limitation
A141.X1.28
LHB/en/Edition: 09/2012

E 909 Failure of boom limitation Angle sensor of slewing gear faulty Do not execute any work that
A141.X1.29 requires boom limitation
E 910 Failure of boom limitation Pressure sensor of slewing gear Do not execute any work that
A141.X1.30 faulty requires boom limitation; check
pressure sensor; replace, if
necessary
E 911 Control system failure Error in EEPROM record Check control data record

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Error code list Service Manual
Error code list

E 912 Uppercarriage cannot be swivelled to No release signal to control system Check cable and plug connections
the left A141.X2.36 for swivelling to the left Check control system
E 913 Uppercarriage cannot be swivelled to No release signal to control system
the right A141.X2.35 for swivelling to the right
E 914 Hoist cylinder cannot be moved No release signal for lifting the hoist
A141.X2.34 cylinder to control system
E 915 Slewing gear fails to turn or turns Slewing gear fine control Y451 Check cable and plug connections;
only very slowly A141.X2.33 Wire break, short circuit check control output DO.4 (X2.33)
E 916 Hoist cylinder cannot be moved No release signal to control system Check cable and plug connections
A141.X2.32. for hoist cylinder preliminary shut- Check control system
down
E 917 Adjustable boom cylinder cannot be No release signal for lifting of
moved A141.X2.31. adjustable boom cylinder to control
system
E 918 Adjustable boom cylinder cannot be No release signal to control system
moved A141.X2.30 for adjustable boom cylinder
E 919 Stick cylinder cannot be moved No release signal for lifting of stick
A141.X2.29 cylinder to control system
E 920 Adjustable boom cylinder cannot be No release signal to control system
moved A141.X2.28 for adjustable boom cylinder
E 921 Super Finish does not work Super Finish solenoid valve, earth
A141.X2.27 contact or wire break
E 929 Working attachment cannot be Stroke limitation, failure in power Switch stroke limitation to
operated supply to sensors emergency mode, check cable and
plug connections
E 941 Automatic mode of rail guide system High pressure sensor at left front axle Move machine from the track, check
is switched off, manual lifting and defective A140.X1.26 B330 cable and plug connections
lowering remains possible Check sensors; replace, if necessary
E 942 High-pressure sensor at right front
axle defective A140.X1.25
E 943 High-pressure sensor at right rear
axle defective A140.X1.28
E 944 High-pressure sensor at left rear axle
defective A140.X1.27
E 945 High pressure sensor of ZW pump
defective A140.X1.29
E 946 Travel function and rail gear locked Level sensor of front rail guide Check cable and plug connections
system defective A140.X1.32 Check sensors; replace, if necessary
E 947 No angle value is sent to overload Inclination sensor defective
warning system and a less
favourable angle is applied; warning
signals are therefore triggered earlier
A140.X1.30
E 948 Travel function and rail gear locked Level sensor of rear rail guide system Check cable and plug connections
defective Check sensors; replace, if necessary
E 949 Front axle verification error Switching points of proximity switch Check cable and plug connections
are outside permissible range of Check switching point of proximity
angle sensor switch (indicator light)
LHB/en/Edition: 09/2012

Rail gear lowered: 370 ±15


Rail gear lifted: 885 ±75
E 950 Rear axle verification error Switching points of proximity switch Check cable and plug connections
are outside permissible range of Check switching point of proximity
angle sensor switch (indicator light)
Rail gear lowered: 370 ±15
Rail gear lifted: 885 ±75

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Service Manual Error code list
Error code list

E 951 Pump is fully swivelled out, even if Wire break at pump valve Check cable and plug connections
there is no need for this movement
Automatic rail guide mode is
switched off A140.X2.36
E 952 Automatic rail guide mode is Front rail guide system - wire break Move machine from the track, check
switched off at valve, at pump side (P) cable and plug connections
A140.X2.32
E 953 Rear rail guide system - wire break at
valve, at pump side (P) A140.X2.29
E 954 Valve of rear axle pressure control
A140.X2.32
E 955 Front rail guide system - wire break
at valve, at pump side (P)
A140.X2.35
E 956 Front rail guide system - wire break
at valve, at tank side (T) A140.X2.31
E 957 Rear rail guide system - wire break at
valve, at tank side (T) A140.X2.30
E 958 Rear rail guide system - wire break at
valve, at pump side (P) A140.X2.29
E 959 Valve outrigger release, front left
A140.X2.28
E 960 Valve of front axle pressure control
A140.X2.27
E 961 Is displayed, if automatic mode has One of the above faults has
been terminated due to one of the terminated the automatic mode
above faults
E 962 No CAN bus connection between CAN bus timeout to uppercarriage Check CAN bus connection
control (uppercarriage) and control control (stroke limitation) Check cables and plug connections
(undercarriage) between the control units
Check slip-ring rotary connection
E 963 ZW control panel without function CAN bus timeout TDS 01 Carry out emergency lowering
Automatic rail guide mode is manoeuvre
switched off Using the hand-operated emergency
Manual lifting and lowering is not control device, lift the rail guide axles
possible Move machine from the track, see
group 8.81
E 964 Acoustic warning signal indicating Pressure of one of the rail guide Move machine from the track; check
that machine might become derailed axles is too low traction; readjust, if necessary
With friction wheel guide system:
loss of traction or incorrect traction
settings
E 965 Machine cannot be steered properly Power supply UB1, UB2 or UB3 If necessary move machine from the
Automatic rail guide mode is interrupted Cable or fuse defective track, check cable and plug
switched off connections
Replace fuse, if necessary
E 966 Automatic rail guide mode is Reference voltage overload at angle Move machine from the track; check
switched off sensors sensors
LHB/en/Edition: 09/2012

Manual lifting and lowering is


possible
E 967 Automatic rail guide mode is Overload at protected output voltage Move machine from the track, check
switched off fuse; replace, if necessary
Manual lifting and lowering is
possible
E 968 When switching off the ignition, no Constant positive pole supply Replace fuse, if necessary
data is stored defective
E 969 Error is displayed Info: new software has been loaded Check software version

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Error code list Service Manual
Error code list

E 970 Right AHS pedal faulty A159.X1.25 Short circuit or wire break signal 1 Check cable and plug connections
E 971 Right AHS pedal faulty A159.X1.26 Short circuit or wire break signal 2 Check cable and plug connections
E 972 Left AHS pedal faulty A159.X1.27 Short circuit or wire break signal 1 Check cable and plug connections
E 973 Left AHS pedal faulty A159.X1.28 Short circuit or wire break signal 2 Check cable and plug connections
E 974 Travelling pedal faulty A159.X1.29 Short circuit or wire break signal 1 Check cable and plug connections
E 975 Travelling pedal faulty A159.X1.30 Short circuit or wire break signal 2 Check cable and plug connections
E 976 Error is displayed Error in EEPROM Check control system
E 977 Affected functions are locked Error in I/O configuration due to Check display programming
duplicate assignment
E 978 Right AHS pedal faulty Comparison error signals 1 and 2 Check cable and plug connections
E 979 Left AHS pedal faulty Comparison error signals 1 and 2 Check cable and plug connections
E 980 Travelling pedal faulty Comparison error signals 1 and 2 Check cable and plug connections
E 981 Adjustable boom cylinder cannot be Solenoid valve, short circuit or wire Check cable and plug connections
extended A159.X2.36 break
E 982 Adjustable boom cylinder cannot be Solenoid valve Y481, short circuit or Check cable and plug connections
retracted A159.X2.35 wire break If necessary, replace solenoid valve
E 983 Failure of function "closing cylinder Solenoid valve Y482, short circuit or Check cable and plug connections
A1" A159.X2.34 wire break If necessary, replace solenoid valve
E 984 Failure of function "closing cylinder Solenoid valve Y483, short circuit or Check cable and plug connections
A2" A159.X2.33 wire break If necessary, replace solenoid valve
E 985 Failure of function "travel" Solenoid valve Y353, short circuit or Check cable and plug connections
A159.X2.32 wire break If necessary, replace solenoid valve
E 986 Left AHS pedal faulty A159.X2.31 Solenoid valve Y485, short circuit or Check cable and plug connections
wire break If necessary, replace solenoid valve
E 987 Right AHS pedal faulty A159.X2.30 Solenoid valve Y484, short circuit or Check cable and plug connections
wire break If necessary, replace solenoid valve
E 988 Failure of function "grapple turning" Solenoid valve Y23, short circuit or Check cable and plug connections
A159.X2.29 wire break If necessary, replace solenoid valve
E 989 Failure of function "grapple turning" Solenoid valve Y22, short circuit or Check cable and plug connections
A159.X2.28 wire break If necessary, replace solenoid valve
E 990 Magnet system failure A159.X2.27 Solenoid valve Y500, magnet Check cable and plug connections
system, short circuit or wire break If necessary, replace solenoid valve
E 991 Failure of function "reverse travel" Solenoid valve, magnet system, Check cable and plug connections
Y63 A159.X2.26 short circuit or wire break If necessary, replace solenoid valve
E 992 Failure of function "forward travel" Short circuit or wire break Check cable and plug connections
Y62 A159.X2.25 If necessary, replace solenoid valve
E 993 Control system switching not Solenoid valve, short circuit or wire Check cable and plug connections
possible break If necessary, replace solenoid valve
E 994 Working attachment cannot be Stroke limitation, failure in power Switch on stroke limitation
operated A159.X1.11 supply to sensors

The faults and errors listed below are indicated by symbols on the screen or by indicator lights. The
respective error codes are not shown in the EC field of the operator menu. The only way to read them
is the "list-S-Exxx" menu.
LHB/en/Edition: 09/2012

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Service Manual Error code list
Error code list

E 501 Indicator light H2 on, Oil pressure of diesel engine too Set the diesel engine to low idle
acoustic warning signal low speed and switch it off after 30
seconds

E 502 Symbol is displayed, Coolant level too low Set the diesel engine to low idle
acoustic warning signal speed and switch it off after 30
seconds; locate leak and seal it

E 503 Symbol and P2 are on at the Coolant overheating Set the diesel engine to low idle
same time, acoustic warning speed and shut it down after 30
signal seconds; check cooler for dirt; check
coolant level
E 504 Symbol is displayed, Hydraulic oil level too low Set the diesel engine to low idle
acoustic warning signal speed and shut it down after 30
seconds; locate leak and seal it; add
hydraulic oil
E 505 Symbol is displayed, Hydraulic oil overheating Set the diesel engine to low idle
acoustic warning signal speed and shut it down after 30
seconds; check cooler for dirt

E 506 Symbol is displayed, Oil temperature in pump Set the diesel engine to low idle
acoustic warning signal distribution gear too high speed and shut it down after 30
seconds; check hydraulic oil cooler
for dirt
E 509 Indicator light H24 on, Flow indication of steering Check hydraulic system of steering
acoustic warning signal system: no hydraulic oil or system; check flow indicator and
steering pump defective steering pump; replace, if necessary

E 510 Indicator light H23 on, Accumulator pressure of Load accumulator while diesel
acoustic warning signal operating brake too low engine is on; if problem persists:
(< 100 bar)

E 511 Symbol is displayed Overvoltage at control panel

E 512 Problems at start-up of Battery voltage too low,


hydraulic excavator; symbol undervoltage at PLD
is displayed

E 513 Control shuts down hydraulic Battery voltage too high,


excavator; battery gasses, overvoltage at PLD
symbol is displayed

E 514 Central lubrication system: Signal to clock pulse generator Carry out intermediate lubrication
E 515 lubrication control without valve continues after the set
function, symbol is displayed monitoring time has lapsed
(clock pulse generator B51)
E 516 Diesel engine cannot be Emergency-stop EDC error,
started, or engine shut-down engine control has detected an
LHB/en/Edition: 09/2012

internal error

E 517 Diesel engine shuts down; Injector fault


symbol is displayed

E 518 Diesel engine shuts down; Start synchronisation error


symbol is displayed

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Error code list Service Manual
Error code list

E 519 Symbol is displayed, Engine speed: warning threshold


acoustic warning signal exceeded

E 520 Diesel engine shuts down; Engine speed: safety threshold


symbol is displayed, exceeded
acoustic warning signal

E 521 Diesel engine shuts down; Both speed transducers


symbol is displayed defective

E 522 Diesel engine shuts down; Low lubricating oil pressure


symbol is displayed, (safety threshold exceeded)
acoustic warning signal

E 523 Symbol is displayed, Coolant overheating (7> Let machine cool down, e.g. in F
acoustic warning signal seconds); safety threshold mode; check cooler for dirt; check
exceeded coolant level

E 524 Symbol is displayed, Intercooling air overheating Check cooler for dirt
acoustic warning signal (7>seconds); safety threshold
exceeded

E 525 Symbol is displayed, Engine fault in emergency mode. Set the diesel engine to low idle
acoustic warning signal Engine was started in speed and switch it off after 30
Collective warning after error emergency mode; no connection seconds
E501, E502, etc. between engine control system
and keyboard
E 526 Symbol is displayed, Fuel temperature: warning Check radiator for dirt
acoustic warning signal threshold exceeded

E 527 Symbol is displayed, Fuel temperature: safety Set the diesel engine to low idle
acoustic warning signal threshold exceeded speed and switch it off after 30
seconds

E 528 Symbol is displayed Water in fuel filter Remove the water from the fuel filter

E 530 Diesel engine shuts down; Internal error in engine control Restart the engine; in the event of
symbol is displayed, unit failure
acoustic warning signal

E 532 Symbol is displayed Fuel pressure: warning threshold Check fuel, filter, tank
exceeded

E 533 Symbol is displayed Fuel pressure: safety threshold Set the diesel engine to low idle
exceeded speed and shut it down after 30
LHB/en/Edition: 09/2012

seconds

E 534 Symbol is displayed Fuel pressure: warning threshold


exceeded

E 535 Symbol is displayed Fuel pressure: safety threshold


exceeded

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Service Manual Error code list
Troubleshooting

E 536 Symbol is displayed Fuel pressure Rail 1; warning


threshold exceeded

E 537 Symbol is displayed Fuel pressure Rail 1; safety


threshold exceeded

E 538 Symbol is displayed Fuel pressure Rail 2; warning


threshold exceeded

E 539 Symbol is displayed Fuel pressure Rail 2; safety


threshold exceeded

E 597 Engine power reduced; Intercooling air temperature: Let machine cool down, e.g. in F
symbol displayed, acoustic warning threshold exceeded mode; check cooler for dirt
warning signal

* Screen symbol or indicator light

In machines equipped with a hydraulic quick-change adapter (optional equipment), an additional


warning symbol is shown in the field:

This symbol, together with a buzzer warning sound, indicates that the quick-change adapter is not
properly locked.
If the symbol is displayed, immediately halt operation, unless you wish to release the adapter. If the
symbol is not displayed while the quick-change adapter is being released, also immediately stop the
procedure.
The alarm signals might be triggered if a lock bolt has inadvertently become dislodged, or by
mechanical or hydraulic damage. The alarm signals might also be caused by defects in the electrical
system (e.g. at the proximity switch or buzzer).
Only resume operation after the defective part has been repaired or replaced.
LHB/en/Edition: 09/2012

Starter fails to turn Main fuse defective Replace fuse


Battery connections loose or corroded Clean and tighten loose connections
Battery voltage too low Charge or replace battery
Starter circuit open, or contacts Contact LIEBHERR customer service.
corroded
Starter defective Contact LIEBHERR customer service.

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Error code list Service Manual
Troubleshooting

Starter turns slowly Battery voltage too low Charge or replace battery
Battery connections loose or corroded Clean and tighten loose connections
Ambient temperature too low Take measures required for winter
operation
Diesel engine fails to start Fuel tank nearly/completely empty Add fuel and bleed fuel system
Underpressure in tank Remove tank lid
Fuel filter dirty Clean or change filter and bleed fuel
system; drain off fuel / clean tank
Ambient temperature below 0°C For operation and control under extreme
conditions, see operating instructions
Heater flange defective (at low Check heater flange; replace, if
temperatures) necessary
Starter failure Check line connections, service starter
Batteries flat Recharge / replace batteries
Engine starts, but stops immediately or Fuel tank empty (underpressure in tank) Add fuel and bleed fuel system
runs irregularly Fuel filter dirty Clean or change filter and bleed fuel
system (tank)
During cold season: engine oil viscosity Use an engine oil that is suitable for the
too high actual ambient temperature
Dry air filter dirty Clean or replace main filter element
Air in fuel system Bleed fuel system
Bleeder valve in fuel tank blocked Cleaning
Fuel line, pre-filter or strainer in fuel tank Clean and bleed fuel system
blocked
Fuel line kinked Check line and repair, if required
Diesel engine emits grey or black fumes Dry air filter dirty Clean or replace filter
Injection nozzles jammed or no injection
Turbo charger defective
Diesel engine constantly emits steam Water in combustion chamber
Injection too late
Heater flange defective (at low Check heater flange; replace, if
temperatures) necessary
Blue exhaust fumes Oil level too high Correct oil level
Lubricating oil in combustion chamber
Crankcase ventilation defective
Diesel engine knocking Combustion problems
Diesel engine knocking Excessive valve play
Injection nozzles damaged or
carbonised
Damaged bearing
LHB/en/Edition: 09/2012

Piston rings worn or broken


Diesel engine does not reach full speed Throttle control not set to maximum Set throttle control to maximum value
value
Injection unit settings incorrect
Dry air filter dirty Clean or replace filter
Insufficient fuel supply Clean or replace fuel filter; check lines,
drain water from tank

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Service Manual Error code list
Troubleshooting

Poor diesel engine performance Fuel system defective (blockage, Visually check for leakage; replace filter
leakage)
Intercooling pressure too low Visual inspection for loose clamps,
defective seals and damaged hoses;
clean air filter
Intercooling air temperature too high Clean intercooling cooler
(power reduced by engine control unit)
Coolant temperature too high (power Check coolant level; check cooler for
reduced by engine control unit) dirt, clean if necessary; check fan and
thermostat
Fuel temperature too high (power
reduced by engine control unit)
Injection nozzles jammed or no injection
Diesel engine compression too low
Fault in electronics
Diesel engine too hot Insufficient coolant Add coolant, check for tightness
Water pump defective Repair
Thermostats fail to work Replace thermostats
Radiator dirty Clean radiator
Coolant temperature sensor defective Contact LIEBHERR customer service
Insufficient oil pressure in diesel engine Oil level too low Adjust oil level
Oil pressure indicator defective Change oil pressure switch
Immediately switch off diesel engine
Diesel engine uses too much oil Leakage in diesel engine Retighten screws; replace seals, if
required
Oil in coolant or coolant in oil Contact LIEBHERR customer service.
Unusual noises / noise at exhaust side Leakage in exhaust gas system Check / repair exhaust gas system

Unusual noises / noise from hydraulic Stop valve on hydraulic tank closed Open stop valve
pumps Hydraulic pumps take in air Check oil level in hydraulic tank, check
suction lines for leakage
Immediately switch off diesel engine
Modes E and P show poor performance No performance adjustment by means Disconnect cable at connection Y50,
of proportional solenoid valve Y50 remove cotter pin, set handle switch to
emergency position
Hydraulic oil temperature too high Radiator dirty Clean radiator
Fan or fan control defective Eliminate fault
Hydraulic oil level too low Oil loss Repair leak, replace hoses, add oil
LHB/en/Edition: 09/2012

through the return filter

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Error code list Service Manual
Troubleshooting

Travel function not available Safety lever moved up Move safety lever down
No direction of travel selected Select direction of travel using the travel
selection switch in the right joystick
Pressure switch of parking brake
defective
Parking brake not released Release parking brake using the switch
Parking brake cannot be released with Servo pressure OK:
the switch actuate emergency function Y6
No servo pressure:
operating brake applied Release operating brake
Slewing gear failure Servo control not working Move safety lever down
Switch on servo control
Slewing gear brake activated Move safety lever down
Release slewing gear brake
No working movement Servo control not working Move safety lever down
Switch on servo control
No servo pressure
No pump high pressure

Machine fails to travel forward or back Safety lever moved up Move the safety lever down. Release
Parking brake applied with switch parking brake with switch
No direction of travel selected Preselect direction of travel with
Operating brake applied with brake switch
pedal and retainer Release operating brake with the
retainer
Machine moves too slowly Incorrect gear ratio reduction with Select different gear ratio reduction,
switch using switch
Creeper gear activated with switch Deactivate creeper gear with switch
Travelling pedal cannot be fully pushed Clean cab floor
down Deactivate Super-Finish with
Super-Finish activated with switch switch (if installed) Switch off
(if installed) emergency control and switch machine
Emergency control activated to standard operating mode.
LHB/en/Edition: 09/2012

Warning message re. accumulator Fault in steering pump


charge pressure Brake accumulator defective

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Service Manual Error code list
Troubleshooting

Battery charging indicator light does not V-belt of alternator loose or broken Tighten or replace V-belt.
go off Alternator defective Replace alternator.
Batteries not sufficiently charged Batteries defective Replace batteries.
Battery connections dirty / oxidised Clean battery connections.
Cable loose or defective Connect or replace cable.
Failure of indicator light or indicating Incandescent lamp burnt out; indicating Replace defective part
instrument instrument defective
Failure of one or more instrument panel Adapters disconnected or defective; Plug in or change adapter; eliminate
functions earth connector disconnected; short cause of short circuit; replace fuse or
circuit - fuse blown reset automatic cut-out.
Diesel engine speed cannot be adjusted Low idle automatic switch actuated Touch joystick or release switch of low
through keyboard (mode and arrow idle automatic
keys) Excavator electronics for throttle control Changeover to emergency control for
not working throttle control and
No signal from speed sensor
Low idle automatic without function; Permanent sensor signal Contact LIEBHERR customer service.
speed fails to drop Switch deactivated Activate switch
Servo control cannot be activated with Fault in electrical system of excavator Activate emergency operation with
switch switch in the right joystick
Parking brake cannot be released with Caution: The servo and brake circuit can
switch now only be switched off with the safety
lever Keyboard is disabled
Slewing gear brake cannot be released
with switch

No warm air from heating system Stop valves of coolant line at diesel Open stop valve
engine closed
Engine not at operating temperature Run engine to operating temperature
Heating blower not working No power Check fuse and cable; replace if
required
Blower motor defective Replace blower motor
Low air circulation rate in operator's cab Ambient air filter / recirculated air filter Clean air intake openings; replace
dirty ambient air filter
Air outlet closed Open air outlet.
LHB/en/Edition: 09/2012

Cylinder responds to load Piston seal in cylinder defective Service cylinder


Excessive bearing play in attachment Bearings worn Replace bearing components.
Attachment cannot be rotated / Auxiliary function not activated Release auxiliary function with switch
swivelled / operated S19
Lines not connected Connect lines

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Error code list Service Manual
Troubleshooting

Rail guide axles cannot be moved ZW system is switched off Switch on ZW system.
One rail guide axle is locked Release rail guide axle.
Hydraulic or electrical fault See error code table
Automatic rail guide mode is switched Hydraulic or electrical fault (e.g. angle See error code table
off sensor)
Manual lifting and lowering is possible
Cylinder responds to load Piston seal in cylinder defective Service cylinder.
Poor tracking, rough travelling Excessive play at bearings, bearing Replace bearing components.
points worn
Rail wheels excessively worn Replace or re-turn rail wheels (max. to
wear limit).
Poor traction, drive wheels spinning, Tyres worn Replace tyres
poor braking behaviour Load to be moved requires increased Briefly activate "lift rail guide" function
contact pressure
Impression depth of drive wheels
insufficient, despite intact tyres

Rail guide axles cannot be moved ZW system is switched off Switch on ZW system.
One rail guide axle is locked Release rail guide axle
Hydraulic or electrical fault See error code table
Automatic rail guide mode is switched Hydraulic or electrical fault (e.g. angle See error code table
off sensor)
Manual lifting and lowering is possible
Cylinder responds to load Piston seal in cylinder defective Service cylinder
Poor tracking, rough travelling Excessive play at bearings, bearing Replace bearing components
points worn
Rail wheels excessively worn Replace or re-turn rail wheels (max. to
wear limit).
Poor traction, drive wheels spinning, Tyres worn Replace tyres
poor braking behaviour Load to be moved requires increased Briefly activate "lift rail guide" function
contact pressure
Impression depth of drive wheels
insufficient, despite intact tyres
LHB/en/Edition: 09/2012

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Service Manual Emergency actuation (emergency operation)
Emergency hydraulics (optional equipment)

Fig. 1 Emergency hydraulics fuse

The fuse of the emergency hydraulics is accessible when the right access door is opened.

300 A Emergency hydraulics

In certain situations, it might be necessary to restore a function that failed before the machine is
properly repaired. Depending on the type and extent of the malfunction, this might be achieved by
setting the machine to emergency mode.
In emergency mode, certain control electronics and control elements are bypassed so that certain
functions can be controlled directly. This mode allows for the temporary limited operation of the
machine.
Emergency mode is designed for use in emergency situations only.
Due to the reduced functionality of the machine in emergency mode and the associated risks, this
mode may only be used in exceptional situations.
:

– Control Short-term continuation of operation until repair can


– Gear shifting system be performed (it is always recommended to carry out
repairs without delay)

– Hydraulic pump Move the machine away from the construction site or
– Slewing gear brake a dangerous position (immediate repair is required)
– Stroke limitation
– Boom limitation
LHB/en/Edition: 09/2008

– Travelling
– Emergency hydraulics

– Disengage transmission Tow the machine to the workshop

Tab. 1 Emergency mode, purpose

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Emergency actuation (emergency operation) Service Manual
Emergency mode control

In emergency mode, certain safety functions of the control system are disabled. This can lead to
accidents or damage to the machine.
Use the emergency mode only for the intended purpose.
Inform all persons involved in the operation and maintenance of the machine that it is in
emergency mode.
Immediately switch off the emergency mode when it is no longer required.
All repairs to the machine must be carried out without delay.

In the event of a failure of the steering electronics, certain machine components might not work
properly.
Depending on the type and extend of the malfunction, it might be possible to re-establish proper
operating conditions for the machine components:
The emergency control feature includes three functions:
– Emergency operation of diesel engine
– Emergency speed adjustment
– Emergency control of control devices
These functions may be combined with each other.
The control panel for emergency control operation is located in the rear section of the right control
console.

Fig. 2 Control panel in the right control console


LHB/en/Edition: 09/2008

Fig. 3 Control panel for emergency control

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Service Manual Emergency actuation (emergency operation)
Emergency operation of diesel engine

Emergency start / emergency operation Speed adjustment switch


switch for diesel engine
Switch for emergency operation Emergency control indicator light
Diesel engine failure indicator light

In normal operating mode, the electronic devices of the diesel engine communicate with the control
electronics of the machine. In the event of a malfunction or failure, it might not be possible to start the
diesel engine or to control it properly. In such a case, the diesel engine can be started in emergency
mode.
Press the emergency start switch to the right.
Start the diesel engine with the ignition key.
The indicator light is on.
The symbol is shown at the display.
The diesel engine runs in emergency mode.
Resetting to normal operating mode is only possible after the diesel engine has been switched off
and restarted again.

In emergency mode, communication between the diesel engine and the control electronics of the
machine might be impaired. Error messages from the diesel engine might not be displayed. In
addition, the following safety functions are disabled:
– Automatic shut-down of the diesel engine in the event of insufficient engine oil pressure
– Automatic shut-down of the diesel engine in the event of excessive coolant or intercooling air
temperature

Engine failures are indicated as follows:


– The indicator light at the emergency control unit is on.
– Acoustic warning signal
– Error code
Immediately shut down the diesel engine, if an engine failure is indicated in diesel engine
emergency mode, or if the operating status is outside the permissible range (e.g. overheating).
Do not operate the diesel engine in emergency mode for longer than is necessary in order to bring
the machine to the repair workshop.

The emergency speed adjustment caters for the following failures:


– Power selection (mode) with switch
LHB/en/Edition: 09/2008

– Speed adjustment by means of arrow buttons and


If the diesel engine is in emergency mode, the engine speed can be adjusted with the switch .
The operator can set the engine to an upper or a lower emergency speed.
Push the switch to left (tortoise icon): Lower emergency speed
Push the switch to right (hare icon): Upper emergency speed

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Emergency actuation (emergency operation) Service Manual
Emergency control of control devices

If the diesel engine has been automatically switched into emergency mode, the current engine
speed is maintained.

The emergency control of the control devices caters for the following situations:
– servo control
– Parking brake, slewing gear brake

In emergency mode, the servo control system, the parking brake and the slewing gear brake cannot
be operated with the normal switches and buttons, but only with the safety lever.
In emergency mode, the machine might make unexpected movements when the safety lever is
pushed down (instant release of slewing gear brake and parking brake). There is thus an increased
risk of accidents!
Therefore, use the emergency mode for control devices only when absolutely necessary.
In emergency mode, only complete the manoeuvres necessary to remove the machine from the
danger zone.

Fig. 4 Emergency control screen

Move the safety lever up.


Press the switch to the right.
The emergency control system is now on.
The emergency mode symbols are shown on the display.
The servo control, the parking brake and the slewing gear brake can now be operated with the
safety lever.
Move the safety lever down.
The parking brake and the slewing gear brake are released.
The servo control is activated.

In the event of a failure in the pump control, the performance of the hydraulic pumps is automatically
reduced to a minimum.
For such a situation, the excavator is equipped with an emergency operation system for the hydraulic
pump.
LHB/en/Edition: 09/2008

It bypasses the control electronics so that the hydraulic pump can be operated at an only slightly
reduced output rate.

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Service Manual Emergency actuation (emergency operation)
Emergency operation of servo control

Fig. 5 Control oil unit, hydraulic pump emergency operation

Switch off the diesel engine.


Disconnect the plug connector .
Remove the cotter pin .
Move the lever into a horizontal position (emergency position).
The hydraulic pump is switched to emergency operation.
Start the diesel engine.

The the emergency control for the servo control system is used, if it is not possible to restore the servo
control with any other emergency mode. In this case, the respective solenoid valve must be
operated by hand.
The solenoid valve is equipped with an emergency actuating device.

Fig. 6 Control oil unit, servo control emergency operation


LHB/en/Edition: 09/2008

Switch off the diesel engine.


Fully turn in the handle of the solenoid valve .
Servo control is activated.
Start the diesel engine.

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Emergency actuation (emergency operation) Service Manual
Emergency operation of slewing gear brake

The safety lever is disabled while the machine is in servo control emergency mode. If a joystick is
moved inadvertently, the machine might perform an unexpected movement. There is thus an
increased risk of accidents!
Therefore, use the emergency mode for control devices only when absolutely necessary.
In emergency mode, only complete the manoeuvres necessary to remove the machine from the
danger zone.

The emergency control for the slewing gear brake is used, if it is not possible to release the slewing
gear brake in any other emergency mode. In this case, the respective solenoid valve must be
operated by hand.
The solenoid valve is equipped with an emergency actuating device.

The slewing gear brake is immediately released when the slewing gear emergency operation is
actuated. The machine might perform an unexpected movement. There is thus an increased risk of
accidents!
Therefore, use the emergency control for the slewing gear brake only when absolutely
necessary.
In emergency mode, only complete the manoeuvres necessary to remove the machine from the
danger zone.

Fig. 7 Control oil unit, solenoid valve Y7 (slewing gear brake)

Switch off the diesel engine.


Fully turn in the handle of the solenoid valve .
LHB/en/Edition: 09/2008

Start the diesel engine.

When the shut-down points are reached, the stroke and boom limitation disconnects the pilot control
devices of the working tool and/or slewing gear. The pilot control equipment is again released, when

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Service Manual Emergency actuation (emergency operation)
Emergency operation of stroke and boom limitation (optional equipment)

the limitation function is switched off or when the components are again within the permissible range
of movement.
In the event of a control system failure, the release signal might not be generated, so that the working
attachment or the uppercarriage cannot be moved.
In this case, the respective solenoid valves must be operated by hand. The solenoid valves are
equipped with an emergency actuating device. They is located beside the engine compartment at the
rear of the operator's cab.
The emergency operation of the stroke and boom limitation is designed for assistance when the
following functions fail:
– Control of the working attachment
– Control of the slewing gear

Fig. 8 Valve block for stroke and boom limitation, travel direction preselection

Solenoid valve / tilt cylinder release


Solenoid valve / boom cylinder release
Solenoid valve / boom regulating cylinder release
Solenoid valve / slewing gear, left
Solenoid valve / slewing gear, right
Solenoid valve / stick cylinder release
Solenoid valve / boom cylinder preliminary shut-down

If one of the above solenoid valves fails, all other solenoid valves for boom limitation or slewing gear
movement are disabled. This means that these valves must be operated in emergency mode.
Switch off the diesel engine.
LHB/en/Edition: 09/2008

Fully turn in the T-handle of the following solenoid valves: .


Then switch solenoid valve .

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Emergency actuation (emergency operation) Service Manual
Travel emergency mode

Fig. 9 Valve bloc, solenoid valve Y420

At the solenoid valve , the emergency operation is actuated by means of a lever.


Remove the cotter pin .
Move the lever into a horizontal position.
The working attachment is released and can be operated.

Fully turn in the T-handle of the following solenoid valves: .


The slewing gear is released and can be operated.
Start the diesel engine.

In the event of a failure of the control system, the travel pedal might become disabled and the
machine cannot be moved.
In this case, the respective solenoid valves must be operated by hand.
The solenoid valve determines the direction of travel is and is actuated with the travel
direction switch. It is located beside the engine compartment at the rear of the operator's cab. The
valve is attached to a bracket or integrated into the valve block of the stroke and boom limitation
system (if installed).
The solenoid valve on the control oil unit is used to switch on travel operation and is actuated
with the travel pedal.
In the event of a failure of the above solenoid valves, all other solenoid valves involved in travel
operation are automatically disabled ( and ). This means that these valves must be
operated in emergency mode.
The solenoid valves are equipped with a n emergency actuating device. The method by when the
machine can be set to travel mode depends on the cause of the failure.
LHB/en/Edition: 09/2008

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Service Manual Emergency actuation (emergency operation)
Travel emergency mode

Fig. 10 Cable harness for emergency operation

Plug for solenoid valve Plug for 24 V socket (cigarette lighter)


Button

Failure of "Forward travel" or "Reverse travel" Select direction of travel, then


function respectively ( and ) simulate travel pedal operation with the cable
harness.
Travel pedal malfunction

Failure of "Travel" function ( ) Enable travel function, then simulate


the travel direction switch with the cable
harness.

The cable harness supplied with the machine is required for both methods. By connecting the
respective solenoid valve, the travel pedal or the travel direction switch function can be simulated.
LHB/en/Edition: 09/2008

Fig. 11 Valve Y62/63, select travel direction

Check pin
Forward travel
Neutral position - no travel direction selected
Reverse travel

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Emergency actuation (emergency operation) Service Manual
Travel emergency mode

The spool of the solenoid valve is extended outwards and can be shifted by hand. A check
pin is thereby moved inside the manual shift gate and indicates the current switching position.
Switch off the diesel engine.
Turn and shift the spool until the check pin is in the desired position.
The travel direction is preselected.

Tab. 2 Control oil unit, valve Y353, "Travel" function

Travel pedal plug Emergency mode cable harness plug


Solenoid valve "Travel" function

The solenoid valve can be shifted by means of a manual button. To do this, connect the
supplied cable harness.
Remove the plug from the solenoid valve .
Connect the plug of the cable harness.
Lay the cable so that can it be reached from the operator seat.
Connect the plug of the cable harness to the socket of the cigarette lighter (24 V).
Start the diesel engine.
Press and hold the button at the cable harness.
The machine begins to move.
Release the button.
The machine is halted.
LHB/en/Edition: 09/2008

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Service Manual Emergency actuation (emergency operation)
Travel emergency mode

Fig. 12 Control oil unit, valve Y353, releasing travel function

The solenoid valve can be shifted to continuous mode by means of a lever.


Switch off the diesel engine.
Remove the plug from the solenoid valve .
Remove the lead seal at the solenoid valve with a suitable tool (e.g. wire cutter).
Move the lever into a horizontal position (emergency position).
The travel valve is released.

The machine begins to move immediately after the travel function has been released and the travel
selection control is actuated. If there is no operator in the cab, the machine moves without a driver.
This can of course lead to serious injury or even death.
Never operate the solenoid valve manually.
Operate the cable harness with the button while seated on the operator seat (see section below).
LHB/en/Edition: 09/2008

Fig. 13 Valve Y62/63, simulating travel direction switch

Plug of travel direction switch Cable harness plug


Check pin

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Emergency actuation (emergency operation) Service Manual
Emergency hydraulics (optional equipment)

The solenoid valve can be shifted by means of a manual button. To do this, connect the
supplied cable harness see Fig. 10.
Ensure that the check pin is engaged in the neutral position .
Remove both plugs from the solenoid valve.
Insert the plug of the cable harness to the solenoid valve, observing the following instructions
for the selection of the direction of travel: - reverse / - forward.
Lay the cable so that can it be reached from the operator seat.
Connect the plug of the cable harness to the socket of the cigarette lighter (24 V).
Start the diesel engine.
Press and hold the button at the cable harness.
The machine begins to move.
Release the button.
The machine is halted.

The emergency hydraulics make it possible to continue all working and travel motions of the
machines in the event the hydraulic pumps or diesel engine cut out - at least for a certain period of
time.
The emergency hydraulics are powered electrically. Their only purpose is to move the machine out
of the danger zone. Power is supplied from an on-board power system (batteries) or from some
external source.
The emergency hydraulics work only, if the diesel engine and/or generator stand still.

The batteries of the on-board power system can guarantee operation only for about 3 minutes.
When external power supplies are used, on the other hand, there is a danger of overloading the
electric motor.
Please note that the period for which you can use the emergency hydraulics depends on the
state of the batteries.
If using an external power source: Do not operate the emergency hydraulics for longer than 5
minutes in order to prevent an overload of the electric motor.

LHB/en/Edition: 09/2008

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Service Manual Emergency actuation (emergency operation)
Emergency hydraulics (optional equipment)

Fig. 14 Key switch and ball valve of the emergency hydraulics

The control elements of the emergency hydraulics are accessible when the right access door is
opened.

Before you use the emergency hydraulics, it may be necessary to switch to a different operating
mode by actuating the block ball valve:

Components of the emergency hydraulics may be damaged.


Before you change the operating mode, switch emergency hydraulics off.

Hydraulic excavator All components of the machine can be actuated. The functionality of
the rail guide axles is restricted. The machine cannot be lifted from
the track.
Rail guide Only the rail guide axles can be actuated. It is possible to lift the
machine from the track.

Select a mode as needed: Turn block ball valve to position or .


LHB/en/Edition: 09/2008

Select position only for lifting the machine.

The ignition must be on.


The switch (SF3) must be on.
The diesel engine must be off.
Insert the key into the key switch .
Turn the key switch to position .

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Emergency actuation (emergency operation) Service Manual
Emergency gear shifting

Emergency hydraulics are now on and may be used.


A buzzer sound (warning signal) is audible in the operator's cab.
Move machine out of danger zone.
Operate and control functions with emergency hydraulics as in normal operation.
After completion of the process: Turn the key switch to position .
The emergency hydraulics are off.
The warning signal is off.
We recommend to operate emergency hydraulics once every month to prevent seizure of the
hydraulic pump.

If the parking brake cannot be released, this could be due to a failure of the solenoid valve of the gear
shifting system. In this case, turn in the valve manually (emergency operation).

Fig. 15 Valve block of the gear shifting system

Turn in the T-handle at the solenoid valve .


The machine is now in second gear and the parking brake is released.
The machine can now be moved.

Towing the machine is a dangerous manoeuvre, and the responsibility for any damage in connection
with towing rests with the operator.
The machine may only be towed in exceptional situations, e.g. if the machine must be moved for
safety reasons or if it must be repaired at the workshop.
Injuries to persons or damage to equipment caused by towing of the machine are not covered by the
manufacturer's warranty.
LHB/en/Edition: 09/2008

The travel drive can be damaged, if the machine is towed over a certain distance without
disengaging the transmission.
If possible, disengage the transmission before towing the machine see 14.
Adhere to the maximum distance and speed for towing.

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Service Manual Emergency actuation (emergency operation)
Disengaging transmission (emergency release)

Risk of injury! Risk of damage to property!


To tow the machine, use a suitably dimensioned rod.
Never use a cable or rope.

Secure the towing rod to the towing hitch at the undercarriage.


When towing the machine, adhere to the following limits:
– Towing speed: maximum 5 km/h
– Towing distance - at released parking brake: few metres (to remove the machine from a
dangerous position).
– Towing distance - with disengaged transmission: maximum 5 km

When the transmission is disengaged, the parking brake is disabled. The machine might roll away,
if another brake (working brake) is disabled.
When the diesel engine is off the transmission is disengaged, all brakes (working brake,
parking brake) are disabled. The machine might roll away, and the steering is stiff so that its
operation requires some force.
Before disengaging the transmission, secure the machine against rolling off (with towing rod or
chocks).

The transmission can be disengaged by pressing in grease. The respective adapter for connection
to the transmission is found in the tool box.
LHB/en/Edition: 09/2008

Fig. 16 Transmission

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Emergency actuation (emergency operation) Service Manual
Disengaging transmission (emergency release)

Fig. 17 Pressing in grease with the adapter

Emergency release connection Bleeder


Pressure-relief valve Grease gun
Adapter

Attach the adapter to the grease gun .


Engage the adapter at the connection .
Press in grease until it escapes at the pressure-relief valve .
The transmission is disengaged.
The machine can now be towed.
When the diesel engine is on and no other malfunctions are apparent, the machine can be stopped
with the working brake (foot pedal) and steered with the servo steering.
If the diesel engine is not running: all brakes of the machine are disabled!

The transmission might be damaged, if it is disengaged for a prolonged period of time while the
machine is in motion.
Do not put the machine into gear and do not press the accelerator while the transmission is
disengaged.

Loosen the bleeder using a wrench and open it until grease escapes.
Start the diesel engine.
Release the parking brake while the working brake (pedal) remains applied.
Repeatedly shift gear .
Leave the bleeder open until no grease escapes.
Switch off the diesel engine.
Close and tighten the bleeder .
The transmission is re-engaged.
LHB/en/Edition: 09/2008

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Service Manual Slip ring rotary connection
Function

Machines with electrical equipment in the undercarriage (e.g. pressure switches, solenoid valves,
angle sensors, etc.) must be equipped with a special rotary connection for electrical power from the
uppercarriage to the undercarriage.
This slip ring rotary connection is screw-mounted to the 6x oil rotary connection.
Depending on the requirements regarding the rotary connection, a varying number of slip rings/
contact brackets and microswitches are installed.

Fig. 1 Slip ring rotary connection


LHB/en/Edition: 11/2007

The base flange , adapter ring and the associated slip rings are fixed to the stator of the oil
rotary connection and thus permanently fixed to the undercarriage.
The base plate with the contact bracket holder , the shim and the contact bracket is fixed
to the rotor of the oil rotary connection, and thus permanently fixed to the uppercarriage.
In order to allow for the uppercarriage to rotate on the undercarriage, the slip ring is mounted on the
base flange with the groove ball bearing .

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Slip ring rotary connection Service Manual
Description

The slip rings is mounted on the microswitch attachment and the angle sensor of the
swivel angle limitation (optional).
The hood as well as the hood pipe with the O-ring protect the slip ring against physical impact
and contamination.

Fig. 2 Slip ring rotary connection

LHB/en/Edition: 11/2007

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Service Manual Slip ring rotary connection
Functional description

Fig. 3 Exploded view of the slip ring

Adapter ring O-ring


Bearing washer (base plate) Deep groove ball bearing
Base flange Lock washer
Hood, glued to hood pipe 7 Snap ring
Ring 38X42X8 Snap ring
Slip ring 40X2 Lock washer
Hood pipe, glued to hood 4 Hex nut
Threaded cable gland Potentiometer holding plate
Insulating ferrule Notch ring
Slip ring 40X2 Washer with chamfer
Contact bracket, gold-plated Hexagon cap nut
Contact bracket, nickel-plate Washer
Shim Angle gauge (optional)
Contact bracket holder Threaded cable gland
Cover plate Hex nut
Microswitch attachment Hex nut
Forcing screw

(see Fig. 5 on page 6)


The current is fed from the uppercarriage to the undercarriage and vice versa through the electrical
lines that are connected to the contact brackets and the slip rings respectively.
All contact brackets are permanently pressed against the associated slip rings ,
irrespective of the position of the uppercarriage to the undercarriage, thus providing an electrical
connection between the units in the uppercarriage and the undercarriage.

The cable assignment of the individual slip rings/contact brackets is shown in the wiring diagram in
and the diagram below.

Class 30 UEC undercarriage


Class 15 UEC undercarriage
Class 15 UEC undercarriage
LHB/en/Edition: 11/2007

CAN 1.L (gold-plated)


CAN 1.H (gold-plated)
CAN - GND
CAN 2.L (gold-plated)
CAN 2.H (gold-plated)
ZW ON emergency-stop
Emergency-stop

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Slip ring rotary connection Service Manual
Maintenance

Creeper gear Y24


Switching driving/outriggers
ZW pump actuation
Wagon brake Y432
Wagon brake Y433
21 Ground
22 Ground

Hold the nut and loosen the hexagon nut .


Remove the hood 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.
Close the hood with the hood pipe and tighten the nuts.

The slip ring body is easily damaged by humidity, as an oxidant layer might form on the conducting
surfaces, impairing the conductivity. As a consequence, the electrical consumers in the
undercarriage are insufficiently supplied with current, which can result in malfunctions.
Slip ring contacts must be regularly treated with Cramolin contact spray
,

LHB/en/Edition: 11/2007

Fig. 4 Electrical connections

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Service Manual Slip ring rotary connection
Maintenance

Plug connection wire harness slip ring Plug connection (twisted)


Plug connection Ground connection

For a detailed description of the configuration of the angle sensor at dismantled slip ring
rotary connection ,

Adapter ring O-ring


Bearing washer (base plate) Deep groove ball bearing
Base flange Lock washer
Hood with hood pipe Snap ring
Ring 38X42X8 Snap ring
Slip ring 40X2 Lock washer
Threaded cable gland Hex nut
Insulating ferrule Potentiometer holding plate
Slip ring 40X2 Notch ring
Contact bracket, gold-plated Washer with chamfer
Contact bracket, nickel-plated Flat adapter
Shim Hexagon cap nut
Contact bracket holder Washer
Cover plate Angle sensor B314 (optional)
Back-up washer Contact pin
Threaded rod Adapter
Threaded rod Brass pipe
Microswitch attachment Threaded cable gland
Countersunk screw Brass pipe
FGR pipe Threaded rod
Forcing screw Washer
LHB/en/Edition: 11/2007

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Slip ring rotary connection Service Manual
Maintenance

LHB/en/Edition: 11/2007

Fig. 5 Sectional drawing of slip ring

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Service Manual Slip ring rotary connection
Maintenance

Fig. 6 Section A-A Slip ring rotary connection

Fig. 7 Section B-B Slip ring rotary connection


LHB/en/Edition: 11/2007

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Slip ring rotary connection Service Manual
Maintenance

LHB/en/Edition: 11/2007

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Service Manual Resistance measurement
General instructions regarding resistance measurement

The resistance must be measured according to DB instruction 931.0201.


In the event of inadvertent contact with a powered overhead or supply line, the short-circuit current
must be able to run from the highest point of the vehicle including any attachments and
superstructures to the rail.
The electrical resistance between the highest point of the vehicle to the rail must not exceed the value
specified in DIN EN 50153. A measurement must be carried out to verify compliance, (see Tab. 1 on
page 1).
The measurement must be carried out with an earthing wire tester. For instructions regarding the
operation and handling of the earthing wire tester, refer to the manual of the manufacturer.

Measuring range 0-500 mOhm


Test duration 5 seconds
Test current 50 A

Measurement and limit values


Limit value according to DIN EN 50 mOhm
50153 (Europe)
Limit value according to EBAT (Switzerland) 30 mOhm

Tab. 1 Technical data


LHB/en/Edition: 05/2009

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Resistance measurement Service Manual
General instructions regarding resistance measurement

Fig. 1 Connecting earthing wire tester

Connect the measuring cable (magnet) to a blank metal section on the rail.
If this is not possible, place an iron plate onto the rail idle wheel and attach the measuring cable
(magnet).
Connect the measuring cable (clamp) to a bright section on the attachment. Depending on the
design of the attachment, this point might be located in a different position than shown here.

To carry out the measurement correctly, adhere to the instructions in the operating manual of the
tester manufacturer and the specifications in DIN EN 50153.
Carry out the measurement and compare the results with the prescribed limit values, (see Tab. 1
on page 1).
Please note that limit values might vary from country to country.

LHB/en/Edition: 05/2009

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