Wheel Loader Liebherr L 504-L 522 - Service Manual

Service Manual
(20
Wheel loader
(10 points)
L504 - L522
(10
en
Address
Address: LIEBHERR-WERK BISCHOFSHOFEN GMBH
Dr. Hans Liebherr Strae 4
A 5500 BISCHOFSHOFEN
Product identification
Manufacturer: LIEBHERR-WERK BISCHOFSHOFEN GMBH
Product Group: Wheel loader
Type: L 504 L 506 L 507 L 508 L 509 L512 L522
Construction Number: 424 426 427 428 429 430 422
Serial Number: 0101 0101 0101 0101 0101 0101 0101
Document identification
Order Number: 8450301
Author: LBH / Dept. - TIP
Document version: 01
Manual number:
Owner:
Service Manual
(20
Wheel loader
(10 points)
L504 - L522
(10
en
General 1
2
3
Special Tools 4
5
Lubricants 6
Technical Data- Inspection Plans 7
Engine 8
9
Travel Hydraulic 10
Working Hydraulic 11
Electrical System 12
Heating, Air conditioning System 13
Travel Gear 14
Axles 15
Steering 16
Brakes 17
Main Frame / Cab 18
Hoist Frame / Accessories 19
Special Installations 20
Sub Group lndex
Datum / Edition / Date
Benennung / Description / D enomination Typ / Model / Type Ab / From / A partir de
Blatt / Page / Feuille
05.97
GeneraI
1.
1. 01. Foreword
1. 06. General Design Description L 506, L 507 .............................................................
L 508, L 509
L 512, L 522
1. 10. Component Overview
04.95
Foreword
1.01.01
This manual has been issued to provide you with technical information regarding the design, function,
disassembly, adjusting work and troubleshooting on the components and models of the Liebherr wheel
loaders.
The descriptions are brief but precise and are supported by photographs, notes, drawings, hydraulic and
electrical schematics, as well as exploded and sectional drawings. All this information is intended to
simplify any necessary repair work which can be performed on Liebherr wheel loaders.
We deliberately avoided full photographic details of each repair stage, since only skilled mechanics
already familiar with most repair work described in this manual should perform repair work. This manual
also contains information about adjusting work and valuable reference data for such adjustment values.
lnstructions on regular care and maintenance is excluded from this manual, since they are covered in the
individual operation and maintenance manuals.
For all maintenance and repair work on wheel loaders, all accident prevention guidelines must be strictly
observed. To perform all repairs listed in this manual, a complete set of standard tools, as well as the
special tools and fixtures shown and listed are necessary. lt is essential to keep all equipment, tools and
working areas clean and tidy.
No special emphasis is put on replacing sealing components, such as O-rings, gaskets, etc. as we
assume that these items are replaced during any repair. Unless specific values are given, all threaded
connections should be tightened according to the required tightening torques listed on torque charts.
When describing work, which can be dangerous, we have described the required safety measures in this
manual and indicated them by special remarks - DANGER, CAUTION or NOTE .
This symboI in the Service ManuaI means :
DANGER
lt designates the possibility of personal injury or death if no appropriate safety measures are taken.
CAUTION
This symbols denote certain safety practices must be taken or warns that certain working procedures
could cause injury or damage to the machine .
NOTE
We use the Note symbol to denote operational or maintenance procedures, which must be observed
to assure high operational availability and long service life and / or to simplify certain working
procedures.
Observing these notes does not reIieve you from observing aII vaIid safety reguIations
on the job site, nor from those issued by Government agencies, such as traffic
reguIations for machines operating on pubIic highways, and from guideIines issued
by trade unions or other associations.
This Service Manual has been issued by the Customer Service Department of
LIEBHERR-WERK BISCHOFSHOFEN GMBH Department: KD-SchuIe (Customer Service SchooI /
Training Dept.)
No part of this publications may be reproduced or copied in any form or by any means without our
explicit prior approval!
All rights reserved - Printed in Austria
Updates will be issued only to registered Service Manual owners. Manual, which are not registered, will
not be updated.
Some Service lnformation bulletins might also be used as updates.
We trust that with this information contained in this Manual and your cooperation we have taken another
step toward achieving a still more satisfactory standard for LlEBHERR wheel loaders.
Diverse changes reserved.
LIEBHERR-WERK BISCHOFSHOFEN GMBH
1. lssue: 11.93
ld. No. 8450302
EXPLANATIONS
ln order to make it easy to find certain information or to remove and/ or add pages in case of changes,
the following system has been established:
The index for the main sections can be found on the front page of this manual.
The sub groups can be found on the page in front of each main group which is the subgroup index.
ln case of minor changes, we will issue the revised pages with the latest date.
lf an already existing subgroup is to be completed, a new subgroup number will be assigned.
The new group shows from which machine or Serial Number this new or revised subgroup is valid .
05.97
GeneraI
Design Description
Stereo Ioader
L 506 - L 509 101
1.06.01
1. The design consists of the foIIowing "Stereo" features:
Combination of articulated steering and rear steering axle
Combination of oscillating axle and oscillating articulating linkage
Choice of Parallel- or Z- Kinematics
2. The user wiII be abIe to reaIize the foIIowing advantages:
2.1 Combination of articuIated steering - rear steering axIe
- Compared to standard articulated steering systems, the turning radius is improved by up to 20% .
- Safe transport of increased loads on the fork due to reduction of the articulation angle.
- lmproved side stability due to articulation angle reduction.
2.2 Combination of osciIIating axIe and osciIIating articuIating Iinkage
- Comfortable driving in the field due to reduction of maximum oscillating angle of cab
- Absorbtion of vibrations due to damper elements in the oscillating articulating linkage
- Quiet and steady behavior when driving in curves
2.3 Choice of ParaIIeI- or Z- Kinematics
- lncreased economy, machine can be matched to current application
2.4 Driving comfort and safety
- Simple operation in Liebherr cab
- Good visibility due to large windows
- Easy maintenance due to functional design
ParaIIeI Kinematics Z- Kinematics
05.97
GeneraI
Design Description
L 512, L 522 101
1.06.02
1. The design consists of the foIIowing features:
Hydrostatic travel drive with two motors
Combination of oscillating axle and oscillating articulating linkage
Choice of Parallel- or Z- Kinematics
2. The user wiII be abIe to reaIize the foIIowing advantages:
2.1 Hydrostatic traveI drive with two motors
- Lower fuel consumption due to improved effectiveness
- Almost no brake wear due to hydraulic braking action of travel drive
- Less tire wear due to stepless traction regulation and automatic self locking differentials.
2.2 Combination of osciIIating axIe and osciIIating articuIating Iinkage
- Comfortable driving in the field due to reduction of maximum oscillating angle of cab
- Absorption of vibrations due to damper elements in the oscillating articulating linkage
- Quiet and steady behavior when driving in curves
2.3 Choice of ParaIIeI or Z- Kinematics
- lncreased economy, machine can be matched to current application
ParaIIeI Kinematics Z- Kinematics
11.93
Component Overview
1.10.01
1.00 Front section
1.02 Front axle
2.00 Rear section
2.02 Rear axle
2.04 Steering cylinder
2.05 Step
2.10 Articulation lock
3.00 Engine hood
3.06.01 Fuel filler neck
5.00 Operator's cab
8.00 Attachment
8.01 Bucket arm
8.02 Lift cylinder
8.03 Tilt cylinder
8.04 Linkage
8.05 Connector bracket
12.00 Wheel chocks
20.01 Bucket
2.06 Towing device
3.01 Rear cover
5.07.1 Side mirror - right
5.07.2 Side mirror - left
5.55 Windshield wiper - front
5.57 Windshield wiper - rear
6.60 Headlight - left
6.61 Headlight - right
6.63 Blinker - left front
6.64 Blinker - right front
6.65 Brake light - left
6.66 Tail light - left
6.67 Brake light - right
6.68 Tail light - right
6.69 Blinker - right rear
6.70 Blinker - left rear
6.73 License plate light - left rear
6.74 License plate light - right rear
9.76 Horn
20.01.2 Bucket lip protector
LIFT ARMS
Z-BAR KINEMATIC PARALLELOGRAM GEOMETRY
8.10 Hydr. quick change coupler *
10.00 Hydr. lines / added attachments *
* = available as optional equipment.
Untergruppen - Verzeichnis
Sub Group lndex
Sous-groupes - D esignation
04.96
SpeziaIwerkzeuge
SpeciaI tooIs
OutiIIage sp eciaI
4.
4. 01. Allgemeine Spezialwerkzeuge f ur Radlader
General special Tools for Wheel loader
Outillage sp ecial g eneral pour chargeuse sur pneus
4. 02. Spezialwerkzeuge f ur LlEBHERR Dieselmotor
Special Tools for LlEBHERR Engine
Outillage sp ecial pour moteur LlEBHERR
4. 03. Spezialwerkzeuge f ur DEUTZ Dieselmotor
Special Tools for DEUTZ Engine
Outillage sp ecial pour moteur DEUTZ
4. 04. Spezialwerkzeuge f ur Elektrik
Special Tools for electric
Outillage sp ecial pour electrique
4. 06. Spezialwerkzeuge f ur ZF - Achsen
Special Tools for ZF - Axles
Outillage sp ecial pour Essieu ZF
4. 07. Spezialwerkzeuge f ur HURTH - Achsen
Special Tools for Hurth - Axles
4. 08. Spezialwerkzeuge f ur ZF - Getriebe
Special Tools for ZF - Powershift transmission
Outillage sp ecial pour Boite reversible sous charge ZF
04.96
SpeziaIwerkzeuge
SpeciaI tooIs
OutiIIage sp eciaI
4.01.
4. 01. Allgemeine Spezialwerkzeuge f ur Radlader
General special Tools for Wheel loader
Outillage sp ecial g eneral pour chargeuse sur pneus
HINWEIS:
NOTE:
AVERTISSEMENT:
= g ultig f ur alle Ger ate
= valid for all models
= valable pour toutes les machines
04.96
SpeziaIwerkzeuge
SpeciaI tooIs
OutiIIage sp eciaI
4.01.01
DrehzahImesser OrneI
RPM gauge
Tachym` etre
1 HT 460 7006 974
Zum Messen der Drehzahl uber Reflexions - Streifen
To check the RPM via reflexion stripe
Pour mesurer un r egime par l'interm ediare d'un
panneau r efl echissant
DrehzahImesser Ono Sokki
RPM gauge
Tachym etre
2 GE 450 7009 538
Zum Messen der Motordrehzahl uber lmpulsfrequenz
der Einspritzleitung
To check the engine RPM via impulse frequency of
the injection line
Mesure de r egime du moteur thermique par rapport
aux impulsion de la pompe ` a injection
ImpuIsgeber f ur DrehzahImesser
Pulse generator for RPM gauge
Generateur d'impulsion
3 ZP 044 8145 836
DigitaI - Sekundenthermometer
Short cycle digital thermometer
Thermom` etre digital
4 GTH 1150 7020 372
Zum

Uberwachen der Temperatur eines Mediums
(mit Sonde) bzw. der Auentemperatur eines Aggre-
gates (mit F uhler und magnet. Halter)
Used to monitor the temperatur of any liquid (using
probe) resp. the housing temperatur of any compo-
nent (using magnetic sensor)
Pour mesurer la temp erature int erieure d'un sujet (au
moyen d'une sonde) ou la temp erature ext erieure
d'un composant (au moyen d'un palpeur et d'un
support magn etique)
04.96
SpeziaIwerkzeuge
SpeciaI tooIs
OutiIIage sp eciaI
4.01.02
SchraubkuppIung f ur Temperaturmessung
Gauge coupling to check the temperatur
Raccord filet e pour mesurer la temp erature
5 M12 x 1,5 7402 580
Zum Messen der Temperatur direkt im Filter
Skizze zur Herstellung, siehe Blatt - Nr. 4.01.14
To measure the temperatur direct in the filter.
For details to manufacture, see page - No. 4.01.14
Pour mesurer la temp erature directement dans le
filtre.
Croquis pour r ealisation, voir 4.01.14
ManometeranschIu
BSP coupling
Embout branchment manometre
7 R 1/2" 7002 436
HochdruckschIauch
High pressure hose
Flexible haute pression
8 1000 mm 7002 437
9 1500 mm 7002 475
10 4000 mm 7009 134
SchraubkuppIung kompIett
Gauge coupling
Raccord filet e
12 M10x1 5005 180 L511 -212 / L521 -211
L531 -279 / L541 -289
L551 -274
13 M12x1,5 7402 580
14 M14x1,5 7619 043
15 R 1/4" 7362 579
04.96
SpeziaIwerkzeuge
SpeciaI tooIs
OutiIIage sp eciaI
4.01.03
Manometer
Hydraulik pressure gauge
Manom etre
16 0 - 6 7500 015
17 0 - 40 7361 288
18 0 - 60 5002 867
19 0 - 250 5002 932
20 0 - 400 7500 002
21 0 - 600 5002 866
DigitaImanometer
Digital RPM gauge
Manom etre - Digital
22 0 - 100 7409 564
23 0 - 500 7409 565
24 3,6 V 6002 780
AbIaschIauch
SchIauchst uck
Oil drain hose
Hose Nipple
Flexible de purge
Raccord
25 0,5 m 7005 660
26 7402 657
Optischer Dichtepr ufer
Leakage test gauge
Densim` etre optique
28 7408 922
Zur

Uberpr ufung des Batterieladezustandes und des
K uhlerfrostschutzes
To check battery charge and antifreeze protection
Sert ` a mesurer la charge batterie et le liquide de
refoidissement
04.96
SpeziaIwerkzeuge
SpeciaI tooIs
OutiIIage sp eciaI
4.01.04
Mestutzen
Gauge adapter
Embout
30 10 L 7619 042
Verschraubung f ur Mestutzen
Threaded union for gauge adapter
Vissage pour embout
31 10 L 7403 571
32 15 L 7404 419
33 10 / 15 L 7616 915
VerschIuteiIe
Blanking components
Obturateur pour conduite
35 ROV 8 - L 7620 462 L 512 -430 / L 522 -422
36 VKA 8 - L 4900 305 L 512 -430 / L 522 -422
Zum Blindschlieen des lnchventils und der
Schlauchleitung an der Fahrpumpe A4VG.
To close the inching-valve and the hydraulik pipe on
the travel pump A4VG.
Sert ` a bouchonner le clapet d'approche lente et le
flexible apr` es la pompe de translation A4VG.
Montageh uIse
Mounting sleeve
Bague de montage
40 70 mm 9110 556 L506 -371 / L508 -372
L506 -426 / L507 -427
L508 -428 / L509 -429
L511 -212 / L521 -211
L531 -279 / L541 -289
41 80 mm 9227 165 L504 -424
L506 -426 / L507 -427
42 85 mm 9998 618 L510 -340 / L541 -289
43 90 mm 9227 161 L504 -424
L508 -428 / L509 -429
L512 -430 / L522 -422
44 100 mm 9998 626 L506 -371 / L506 -426
L507 -427 / L551 -274
45 110 mm 9170 509 L511 -212 / L512 -430
L521 -211 / L522 -422
L531 -279
04.96
SpeziaIwerkzeuge
SpeciaI tooIs
OutiIIage sp eciaI
4.01.05
Montageh uIse
Mounting sleeve
Bague de montage
46 120 mm 9998 778 L506 -371 / L508 -372
L508 -428 / L509 -429
L511 -212 / L541 -289
47 130 mm 9998 624 L512 -430 / L522 -422
L521 -211 / L541 -289
48 140 mm 9998 623 L531 -279
49 150 mm 9998 622 L510 -340
L541 -289 / L551 -274
50 160 mm 9998 621 L512 -430 / L522 -422
L551 -274
51 170 mm 9170 509 L551 -274
Spreitzh uIse
Spreader sleeve
Bague d' ecartement
55 70 mm 9110 402 L506 -371 / L508 -372
L506 -426 / L507 -427
L508 -428 / L509 -429
L511 -212 / L521 -211
L531 -279 / L541 -289
56 80 mm 9227 166 L504 -424
L506 -426 / L507 -427
57 85 mm 9110 404 L510 -340 / L541 -289
58 90 mm 9227 162 L504 -424
L508 -428 / L509 -429
L512 -430 / L522 -422
59 100 mm 9110 405 L506 -371
L506 -426 / L507 -427
L551 -274
60 110 mm 9170 511 L512 -430 / L522 -422
L511 -212 / L521 -211
L531 -279
Spreitzh uIse
Spreader sleeve
Bague d' ecartement
61 120 mm 9110 407 L506 -371 / L508 -372
L508 -428 / L509 -429
L511 -212 / L541 -289
62 130 mm 9110 408 L512 -430 / L522 -422
L521 -211 / L541 -289
63 140 mm 9110 409 L531 -279
64 150 mm 9110 410 L510 -340
L541 -289
L551 -274
65 160 mm 9110 411 L512 -430 / L522 -422
L551 -274
66 170 mm 9110 412 L551 -274
KoIbenschI usseI
siehe Blatt - Nr. 4.01.18
Piston wrench
see page - No. 4.01.18
Cl e pour piston
voir 4.01.18
70 52/8 mm 9131 359 L506 -371 / L508 -372
L510 -340 / L504 -424
L506 -426 / L507 -427
L511 -212 / L521 -211
L512 -430 / L522 -422
L531 -279 / L541 -289
71 60/10mm 9131 362 L508 -428 / L509 -429
72 75/12mm 8007 364 L506 -371
L506 -426 / L507 -427
L511 -212 / L521 -211
L512 -430 / L522 -422
L531 -279 / L551 -274
73 88/12mm 8007 365 L506 -371 / L508 -372
L508 -428 / L509 -429
L511 -212 / L541 -289
74 100/14
mm
8007 366 L510 -340 / L521 -211
L512 -430 / L522 -422
L531 -279 / L541 -289
L551 -274
04.96
SpeziaIwerkzeuge
SpeciaI tooIs
OutiIIage sp eciaI
4.01.06
MontageschI usseI f ur Lagerk opfe
siehe Blatt - Nr. 4.01.19
lnstallation wrench for piston rod bearing
see page - No. 4.01.19
Cl e pour verin hydraulique
voir 4.01.19
75 58/8 mm 9237 826 L506 -371
L506 -426 / L507 -427
L508 -428 / L509 -429
76 70/8 mm 9210 219 L504 -424
L506 -426 / L507 -427
L508 -428 / L509 -429
77 75/12
mm
9239 572 L512 -430 / L522 -422
78 80/12
mm
9238 020 L504 -424 / L506 -371
L506 -426
79 92/12
mm
9241 799 L508 -428 / L509 -429
L512 -430 / L522 -422
80 115/12
mm
9242 203 L512 -430 / L522 -422
Hubmevorrichtung
Spool travel measuring tool
Dispositif de mesure de course
82 8007 363 L511 / L521
L531 / L541
L551
Zum Messen des Hubes der Steuerkolben / Arbeits-
hydraulik
(Skizze zur Herstellung, siehe Blatt - Nr. 4.01.16)
To measure the stroke of the spool in the control
valve / working hydraulic.
(For details to manufacture, see page -No. 4.01.16)
Pour la mesure de la course du tiroir de distribution
dans le bloc.
(Croquis pour r ealisation, voir 4.01.16)
ZwischenpIatte
lntermediate plate
Plaque interm ediaire
94 SAE 3/4"
A 90
B 42
C 5
7370 092
95 SAE 1"
A 90
B 44
C 5
7370 093
96 SAE 1 1/4"
A 90
B 44
C 5
7370 094
Zur Trennung der Aggregate (Pumpe,

Olmotor und
Bypassventil) im geschlossenen Kreis
(Skizze zur Herstellung, siehe Blatt - Nr. 4.01.15)
To devide the components (pump, oil motor and
bypass valve) within the closed circuit
(For details to manufacture, see page -No. 4.01.15)
Pous la s eperation des organes (pompe, moteur
hydraulique et by-passs) dans le circuit ferm e
(Croquis pour r ealisation, voir 4.01.15)
Sicherungskappe
Safety - cap
Capuchon de s ecurit e
100 SW 10 7009 315
SW 13 7615 515
SW 17 7615 589
SW 19 7009 316
SW 19 7009 317
Zum Sichern der Einstellschrauben an Pumpe und
Olmotor von Fahrhydraulik bzw. Pumpe/Arbeitshy-

draulik
To secure the adjustment screws on pump and oil
motor of the travel hydraulic and / or the pump of the
working hydraulic
Pour le blocage des vis de r eglage sur pompe et
moteur hydraulique du syst ` eme hydr. de translation
ou de la pompe du circuit hydr. de travail
04.96
SpeziaIwerkzeuge
SpeciaI tooIs
OutiIIage sp eciaI
4.01.07
Sicherungskappe (SteuerbIock)
Safety - cap (Control valve-block)
Capuchon de s ecurit e (distributeur)
101 SW 19 7616 035
SW 24 7006 730
Zum Sichern der Einstellschrauben an Pumpe der
Fahrhydraulik und Steuerblock/Arbeitshydraulik
To secure the adjustment screws on pump of the
travel hydraulic and control valve block of the wor-
king hydraulic
Pour le blocage des vis de r eglage sur pompe du
syst ` eme hydr. de translation et distributeur du circuit
hydr. de travail
KIemmst uck
Clamp
Bride
111 SM 12 8145 131 L504 -424
L506 -371 / L508 -372
112 SM 18 8145 132 L510 -340
L512 -430 / L522 -422
Zum Halten des Steuerkolbens bei Demontage des
Schaltachseneinschraubst uckes.
To hold the control piston when removing the control
axle fitting.
Bride de maintien du piston dans le r educteur pont
Handpumpe
Hand pump
Pompe haute - pression
113 5870 287
007
8145 835
Handpumpe zur Dichtheitspr ufung von Lamellen-
bremsen.
Hand pump for the tightness check of the multi - disk
brakes.
Pompe haute - pression pour contr ole d' etanch eit e
des freins ` a disques.
F uII und Pr ufvorrichtung mit Koffer
Fill and test device with case
Dispositif pour le remplissage ou la purge avec
coffret
115 FPS-250/
OF2,5G1
8145 359 L506 -426 / L507 -427
L508 -428 / L509 -429
L512 -430 / L522 -422
L521 -211 / L531 -279
L541 -289 / L551 -274
Zur Aufladung bzw.Verminderung und der Kontrolle
des Vorspanndruckes im Druckspeicher. (Fahr-
schwingungsd ampfer)
For precharging of the accumulator bladders as well
as for checking and changing the nidrogen prechar-
ge pressure.
Pour le contr ole, le remplissage ou la purge de
l'accumulateur ` a azote (amortissement de la transla-
tion)
04.96
SpeziaIwerkzeuge
SpeciaI tooIs
OutiIIage sp eciaI
4.01.08
Reduzierstutzen
Reducing fitting
Mamelon de reduction
117 M12x6 8145 060 L506 -371 / L508 -372
Zur Bremsdruckpr ufung am Zuschaltventil
To check brake pressure on cut in valve.
Valve de commutation, contr ole de la pression du
circuit de freinage
Reduzierstutzen
Reducing fitting
Mamelon de reduction
118 M12x1,5-
M8x1
7615 843 L506 -371 / L508 -372
Hochdruckmeadapter MA/MB (bei Ausf uhrung alt)
High pressure test adapter MA/MB (on old execution
only)
Adaptateur pour MA/MB
F uIIanschIu
Filler connection
Raccord de remplissage
119 D46x7G1" 7615 982 L504 -424 / L506 -371
L508 -372 / L510 -340
L506 -426 / L507 -427
L508 -428 / L509 -429
L512 -430 / L522 -422
Bef ullen u. Entl uften der Bremsanlage bei Verwen-
dung des Werkzeuges Nr.: 120
Use fitting to charge or bleed brake system, using
tool no. 120
Remplissage ou purge du circuit des freins ` a utiliser
avec l'outillage n 120
F uII- und EntI uftungsger at
Fill and bleeder unit
Appareil de ventilation et de remplissage
120 MH 100 7615 981 L504 -424 / L506 -371
L508 -372 / L510 -340
L506 -426 / L507 -427
L508 -428 / L509 -429
L512 -430 / L522 -422
Bef ullen und Entl uften der Bremsanlage
To charge and bleed the brake system
Pour remplir ou purger le circuit des freins
04.96
SpeziaIwerkzeuge
SpeciaI tooIs
OutiIIage sp eciaI
4.01.09
Vakuum Pumpe 24 V
mit Zubeh or
Vacuum pump 24 V, complete
Pompe ` a vide 24 V
122 7408 148
Zur Vermeidung von

Olverlusten bei Demontage von
hydraulischen Leitungen
To prevent loss of oil when removing hydraulic lines.
Pour eviter toutes fuites hydrauliques lors des d e-
montages
SpannungswandIer 12 V auf 24 V
Voltage transformer 12 V to 24 V
Transformateur de tension 12 V ` a 24 V
123 12 V 6905 469 L504 -424
L506 -426 / L507 -427
L508 -428 / L509 -429
Bei Verwendung der 24V Vakuumpumpe bei 12V
Anlagen.
By using of 24V Vacuum pump at 12V board current.
Lors de l'utilisation de la pompe ` a vide sur appareils
de 12V.
KraIIen -

OIfiIterschI usseI
Spider wrench f. oil filter
Cl e sp eciale pour filtre ` a huile
126 60-120mm 8145 274
Zum

Offnen von

Ol- und Dieselfilterpatronen ( spe-
ziell bei schwierig zug anglichen Filtern geeignet ).
To open oil and Diesel filter cartridges (especially
useful for hard to reach filters)
Pour le d emontage des filtres ` a huile (en particulier
dans les acc` es difficiles)
04.96
SchraubkuppIung
Gauge coupIing
Raccord fiIet e
4.01.14
SchraubkuppIung f ur Temperaturmessung
Gauge coupIing to check the temperatur
Raccord fiIet e pour mesurer Ia temp erature
04.96
ZwischenpIatte
Intermediate pIate
PIaque interm ediaire
4.01.15
Zur Trennung von Aggregaten im geschIossenen Kreis
To separate components in cIosed hydr. circuit
Pour Ia s eparation des eI ements du circuit ferm e.
Ger at / ModeI / Type A B C
L 504 -424, L 506 -371, 120 40 4
L 506 -426, L 507 -427, L 508 -232 120 44 5
L 508 -372 L 508 -428, L 509 -429,
L 512 -430, L 522 -422, L 511 -212,
L 521 -211, L 531 -279, L 541 -289
L 522 -422, L 551 -274 120 51 6
04.96
Hubmevorrichtung
Deviation indicator
OutiIIage de mesure
4.01.16
Vorrichtung zum Messen des Hubes von servogesteuerten Steuerschiebern
Device for measuring the stroke of the servo controIIed controI vaIves spooIs
Dispositif servant ` a mesurer Ia course des tiges du distributeur
1 Hubmessvorrichtung
Spool measuring tool
Outil mont e
2 Dichtung
Seal
Joint
3 Deckel des Steuerschiebers
Control spool cover
Couvercle du distributeur
4 Schieberstange
Spool
Tige du distributeur
04.96
KoIbenschI usseI
Piston wrench
CI e ` a piston
4.01.18
MontageschI usseI f ur KoIben der HydrauIikzyIinder
InstaIIation TooI for Piston of HydrauIic CyIinders
CI e sp eciaIe pour Ie d emontage ou Ie montage des pistons
Kolben a b c d e f g h ld. Nr.
Piston ld. No.
Piston n. ld.
70 - 85 52 38 75 160 10 8 8 16 9131 359
90 60 44 85 180 14 10 10 16 9131 362
100 - 110 75 54 110 200 14 12 10 20 8007 364
120 88 63 120 210 14 12 10 20 8007 365
130 - 180 100 78 135 230 14 14 10 20 8007 366
04.96
KoIbenschI usseI
Piston wrench
CI e ` a piston
4.01.19
MontageschI usseI f ur Lagerk opfe (HydrauIikzyIinder)
InstaIIation TooI for Piston rod bearing
CI e pour verin hydrauIique
Kolben a b c d e f g h ld. Nr.
Piston ld. No.
Piston n. ld.
70 58 40 80 180 9,5 8 9 15 9237 826
80 70 52 90 180 9,5 8 9 15 9210 219
90 75 54 102 200 14 12 10 20 9239 572
100 80 55 105 200 12 12 10 20 9238 020
110 - 120 92 64 120 210 12 12 10 20 9241 799
160 115 88 142 220 12 12 10 20 9242 203
04.96
SpeziaIwerkzeuge Liebherr DieseImotor
SpeciaI tooIs Liebherr Engine
OutiIIage sp eciaI moteur Liebherr
4.02.
4. 02. Spezialwerkzeuge f ur Liebherr Dieselmotor
Special Tools for Liebherr Engine
Outillage sp ecial pour moteur Liebherr
HINWEIS:
NOTE:
AVERTISSEMENT:
Weiteres Spezialwerkzeug f ur Arbeiten am Dieselmotor siehe "Werkstatthandbuch LH-Motoren".
Additional tool for work on the Diesel engine see "Service Manual LH-Engine".
Pour tous les autres outils sp eciaux consulter le "Manuel Technique LH-moteur".
04.96
4.02.01
Kompressionsdruckpr ufer
Compressionmeter
Compressiom` etre
1 8008 782
Zum Pr ufen des Kompressiondruckes
To check compression
Pour le contr ole de la pression d'injection
D usenpr ufger at
Nozzle testing device
Appareil de cont ole des injecteurs
3 7361 236
Zum Pr ufen der Einspritzventile
To check injection valve
Pour le contr ole des injecteurs
AnschIust uck f ur Kompressionsdruckpr ufer
Fitting of the recorder of compression pressure
Raccord pour le compressiom` etre
7 0524 044 L511 -212 / L521 -211
L531 -279 / L541 -289
L551 -274
An Stelle des Einspritzventiles einzusetzen
Replaces injection valve
A monteur ` a la place de l'injecteur
Hochdruck - Handf orderpumpe mit Zubeh or
High pressure pump with accessories
Pompe manuelle haute pression avec accessoires
9 7009 318 L511 -212 / L521 -211
L531 -279 / L541 -289
L551 -274
Zur Pr ufung des F orderbeginns der Einspritzpumpe
To check the delivery beginn of the injection pump
Sert ` a contr oler le d ebut d'injection
04.96
4.02.02
Ausziehvorrichtung f ur EinspritzventiIe
Extracting device for injection valve
Extracteur ` a chocs pour injecteurs
10 0524 072 L511 -212 / L521 -211
L531 -279 / L541 -289
L551 -274
Zum Ausbau der Einspritzventile
Used to remove injection valves
Pour le d emontage des injecteurs
Adapter f ur Ausziehvorrichtung
Adapter for extracting device
Atapteur pour support d'injecteurs
11 0524 029 L511 -212 / L521 -211
L531 -279 / L541 -289
L551 -274
Gemeinsam mit der Ausziehvorrichtung zu verwen-
den.
Used in connection with extracting device.
A utiliser avec l'extracteur.
DrehwinkeI - Anzugsvorrichtung
Torque angle indicator
Cardran gradu e indiquant l'angle de serrage
12 0524 062 L511 -212 / L521 -211
L531 -279 / L541 -289
L551 -274
Zum Festziehen der Schrauben von Zylinderkopf,
Haupt- und Pleuellager.
Torque angle indicator for cylinder head, crankshaft
and connecting rod bearing installation.
Sert ` a mesurer les angles de serrage des vis de
culasse, palier de vilebrequin et bielle.
Drehvorrichtung f ur Schwungrad
Turning device for flywheel
Vireur ` a monter sur le carter du volant d'inertie
13 0524 045 L511 -212 / L521 -211
L531 -279 / L541 -289
L551 -274
Zum Drehen des Dieselmotors uber das Schwun-
grad.
Used to turn engine over the flywheel.
Pour virer le moteur thermique par dessus le volant
moteur.
04.96
SpeziaIwerkzeuge Deutz DieseImotor
SpeciaI tooIs Deutz Engine
OutiIIage sp eciaI moteur Deutz
4.03.
4. 03. Spezialwerkzeuge f ur Deutz Dieselmotor
Special Tools for Deutz Engine
Outillage sp ecial pour moteur Deutz
HINWEIS:
NOTE:
AVERTISSEMENT:
04.96
4.03.01
Kompressionsdruckpr ufer
Compressiontester
Compressiom` etre
1 8008 782
Zum Pr ufen des Kompressiondruckes
To check compression
Pour le contr ole de la pression d'injection
AnschIust uck f ur Kompressionsdruckpr ufer
Adapter for compression tester
Raccord pour le compressiom` etre
2 7016 788 L504 -424
L506 -371 / L508 -372
L506 -426 / L507 -427
L508 -428 / L509 -429
An Stelle des Einspritzventiles einzusetzen
Replaces injection valve
A monteur ` a la place de l'injecteur
D usenpr ufger at
Nozzle testing device
Appareil de cont ole des injecteurs
3 7361 236
Zum Pr ufen der Einspritzventile
To check injection valve
Pour le contr ole des injecteurs
EinsteIIboIzen f ur KurbeI- und NockenweIIe
Adjusting pin for crankshaft and camshaft
Pige de calage pour vilebrequin et arbre ` a cames
4 7016 789 L504 -424
L506 -371 / L508 -372
L506 -426 / L507 -427
L508 -428 / L509 -429
04.96
4.03.02
EinsteIIboIzen f ur EinspritzpumpenregeIstange
Adjusting pin for injection pump control rod
Pige de calage pour cr emaill ` ere de pompe
d'injection
5 7016 795 L504 -424
L506 -371 / L508 -372
L506 -426 / L507 -427
L508 -428 / L509 -429
Zahnriemenspannungsmeger at
Device for measuringtoothed belt tension
Appareil de mesure de tension de courroie crant ee
6 7016 793 L504 -424
L506 -371 / L508 -372
L506 -426 / L507 -427
L508 -428 / L509 -429
Montagevorrichtung f ur
KurbeIweIIendichtringe vorne
Assembly tool for crankshaft seal, front
Dispositif de montage pour bague d' etanch eit e
7 7016 792 L504 -424
L506 -371 / L508 -372
L506 -426 / L507 -427
L508 -428 / L509 -429
Zum Eindr ucken der Kurbelwellendichtringe
To press on the oil seal to the crankshaft
Pour le montage du joint de vilebrequin
Montagevorrichtung f ur
KurbeIweIIendichtringe hinten
Assembly tool for crankshaft seal, rear
Dispositif de montage pour bague d' etanch eit e
8 7016 791 L504 -424
L506 -371 / L508 -372
L506 -426 / L507 -427
L508 -428 / L509 -429
Zum Eindr ucken der Kurbelwellendichtringe
To press on the oil seal to the crankshaft
Pour le montage du joint de vilebrequin
04.96
4.03.03
Torx Werkzeugsatz
Torx tool kit
Jeu d'outils Torx
9 7014 716 L504 -424
L506 -371 / L508 -372
L506 -426 / L507 -427
L508 -428 / L509 -429
F ur Reparaturarbeiten am Deutz - Motor
For repairs on Deutz - engine
Pour effectuer les r eparations sur le moteur Deutz
KraftvervieIf aItiger f ur ZentraIschraube
Multipower tool for central bolt
Multiplicateur de force pour vis centrale
10 7016 794 L504 -424
L506 -371 / L508 -372
L506 -426 / L507 -427
L508 -428 / L509 -429
GegenhaIter f ur KraftvervieIf aItiger
Stecknu
Dolly for multipower tool
Socket
Contre-but ee pour multiplicateur de force
Douille
11 7016 790 L504 -424
L506 -371 / L508 -372
12 SW 32 8041 172 L506 -426 / L507 -427
L508 -428 / L509 -429
Arretierungsdraht f ur AnIenkhebeI
Einspritzpumpe
Locking wire for control lever, injection pump
Fil d'arr et pour levier articul e de pompe d'injection
13 7621 289 L504 -424
L506 -371 / L508 -372
L506 -426 / L507 -427
L508 -428 / L509 -429
04.96
4.03.04
Lange Stecknu
Long socket
Cl e ` a douille longue
14 SW 15 8145 858 L504 -424
L506 -371 / L508 -372
L506 -426 / L507 -427
L508 -428 / L509 -429
SpeziaIschI usseI f ur EinspritzIeitung
Special wrench for injection line
Cl e sp ecial pour conduite d'injection
15 SW 13 7621 288 L504 -424
L506 -371 / L508 -372
L506 -426 / L507 -427
L508 -428 / L509 -429
Montagewerkzeug f ur VentiIschaftabdichtung
Sleeve for fitting valve stem seal
Outil de montage pour joint de tige de soupape
16 7020 920 L504 -424
L506 -371 / L508 -372
L506 -426 / L507 -427
L508 -428 / L509 -429
04.96
SpeziaIwerkzeuge f ur EIektrik
SpeciaI tooIs for eIectric
OutiIIage sp eciaI pour eIectrique
4.04.
4. 04. Spezialwerkzeuge f ur Elektrik
Special Tools for electric
Outillage sp ecial pour electrique
HINWEIS:
NOTE:
AVERTISSEMENT:
04.96
4.04.01
Magnet - Tester
Magnet - Tester
Testeur pour electro - vanne
1 8145 743
DigitaIes VieIfachmeger at
kpI. mit KabeI und Tasche
Digital multi meter, complete with cable and bracket
Multim` etre avec c able et botier
2 Chauvin
Arnoux
MAX 3000
8502 956
f ur
Spannungs- (V) / Stromst arke- (A) / Widerstand-
(Ohm) / Frequenz- (Hz) Messungen
for
Voltage (V) meter / Amp (A) meter / Resistance
(Ohm) meter / Frequency (Hz) meter
pour
tension (V) / intensit e (A) / r esistance (Ohm) /
frequence (Hz)
VieIfachmeger at 3
mit KabeIset 3.1 und Tragtasche 3.2
Multimeter 3 with cable 3.1 and carrying bag 3.2
Multim` etre 3 avec c able 3.1 et botier 3.2
3 6001 128
3.1 6001 129
3.2 7013 246
F ur Spannungs-, Strom und Widerstandsmessungen
im ublichen Mebereich
To measure voltage, current and resistance
Pour mesurer la tension, l'intensit e, la r esistance
FIachstecksicherungspr ufer
Flat - type fuse tester
Test eur de fusibles plats
5 8145 834
Zum Pr ufen sowie zum Ausziehen von Flachstecksi-
cherungen.
To check the flat - type fuse and to pull out.
Outil de contr ole et d'extraction des fusibles plats.
04.96
4.04.02
Meadapter
(linke und rechte Ausf uhrung)
Measuring adapter
(left and right version)
Adapteur de mesure
(gauche et droite version)
6 MA - L131 7621 300
7 MA - R131 7621 301
Handcrimpzange f ur Steckverbinder
Mate - N - LOK
Manual crimping tool for connectors Mate - N - LOK
Pince ` a sertir pour connecteurs Mate - N - LOK
10 8145 434
Zum Herstellen einwandfreier Crimpverbindungen
Tool for satisfactory crimp connections
Pince ` a sertir les contacts des connecteurs
Einsetzwerkzeug
lnstallation tool
Outil d'insertion
11 8145 432
Zum Einsetzen der Stifte bzw. Buchsen in den
Steckergeh ausen (MATE - N - LOK) Steckverbindun-
gen
To insert pins or bushings in plug housing
Outil servant ` a ins erer les douilles et broches serties
dans les prises (MATE - N - LOK)
Ausziehwerkzeug
Removal tool
Outil ` a extraire
12 7366 655
Werkzeug zum Ausbauen der verkabelten Crimpkon-
takte aus den Steckverbindern MATE-N-LOK.
Extraction tool to push a crimped contact of to the
MATE-N-LOK connectors.
Outil pour extraire les contacts sertis des connec-
teurs MATE - N - LOK.
04.96
4.04.03
Ersatzr ohrchen f ur Ausziehwerkzeug (Nr. 12)
Replacement tube for removal tool (No. 12)
Douilles de rechange pour l'outil n 12
13 7015 180
SURE - SEAL
Manual crimping tool for connectors SURE - SEAL
Pince ` a sertir pour connecteurs SURE - SEAL
20 7367 025 L512 -430 / L522 -422
L521 -211 / L531 -279
L541 -289 / L551 -274
Einbauwerkzeug f ur die Steckverbinder
SURE - SEAL
lnsertion tool for connectors SURE - SEAL
Outil d'insertion pour connecteurs SURE - SEAL
21 7367 023 L512 -430 / L522 -422
L521 -211 / L531 -279
L541 -289 / L551 -274
Ausbauwerkzeug Stiftkontakte (SURE - SEAL)
Extraction tool for pin contacts (SURE - SEAL)
Outil d'extraction pour broches (SURE - SEAL)
22 7367 020 L512 -430 / L522 -422
L521 -211 / L531 -279
L541 -289 / L551 -274
Zum Ausbauen der Stiftkontakte aus den Steckerge-
h ausen.
To remove pins from plug housing.
Outil d'extraction des contacts m ales du connecteur.
04.96
4.04.04
Ausbauwerkzeug Buchsenkontakte
SURE - SEAL
Extraction tool for socket contacts (SURE - SEAL)
Outil d'extraction pour douilles (SURE - SEAL)
23 7367 022 L512 -430 / L522 -422
L521 -211 / L531 -279
L541 -289 / L551 -274
Zum Ausbauen der Buchsenkontakte aus den Stek-
kergeh ausen.
To remove pushings from plug housing.
Outil d'extraction des contacts femelles du
connecteur.
HiIfswerkzeug zum HaIten der
SURE - SEAL Steckverbinder
Auxiliary tool for holding SURE - SEAL connectors
Outil de maintien des connecteurs SURE - SEAL
24 7367 021 L512 -430 / L522 -422
L521 -211 / L531 -279
L541 -289 / L551 -274
Hilfswerkzeug zum Halten der SURE - SEAL Steck-
verbinder 2, 3 und 4 polig beim Ein- und Ausbau der
angecrimten Kontakte.
Auxiliary tool for holding SURE - SEAL connectors
with 2, 3 and 4 contacts during insertion and extrac-
tion of crimped contacts.
Outil de maintien des connecteurs SURE - SEAL 2, 3
et 4 p oles pedant l'insertion et l'extraction des con-
tacts sertis.
Reparatur - Set (SURE - SEAL)
Kit for field repair (SURE - SEAL)
N ec essaire de r eparation (SURE - SEAL)
25 7015 073 L512 -430 / L522 -422
L521 -211 / L531 -279
L541 -289 / L551 -274
Reparatur - Set
beinhaltet Sonderwerkzeuge 20, 21, 22, 23 und 24,
sowie Bedienungsanleitung und Gleitmittel
Kit for field repair
Contents special tools 20, 21, 22, 23 and 24, opera-
ting instruction and lucating fluid
N ec essaire de r eparation
Contient les outillages sp eciaux 20, 21, 22, 23 et 24,
une notice d'utilisation et le lubrifiant pour les con-
tacts.
DEUTSCH und CA-COM
Manual crimping tool for connectors
DEUTSCH and CA-COM
Pince ` a sertir pour connecteurs
DEUTSCH et CA-COM
30 7367 086
04.96
4.04.05
Ausbauwerkzeug f ur Pin- und
Buchsenkontakte (DEUTSCH)
Extraction tool for pin- and
socket contacts (DEUTSCH)
Outil d'extraction pour broches et douilles
(DEUTSCH)
32 AWG 12 8145 674
33 AWG 16 8145 673
Zum Ausbauen f ur Pin- und Buchsenkontakte aus
den Steckergeh ausen.
To remove pins or pushings from plug housing.
Outil d'extraction des contacts m ales et femelles du
connecteur.
EIektronisches Pr ufger at
Electronic tester
Appareil electronique de contr ole
84 PR-59 5005 310 L511 -212 / L521 -211
L531 -279 / L541 -289
L551 -274
Zur

Uberpr ufung der Steuereinheit / Lastschaltgetrie-
be.
To check the control unit / power shift transmission.
Pour le contr ole de l'unite de pilotage Bote de
vitesses commutable sous charge.
AdapterkabeI
in Verwendung mit Pos. 84
Adapter cable
to use with Pos. 84
C able d'adaptadeur
` a utiliser avec Pos. 84
85 7011 137 L511 -212 / L521 -211
L531 -279 / L541 -289
L551 -274
Zur

Uberpr ufung des Fahrschalters / Getriebesteue-
rung mittels Pr ufger at Nr. 84
To check the travel switch / transmission control unit
via electronic tester No. 84
Pour contr ole de l'interrupteur de translation / com-
mande de bote ` a l'aide de l'appareil electronique de
contr ole n 84
AdapterkabeI
in Verwendung mit Pos. 85
Adapter cable
to use with Pos. 85
C able d'adaptadeur
` a utiliser avec Pos. 85
86 6905 189 L521 -211 / L531 -279
L541 -289 / L551 -274
Zur

Uberpr ufung des Fahrschalters / Getriebesteue-
rung mittels Pr ufger at Nr. 84
To check the travel switch / transmission control unit
via electronic tester No. 84
Pour contr ole de l'interrupteur de translation / com-
mande de bote ` a l'aide de l'appareil electronique de
contr ole n 84
04.96
4.04.06
HiIfssteuerung HST-3
Control Aid Unit HST-3
Botier de secours HST-3
114 8145 022 L511 -212 / L521 -211
L531 -279 / L541 -289
L551 -274
Bei Ausfall der Steuerelektronik EST-3
To be used, if the electronic control EST-3 is not
working.
A utiliser dans le cas d'un d efaut du botier EST-3
04.96
SpeziaIwerkzeuge f ur ZF - Achsen
SpeciaI tooIs for ZF - AxIes
OutiIIage sp eciaI pour Essieu ZF
4.06.
4. 06. Spezialwerkzeuge f ur ZF - Achsen
Special Tools for ZF - Axles
HINWEIS:
NOTE:
AVERTISSEMENT:
04.96
4.06.01
Spannzange f ur Achsen
Clamping - pliers for axles
Pince de serrage pour essieux
1 5870 900
010
7009 536 AP 405, AP 407
AP 409, AP 411
AP 415, AP 417
AP 420
Zum Aus- und Einfedern des Sicherungsringes im
Planetentrieb der Achsen
To remove or insert snap rings in the planetary drive
of the axles
Pour la mise en place ou le d emontage du circlips
dans le train plan etaire des essieux
Zangenspitzen
Tip of pliers
Bout de pieces
2 5870 900
019
3,5mm
8145 768 AP 405
3 5870 900
020
4,4mm
8145 769 AP 407, AP 409
AP 411, AP 415
4 5870 900
022
8,0mm
8145 770 AP 417, AP 420
Zangenspitzen f ur Werkzeug Nr. 1
Tip of pliers for tool No. 1
Bout de pieces pour outil n 1
Federhaken
Spring hook
Crochets ` a ressorts
5 5870 281
034
8145 767 AP 407, AP 409
AP 411, AP 415
AP 417, AP 420
Federhaken zum Aus- und Einhaken der R uckzugfe-
dern im Hohlradtr ager / Bremskolben
Spring hook to unhook and engage the return
springs in the internal gear carrier / brake piston
Crochets ` a ressorts pour accrochage et de'crochage
des ressorts de rappel dans le porte - couronne /
piston de frein
SchIupfbuchse 260 mm
lnstaller inner 260 mm
Douille de glissement Diam. int 260 mm
7 5870 651
042
7017 559 AP 407, AP 409
AP 411
Schlupfbuchse zum Einsetzen des Kolbens in den
Hohlradtr ager
lnstaller to install the piston into the internal gear
carrier
Douille de glissement pour insertion du piston dans
le porte - couronne
04.96
4.06.02
SchIupfbuchse 315 mm
lnstaller inner 315 mm
Douille de glissement Diam. int 315 mm
8 5870 651
043
7017 556 AP 415, AP 417
AP 420
Schlupfbuchse zum Einsetzen des Kolbens in den
Hohlradtr ager
lnstaller to install the piston into the internal gear
carrier
Douille de glissement pour insertion du piston dans
le porte - couronne
SchIupfbuchse M 90 x 1,5
lnstaller M 90 x 1,5
Douille de glissement M 90 x 1,5
10 5870 651
048
7017 558 AP 407, AP 409
Schlupfbuchse als Montagehilfe beim Montieren des
Hohlradtr agers samt Hohlrad auf den Nabentr ager.
lnstaller to aid in the installation of the internal gear
carrier along with internal gear upon the hub carrier.
Douille de glissement en tant qu'aide ou montage du
porte - couronne avec la couronne our le porte -
moyeu.
11 5870 651
049
7017 557 AP 411, AP 415
moyeu.
12 5870 651
041
7017 555 AP 417, AP 420
moyeu.
04.96
4.06.03
Griff f ur Aufsetzer
Handle
Poign ee
15 5870 260
004
7017 566 AP 407, AP 409
AP 411, AP 415
AP 417, AP 420
Handle for different drivers
Poign ee pour tampons drivers
Aufsetzer
Driver
Tampon
17 5870 051
025
7017 563 AP 407, AP 409
Aufsetzer zum Einsetzen des Kassettendichtringes in
die Nabenbohrung.
Verwendbar mit Griff Nr. 15
Driver do insert the plug - in seal ring into the hub
bore.
To be used with handle Nr. 15
Tampon pour insertion de la bague d' etanch eit e ` a
cassette dans l'al esage du moyeu.
Utilisable avec la poign ee n 15
Aufsetzer
Driver
Tampon
18 5870 051
023
7017 560 AP 411, AP 415
AP 417, AP 420
Aufsetzer zum Einsetzen des Kassettendichtringes in
die Nabenbohrung.
Verwendbar mit Griff Nr. 15
Driver do insert the plug - in seal ring into the hub
bore.
To be used with handle Nr. 15
Tampon pour insertion de la bague d' etanch eit e ` a
cassette dans l'al esage du moyeu.
Utilisable avec la poign ee n 15
NutmutterschI usseI
Spezial wrench for axles
Outillage de montage pour ecrou ` a essieux
20 siehe Seite
see page
voir page
4.06.10
AP 405, AP 407
AP 409, AP 411
AP 415, AP 417
Zum L osen und Anziehen der Nutmutter im Plane-
tentrieb / Achsen von ZP (in Verbindung mit Werk-
zeug Nr. 21)
To remove and / or tighten the slotted nut in the
planetary drive of ZP axles. (in connection with tool
no. 21)
Pour le serrage et le desserrage de l' ecrou rainur e
dans le train plan etaire / Essieux n 21
04.96
4.06.04
Zentrierb ugeI
Centering bracket
Bride de centrage
21 5870 912
012
7013 775 AP 407, AP 409
AP 411, AP 415,
AP 417
Zum Festhalten des Nutmutterschl ussel (Werkzeug
Nr. 20)
To hold axle wrench, tool No. 20
Sert au maintien de la cl e sp eciale n 20
Zentrierscheibe
Centering disk
Disque de centrage
22 5870 912
011
7013 920 AP 405,
Zum Festhalten des Nutmutterschl ussel (Werkzeug
Nr. 20)
To hold axle wrench, tool No. 20
Sert au maintien de la cl e sp eciale n 20
Mevorrichtung
Measuring device
Appareilage de mesure
23 9133 282 AP 405, AP 407
AP 409, AP 411
AP 415, AP 417
Zum Messen des Belagverschleies der Lamellen-
bremse (Achsen).
Skizze zur Herstellung, siehe Blatt Nr. 4.06.11
To measure wear of disk brakes pads (axles).
To manufacture, see drawing, page No. 4.06.11
Pour contr oler l'usure des freins ` a lamelles (mesure
de l' epaisseur des lamelles), pour la r ealisation voir
la page n 4.06.11
Meschraube M 16 x 1,5
Gaging screw M 16 x 1,5
Vis de contr ole M 16 x 1,5
24 5870 204
051
7019 556 AP 407, AP 409
AP 411, AP 415
25 5870 204
050
8145 771 AP 417, AP 420
Zum Messen des Belagverschleies der Lamellen-
bremse.
To measure wear of disk brakes pads.
Pour contr oler l'usure des freins ` a lamelles (mesure
de l' epaisseur des lamelles).
04.96
4.06.05
AufspanngabeI
Back - up tool
Contre support
27 5870 240
025
7011 522 AP 407, AP 409
AP 411, AP 415
AP 417, AP 420
Zum Arretieren des Antriebsflansches beim L osen
und Festdrehen der Antriebsritzelverschraubung.
To lock the drive flange when tighting the drive pinion
bolting.
Pour blocage de la bride d'antr ee lors du serrage du
raccord ` a vis du pignon d'entranement.
Aufsetzer
Driver
Tampon
28 5870 048
089
7013 923 AP 407, AP 409
AP 411, AP 415
AP 417, AP 420
Aufsetzer zum Einsetzen des Wellendichdringes in
das Achstriebgeh ause.
Driver to install the shaft seal into the axle carrier.
Tampon pour insertion de la bague d' etanch eit e le
carter de nez de pont.
Aufsetzer
Driver
Tampon
29 5870 048
118
7013 922 AP 407, AP 409
AP 411, AP 415
AP 417, AP 420
Aufsetzer zum Einsetzen des Wellendichdringes in
das Achstriebgeh ause.
Driver to install the shaft seal into the axle carrier.
Tampon pour insertion de la bague d' etanch eit e le
carter de nez de pont.
04.96
NutmutterschI usseI ZF-Achsen
Wrench for ZF-AxIes
CI e sp eciaIe pour pont ZF
4.06.10
Achseinsatz / AxIe - DifferentiaI / DifferentieI
Ger at
Model
Type
Achse
Axle
Pont
Markierung
Mark
R ef erence
LH ld. Nr.
LH ld. No.
LH n ldent
Di (mm)
Di (mm)
Di (mm)
Anzugsmoment
Torque
Couple serrage
L551/541 # AP 411 5870 401 093 7013 773 71 1200 Nm
L551 AP 417 5870 401 093 7013 773 71 1200 Nm
Abtrieb / Whee Hub / Sortie pont
Ger at
Model
Type
Achse
Axle
Pont
Markierung
Mark
R ef erence
LH ld. Nr.
LH ld. No.
LH n ldent
Di (mm)
Di (mm)
Di (mm)
Anzugsmoment
Torque
Couple serrage
L511/521 AP 405 5870 401 096 7011 247 117 1400-1600 Nm
L521 * AP 405 5870 401 105 7014 452 128 1400-1600 Nm
L521/531/541 AP 407 5870 401 084 7009 537 111 800-1000 Nm
L531/541 AP 409 5870 401 084 7009 537 111 800-1000 Nm
L551 AP 411 5870 401 097 7011 251 140 1300-1500 Nm
L551 AP 417 5870 401 098 7013 774 169 2000-2200 Nm
Zentrierb ugel f ur Nutmutterschl ussel siehe Werkzeug Nr. 20
Centering bracket for axle wrench see Tool No. 20
Bride de centrage pour la cl e voir outil n 20
# bis Ger at 770
up to Sr. No. 770
jusqu'au n 770
* ab Ger at 291
from Sr. Nr. 291
` a partir de 291
04.96
Mevorrichtung (ZF-Achsen)
Testing Device (ZF-AxIes)
Gabarit de mesure
4.06.11
Zum Messen des BeIagverschIeies der LameIIenbremse
To measure wear of disk brake pads (axIes)
Pour mesurer I' etat d'usure des freins ` a IameIIes
1 Flansch
Flange
Ecrou
2 Sechskantschraube M8x30
Hex Head Screw M 8x30
Vis six pans
3 Sechskantschraube M12x150
Hex Head Screw M12 x 150
Vis six pans
Einzelteilzeichnung, siehe R uckseite
Sectional drawing, see reverse page
Dessins de d etails voir au verso
04.96
SpeziaIwerkzeuge f ur Hurth - Achsen
SpeciaI tooIs for Hurth - AxIes
OutiIIage sp eciaI pour Essieu Hurth
4.07.
4. 07. Spezialwerkzeuge f ur Hurth - Achsen
Special Tools for Hurth - Axles
Outillage sp ecial pour Essieu Hurth
HINWEIS:
NOTE:
AVERTISSEMENT:
04.96
SpeziaIwerkzeuge f ur Hurth - Achsen
SpeciaI tooIs for Hurth - AxIes
OutiIIage sp eciaI pour Essieu Hurth
4.07.01
F uhIerIehre 4,3 / 4,5 mm
Slip gauge 4,3 / 4,5 mm
jauge de mesure 4,3 / 4,5 mm
128 siehe Seite
see page
voir page
4.07.10
8145 535 L506 -371 / L508 -372
L506 -426 / L507 -427
L508 -428 / L509 -429
L510 -340 / L512 -430
L522 -422
Bremsbelagverschleimessung
Brake pad wear tester
Mesure du degre' d' usure des freins
04.96
Mevorrichtung (Hurth Achs.)
Testing Device (Hurth AxIe)
Jauge de mesure
4.07.10
Zum Messen des BeIagverschIeies der LameIIenbremse
To measure wear of disk brake pads (axIes)
Pour mesurer I' etat d'usure des freins ` a IameIIes
max. zul assiger Verschlei: 4,5 mm
bei einem kleineren Wert als 4,5 mm sind die Bremsscheiben zu tauschen
max. allowable wear: 4,5 mm
at smaller gab than 4,5 mm replace disk brake pads
Usure max. 4,5 mm pour un espace inf. ` a 4,5 mm les disques fritt es sont ` a echanger.
04.96
SpeziaIwerkzeuge f ur ZF - SchaItgetriebe
ZF - Powershift transmission
Boite reversibIe sous charge ZF
4.08.
4. 08. Spezialwerkzeuge f ur ZF - Schaltgetriebe
Special Tools for ZF - Powershift transmission
Outillage sp ecial pour Boite reversible sous charge ZF
HINWEIS:
NOTE:
AVERTISSEMENT:
04.96
4.08.01
AufspanngabeI
Back - up tool
Contre support
1 5870 240
025
7011 522 L531 / L541
Zum Arretieren des Antriebsflansches beim L osen
und Festdrehen der Antriebsritzelverschraubung.
To lock the drive flange when tighting the drive pinion
bolting.
Pour blocage de la bride d'antr ee lors du serrage du
raccord ` a vis du pignon d'entranement.
HaIter (3 St uck)
Compression bar (3 pieces)
R eglette de preserrage (3 pi eces)
2 5870 654
017
7017 565 L531 / L541
Zum fixieren der Abtriebswelle.
To preload the output shaft axially.
Pour pr econtrainte axiale de l'arbre de sortie.
Aufsetzer
Driver
Tampon
3 5870 057
014
7017 562 L531 / L541
Aufsetzer zum Aufpressen des Sicherungsbleches
auf die Verschraubung des Abtriebflansches.
Driver to press the lock plate upon the bolting of the
output flange.
Tampon pour montage de la t ole - frein sur le
raccord de la bride de sortie.
Handle
Poign ee
4 5870 260
002
7011 518 L531 / L541
Handle for different drivers
Poign ee pour tampons drivers
04.96
4.08.02
SchIupfbuchse
lnstaller
Douille de glissement
5 5870 651
034
7017 554 L531 / L541
Schlupfbuchse als Montagehilfe beim Einbau des
Kolbens in den Lamellentr ager.
lnstaller as mounting aids for the installation of the
piston into the plate carrier.
Douille de glissement entant qu'aide au montage du
piston dans le porte - satellites.
Montagevorrichtung
Assembly device
Dispositif de montage
6 5870 345
028
7017 561 L531 / L541
Montagevorrichtung zum Vorspannen der Tellerfeder
beim Aus- und Einfedern des Sicherungsringes.
Assembly device to preload the cup spring when
squeezing out and engaging the circlip.
Dispositif de montage pour pr econtrainte des ress-
orts ` a disques lors du montage et d emontage du
circlips.
Montagering
Assembly ring
Bague de montage
7 5870 347
003
7017 553 L531 / L541
Montagering als Montagehilfe des Kolbens in das
Geh ause (2. Gang).
Assembly ring as mounting aids for the installation of
the piston into the housing (2. GEAR).
Bague de montage en tant qu'aide au montage, pour
l'insertion du piston dans le carter (2. VlTESSE).
Montagering
Assembly ring
Bague de montage
8 5870 347
002
7017 552 L531 / L541
Montagering als Montagehilfe beim Einsetzen des
Kolbens in den

Olzuf uhrungsring.
the piston into the oil supply ring.
l'insertion du piston dans la bague d'ariv ee d'huile.
04.96
4.08.03
Montagering
Assembly ring
Bague de montage
9 5870 347
007
7017 551 L531 / L541
10 5870 347
006
7017 550 L531 / L541
Montagering als Montagehilfe des Kolbens in das
Geh ause (1. Gang).
the piston into the housing (1. GEAR).
l'insertion du piston dans le carter (1. VlTESSE).
Aufsetzer
Driver
Tampon
11 5870 048
123
8145 772 L531 / L541
Aufsetzer zum Einsetzen des Wellendichtringes in
den Lagerdeckel.
Driver to insert the shaft seal into the bearing cover.
Tampon pour insertion de la bague d' etanch eit e
dans le couvercle - parlier.
Aufsetzer
Driver
Tampon
12 5870 058
051
8145 773 L531 / L541
Aufsetzer des Kegelrollenlager - Auenringes in den
Lagerdeckel des Abtriebs.
Driver to insert the tapered roller bearing outer race
into the bearing cover of the output.
Tampon pour insertion de la bague ext erieure du
roulement ` a rouleaux coniques dans le couvercle -
parlier de entrainement.
Sub Group lndex
Benennung / Description / Dnomination Typ / Model / Type Ab / From / A partir de
04.95
Lubricants
6.
6. 01. General
Lubrication and Operating Fluids
6. 04. Lubrication chart L 504 ........................................................................................
6. 05. Lubrication chart L 506 / L 507 ..............................................................................
L 508 / L 509
6. 06. Lubrication chart L 512 / L 522 ..............................................................................
11.93
GeneraI
6.01.01
LUBRICANTS AND OPERATING FLUIDS
lt is very important to observe the guidelines given for lubrication, level check and change of operating
fluids, as this increases reliability and service life of the machine.
lt is especially important to perform the various oil changes regularly and in the stated intervals, and to
use the same quality of lubricants are noted.
CAUTION
When checking or changing operating fIuids, you must aIso observe the foIIowing guideIines:
If not otherwise noted, make sure the machine is parked on IeveI ground of sufficient Ioad
carrying capacity when working on the machine, and that the engine is turned off.
CarefuIIy secure aII covers and doors before working in the engine area, to prevent them
from faIIing or cIosing inadvertentIy.
The engine must be turned off before refueIing.
Do not smoke and make sure there are no open fIames when refueIing.
Cleanliness is of utmost importance when changing engine oil, gear oil or hydraulic oil. Before
removing fittings or plugs, make sure the clean them and the surrounding area carefully.
When changing the oil, make sure to clean filler and drain plugs.
NOTE:
Catch the used oil in a suitable container and dispose of it properly in an environmentally sound
manner, along with the filter elements.
04.95
Lubricants and Service FIuids
6.01.02
1. Lubricating oiI for DieseI engines:
1.1 Specification:
Modern Diesel engines use only highly alloyed lubricants. They consist of base oils with additives.
Lubricating oils are differentiated according to performance and specification classification. We use API
(American Petroleum lnstitute) and CCMC (Committee of Common Market Automobile Constructors)spe-
cifications.
Approved API - oils: Approved CCMC - oils:
Aspirating engine: CC/SE CC/SF Aspirating engine: D4
CC/SF CD/SF
CE/SF CE/SG
Turbo charged engine: CD/SE CD/SF Turbo charged engine: D4 D5 **
CE/SF CE/SG
SHPD *
* SHPD - (Super- High- Performance- Diesel Oil)
* * D5 (Sulfur content 1.8 %) corresponds to SHPD *
1.2 Viscosity:
Since lubricating oils change viscosity as temperatures change, the ambient temperature around the
engine determines the selection of the viscosity classification (SAE classification). Optimum operating
conditions can be obtained if you select oils according to the oil viscosity diagram.
lf the lower temperature limit is exceeded periodically, it may influence cold start ability, but it does not
cause engine damage.
However, the limits should not be exceeded for a longer period of time to minimize wear.
Oil changes due to season changes can be eliminated by using multi grade oils. Multi grade oils,
especially light oils, may also reduce fuel consumption.
BI
1)
EO 20
EO 30
EO 1540 B
EO 1040 B
Below -25C, the engine must be preheated!
BI
1)
"Lubricants": for earthmoving equipment and vehicles by the Association of German
Construction lndustry e. V. (Bl)
(see brochure)
1.3 OiI change intervaIs:
First oil and filter change at 30 - 60 operating hours. Additional filter change every 500 hrs. and oil
change depending on climatic conditions, sulfur content in fuel and oil specification as shown in chart
below.
When using SHPD, D5 oils in naturally aspirating engines, the change interval of 500 hrs. may not be
exceeded.
Change the engine oil and the filter annually, if the given operating hours are not reached within one
year.
Oil change intervals in operating hours - hrs.
Aspirating
engine
Turbo charged
engine
Operating conditions Sulfur content
in fuel
Oil specification Oil specification
CC/SE CF-4 CF-4 SHPD
CF CF D5
CE CE
D4 D4
Normal climate up to 0.5 % 250 hrs. 500 hrs. 250 hrs. 500 hrs.
up to -10C above 0.5 % 125 hrs. 250 hrs. 125 hrs. 250 hrs.
below -10C up to 0.5 % 125 hrs. 250 hrs. 125 hrs. 250 hrs.
above 0.5 % - 125 hrs. - 125 hrs.
2. CooIant fIuids for water cooIed DieseI engines:
To assure corrosion protection in the cooling system,
the coolant must contain at least 45 %
corrosions / /antifreeze mixture all year round. This protects the coolant system to about -30C.
When fluid is added to the coolant mixture, it must be assured that the mixture maintains a 45 %
antifreeze content.
The ratio of the antifreeze / water mixture must be checked during maintenance work. The coolant must
be changed every 2 years.
2.1 Fresh water guideIines:
To mix the coolant fluid, use only clean and soft water. Often, but not always, regular drinking water may
be used. Sea water, brackish waster, brine and industrial waste water is not suitable.
2.2 Fresh water quaIity for use with corrosion / antifreeze fIuids:
Sum of alkalis (water hardness): 0.9 to 3.6 mmol/l (5 to 20d)
ph-value at 20C: 6.5 to 8.5
Chlorine content: max. 100 mg/l
Sum of chloride + sulfate: max. 200 mg/l
04.95
6.01.03
2.3 Mixture ratio of corrosion protective and antifreeze fIuids:
Freeze protection to:
Percentage (%) of
Antifreeze fluid
Do not use more than 60 % of antifreeze, a higher percentage actually reduces cooling effectiveness
and antifreeze protection.
2.4 The foIIowing corrosion protective / antifreeze fIuids may be used:
Brand Manufacturer
Agip Antifreeze Plus Agip Deutschland AG, Mnchen
Agip Langzeit-Frostschutz Autol-Werke GmbH, Wrzburg
Antigel DB 486 Sotragal SA, St. Priest/Frankreich
Aral Khler-Frostschutz A Aral AG, Bochum
Avia Frostschutz APN (G48-00) Deutsche Avia Minerall-Ges.mbH, Mnchen
BP anti-frost X 2270 A Deutsche BP AG, Hamburg
BP Napgel C 2270/1 BP Chemicals Ltd., London/England
Caltex Engine Coolant DB Caltex (UK) Ltd., London/England
Castrol Anti-Freeze O Deutsche Castrol Vertriebsges.mbH, Hamburg
Century F.L. Antifreeze Century Oil, Hanley, Stoke-on-Trent/England
Deutz Khlschutzmittel 0101 1490 Deutz Service lnternational GmbH, Kln
Esso Khlerfrostschutz Esso AG, Hamburg
Fricofin Fuchs Mineraloelwerke GmbH, Mannheim
Frostschutz Motorex (G 48-00) Bucher + Cie AG, Langenthal/Schweiz
Frostschutz 500 Mobil Oil AG, Hamburg
Glacelf Elf Mineraloel GmbH, Dsseldorf
Clycoshell AF 405 Shell
Glycoshell N Shell
Glysantin (G 48-00) BASF AG, Ludwigshafen
lgol Antigel Type DB lgol France, Paris/Frankreich
Labo FP 100 Labo lndustrie, Nanterre/Frankreich
Motul Anti-Freeze Motul SA, Aubervilliers Cedex/Frankreich
MV-Frostschutzmittel MV AG, Schwechat/sterreich
OZO Frostschutz S Total Deutschland GmbH, Dsseldorf
Total Antigel S-MB 486 Total Deutschland GmbH, Dsseldorf
Total Frostfrei Total Deutschland GmbH, Dsseldorf
Veedol Antifreeze O Deutsche Veedol GmbH, Hamburg
Wintershall Khlerschutz Wintershall Minerall GmbH, Dsseldorf
3. DieseI fueIs:
Diesel fuels should meet
the following minimum qualifications. The sulfur content should not exceed 0.5 %.
A higher sulfur content can influence oil change intervals and engine service life.
3.1 The foIIowing fueI specifications are approved:
CEN EN 590 or DlN/EN 590 (Development)
DlN 51 601 (Feb. 1986)
BS 2869 (1988): A1 and A2 (Note sulfur content with A2)
ASTM D 975-88: 1-D and 2-D
NATO code F-54 and F-75
3.2 DieseI fueIs for very Iow temperatures
ln ambient temperatures below 0C, the flow properties of warm temperature Diesel fuels can be
insufficient, due to paraffin clouding. The same may apply for cold weather type Diesel fuels below
-15C.
To prevent operating problems at even lower temperatures, Diesel fuel should be mixed with normal
gasoline or petroleum.
Adding normal gasoline should be viewed as an emergency measure, and may not exceed 30 % in
volume.
When adding other fuels or additives to the Diesel fuel, engine performance levels may drop. For that
reason, keep the addition as low as possible, depending on the ambient temperatures.
For safety reasons, always mix fuels in the fuel tank.
When refueling, add the lighter additive before the Diesel fuel. Then run the engine until the mixed fuel
has been distributed throughout the complete fuel system.
See chart below for ratios.
3.3 DieseI fueI mixture ratio (VoI.-%)
Ambient temperatures
C
Summer
Diesel fuel
Additive
%
Winter
Diesel fuel
Additive
%
0 to-10 70 30 100 -
-10 to -15 50 50 100 -
-15 to -20 - - 70 30
-20 to -25 - - 50 * 50
lf more than 50 % are required, use only petroleum (no regular gasoline).
3.4 Additives to DieseI fueI (fIow improvers):
Commercially available flow improvers can also improve Diesel fuel performance in cold temperatures.
Read and observe all manufacturer's instructions and quantities when using additives.
04.95
6.01.04
4. HydrauIic oiI:
Use oils meeting
Mercedes Service Fluid Guidelines:
Page No. 226.0 and 227.0 for single grade oils: APl- CC/SF, CD/SF, CE/SF
Page No. 227.1 and 228.1 for multi grade oils: CD/SF, CE/SF,
CD +APl- CC/SF (MlL-L-46152 B),
CD/SF, CE/SF (MlL-L-2104 D),
CD/SF (MlL-L-2104 D), CE/SF,
CD + (MlL-L-46152 B)
4.1 Viscosity cIassifications: BI
1)
HYD 10
HYD 20
HYD 30
HYD 1040
HYD 1030
BI
1)
"Lubricants": for earthmoving equipment and vehicles by the Association of German
Construction lndustry e. V. (Bl)
(see brochure)
4.2 STARTING PROCEDURE:
1.At temperatures to 10C beIow the given Iimit:
Start the Diesel engine and let it run at about 1/2 of the normal speed. Actuate the hydraulic cylinder and
motors and move the cylinder for a short time all the way to stop. Let the system warm up for about 10
minutes.
2.At even Iower temperatures:
Preheat the oil container before starting the engine.
4.3 HydrauIic oiI monitoring - oiI change after taking oiI sampIe - anaIysis and Iab report:
WheeI Ioader in normaI appIication
Operating hours
1. Oil sample
2. Oil sample
Additional oil samples every 500 hrs. ;
Oil change intervals according to sample analysis and lab
report.
Change intervals for hydraulic oil filters every 500 hrs.!
NOTE:
For wheel loaders, Liebherr recomments to use change intervals according to wear check oil sample
analysis reports. See also service and product information bulletins.
5. Gear oiIs:
For traveI gear and axIes:
Gear oils must meet - APl - GL - 5 - 90 and MlL - L - 2105 B specifications,
C or D and conform to viscosity classification SAE 90 LS*.
SAE 80 W 90 may be used instead of viscosity classification SAE 90.
* Gear oils with Limited - SIip - additives for disk brakes and self locking
differentials
6. Brake fIuid:
see paragraph 4. - "Hydraulic oil"
7. Grease for generaI Iube points:
This grease must meet specification - consistency 2 of NL Gl - grade
according to DlN 51 818 and DlN 51 825 or EP 2 according to NF-T-60 132 .
This grease must be lithium based, with a VKA value of at least 2300 N according to DlN 51 350 or
ASTM D 2596 .
LIEBHERR - SpeciaI muIti-purpose grease CTK (400 g)
Adhesive, water proof, complex saponified paste with high pressure additives as well as
increased corrosion protective properties.
Contains properties to counter friction and swing corrosion.
Especially recommended for swing ring connections.
Usage: -30C to +100C.
To order from your LlEBHERR Parts Dept., use ld. No. 861 331 301 .
8. Corrosion protective grease:
To protect exposed piston rods, apply this acid free corrosion protective grease.
or LlEBHERR - Special paste CTK, ld. No. 861 331 301
9. Lubricant for pin instaIIation:
Thinly apply special paste CTK to pins.
04.95
Lubrication Chart
L 504 0101
6.04.01
08.99
Lubrication Chart
L 506 / L 507
L 508 / L 509
2501 / 0101
2501 / 0101
6.05.01
06.94
Lubrication Chart
L 512 / L 522 101
6.06.01
Sub Group lndex
04.95
TechnicaI Data
Inspection PIans
7.
7. 02. Adjustment Chart
7. 06. Technical Data
7. 14. Maintenance and lnspection Schedule L 504 ......................................................
7. 15. Maintenance and lnspection Schedule L 506 / L 507 ............................................
L 508 / L 509
7. 16. Maintenance and lnspection Schedule L 512 / L 522 ............................................
05.97
Adjustment Chart
L 504 0101 - 0246
7.02.04
Customer: L 504: S/N: 424/ ..............................
Operating hours:..............................
Application:......................................
Location: Checked by: ....................................
Checked on: ....................................
Test / Adjustment Adjustment
values
Test point Test value at
test
Test value after
adjustment
Operating temperature
must remain the same for all adjust-
ments
65
5
C see page
10.02.04
C C
DieseI engine RPM
low idle RPM min
-1
900
30
min
-1
min
-1
high idle RPM min
-1
2680
50
min
-1
min
-1
RepIenishing pressure
Replenishing pressure relief valve 31
at high idle RPM bar 28
2
G bar bar
ReguIation begin - Var. dispI. pump
Regulating valve 33
High pressure bar 50 MB 50 bar 50 bar
Diesel engine RPM min
-1
1050
50
min
-1
min
-1
Control pressure bar 7
2
Pst bar bar
Pump output at 380 bar
High pressure
Twist screw 17
-1
2100
100
min
-1
min
-1
2
Pst bar bar
High pressure reIief vaIves
25 forward bar 410
10
MB bar bar
Var. disp. motor HA - reguIation
begin
Adjustment screw A
High pressure bar 215
+5
MB bar bar
Q
min
Q
max
bar 50
10
M1 50
10
bar 50
10
bar
= Blocked machine - 2. travel range
MB = forward
values
test
Test value after
adjustment
Inching / brake pedaI
Travel begin at high pressure bar 150
20
MB bar bar
Slowly release the brake pedal
(at full throttle)
Adjustment on threaded rod / brake
cylinder
Working hydrauIic:
60 Primary pressure
reIief vaIve
bar 260
+5
37 bar bar
Secondary pressure reIief
vaIve 64 - 67
64 Tilt out tilt cylinder bar 100
+5
37 bar bar
65 Tilt in tilt cylinder bar 230
+5
37 bar bar
67 Raise lift cylinder bar 275
+5
37 bar bar
Performance DieseI engine
Max. engine speed reduction
(at full throttle)
min
-1
150 min
-1
min
-1
Working hydraulic
(primary relief valve)
bar 260
+5
37 bar bar
Important:
When adjusting the secondary pressure relief
valves, the added functions and function
lift arms - down" may not be actuated
(these functions are only limited by
primary relief valve 60 ).
The adjustment should be done at
approx. 1200 RPM at operating temperature .
Notes:
Signature:
05.97
Adjustment Chart
L 504 0501
7.02.05
Customer: L 504: S/N: 424/ ..............................
Operating hours:..............................
Application:......................................
Location: Checked by: ....................................
Checked on: ....................................
values
test
Test value after
adjustment
ments
65
5
C see page
10.02.04
C C
DieseI engine RPM
low idle RPM min
-1
900
30
min
-1
min
-1
high idle RPM min
-1
2680
50
min
-1
min
-1
2
G bar bar
ReguIation begin - Var. dispI. pump
Regulating valve 33
-1
1050
50
min
-1
min
-1
2
Pst bar bar
High pressure
Twist screw 17
-1
2100
100
min
-1
min
-1
2
Pst bar bar
25 forward bar 410
10
MB bar bar
Var. disp. motor HA - reguIation
begin
Adjustment screw A
+5
MB bar bar
Q
min
Q
max
bar 50
10
M1 50
10
bar 50
10
bar
MB = forward
values
test
Test value after
adjustment
20
MB bar bar
(at full throttle)
cylinder
Working hydrauIic:
60 Primary pressure
reIief vaIve
bar 210
+5
37 bar bar
Secondary pressure reIief
vaIve 64 - 67
64 Tilt out tilt cylinder bar 150
+5
37 bar bar
65 Tilt in tilt cylinder bar 250
+5
37 bar bar
67 Raise lift cylinder bar 250
+5
37 bar bar
Performance DieseI engine
Max. engine speed reduction
(at full throttle)
min
-1
150 min
-1
min
-1
Working hydraulic
(primary relief valve)
bar 210
+5
37 bar bar
Important:
When adjusting the secondary pressure relief
valves, the added functions and function
lift arms - down" may not be actuated
(these functions are only limited by
primary relief valve 60 ).
approx. 1200 RPM at operating temperature .
Notes:
Signature:
08.99
Adjustment Chart
L 506 / L 507 2501 / 0101
7.02.07
Customer: L 506: S/N.: 426/ .............................
L 507: S/N.: 427/ .............................
Operating Hours: .............................
Application:......................................
Job site: Checked by: ....................................
Checked on: ....................................
values
test
Test value after
adjustment
ments
65
5
C see page
10.02.07
C C
DieseI engine RPM
Low idle RPM min
-1
850
50
min
-1
min
-1
High idle RPM min
-1
2700
50
min
-1
min
-1
2
G bar bar
Begin of reguIation -Var. dispI.
pump
Regulating valve 33
-1
1050
50
min
-1
min
-1
2
Pst bar bar
High pressure
Twist screw 17
-1
1850
100
min
-1
min
-1
Control pressure bar 12,5
2
Pst bar bar
25 forward bar 460
10
MB bar bar
Pressure cut off
Shut off valve 27 bar 425
+5/-10
MB bar bar
Engine reduction, max. difference
to high idle RPM min
-1
50 min
-1
min
-1
2
Pst bar bar
Var. dispI. motor HA
ReguIation begin
Adjustment screw A
10
MB bar bar
Q
min
Q
max
bar 50
10
M1 50
10
bar 50
10
bar
MB = forward
values
test
Test value after
adjustment
20
MB bar bar
(at full throttle)
cylinder
Working hydrauIic:
60 Primary vaIve L 506 bar 210
+5/-10
37 bar bar
+5/-10
37 bar bar
Secondary vaIves 64 - 69
64 Tilt cyl. (tilt in) P-geometry bar 250
+5/-10
37 bar bar
65 Tilt cyl. (tilt out) P-geometry bar 150
+5/-10
37 bar bar
66 Lift cyl. (up) P-geometry bar 250
+5/-10
37 bar bar
64 Tilt cyl. (tilt in) Z-geometry bar 280
+5/-10
37 bar bar
65 Tilt cyl. (tilt out) Z-geometry bar 280
+5/-10
37 bar bar
66 Lift cyl. (up) Z-geometry bar 250
+5/-10
37 bar bar
68 Added attachments bar 250
+5/-10
37 bar bar
+5/-10
37 bar bar
Performance - DieseI Engine
Max. RPM drop from high idle
(at full throttle)
min
-1
150 min
-1
min
-1
Working hydraulic L 506 bar 210
+5/-10
37 bar bar
Working hydraulic L 507 bar 230
+5/-10
37 bar bar
Important:
Function "lift arms - down" may not be actuated
when the secondary pressure relief valves are
adjusted (this function is only limited by primary
pressure relief valve 60 ).
abt. 1200 RPM and at operating temperature .
Pressures above 255 bar may not be actuated!
See page 11.02.07
Notes:
Signature:
08.99
Adjustment Chart
L 508 / L 509 2501 / 0101
7.02.09
Customer: L 508: S/N.: 428/ .............................
L 509: S/N.: 429/ .............................
Operating Hours: .............................
Application:......................................
Checked on: ....................................
values
test
Test value after
adjustment
ments
65
5
C see page
10.02.09
C C
DieseI engine RPM
Low idle RPM min
-1
900
50
min
-1
min
-1
High idle RPM min
-1
2700
50
min
-1
min
-1
2
G bar bar
ReguIating begin-Var. DispI. pump
Regulating valve 33
-1
1050
50
min
-1
min
-1
2
Pst bar bar
High pressure
Twist screw 17
-1
1850
100
min
-1
min
-1
2
Pst bar bar
25 forward bar 460
10
MB bar bar
Pressure cut off
Shutt off valve 27 bar 425
+5/-10
MB bar bar
-1
50 min
-1
min
-1
2
Pst bar bar
Var. dispI. motor HA
ReguIation begin
Adjustment screw A
10
MB bar bar
Q
min
Q
max
bar 50
10
M1 50
10
bar 50
10
bar
MB = forward
values
test
Test value after
adjustment
20
MB bar bar
(at full throttle)
cylinder
Working hydrauIic:
+5/-10
37 bar bar
+5/-10
37 bar bar
+5/-10
37 bar bar
+5/-10
37 bar bar
66 Lift cyl. (up) P-geometry bar 250
+5/-10
37 bar bar
64 Tilt cyl. (tilt in) Z-geometry bar 280
+5/-10
37 bar bar
65 Tilt cyl. (tilt out) Z-geometry bar 280
+5/-10
37 bar bar
66 Lift cyl. (up) Z-geometry bar 250
+5/-10
37 bar bar
+5/-10
37 bar bar
+5/-10
37 bar bar
(at full throttle)
min
-1
150 min
-1
min
-1
Working hydraulik L 508 bar 190
+5/-10
37 bar bar
Working hydraulik L 509 bar 210
+5/-10
37 bar bar
Important:
Function "lift arms - down"may not be actuated
when the secondary pressure relief valves are
adjusted (this function is only limited by primary
pressure relief valve 60 ).
abt. 1200 min
-1
and at operating temperature.
Notes:
Signature:
05.97
Adjustment Chart
L 512 101-151
7.02.12
Customer: L 512: S/N.: 430/ .............................
Operating Hours: .............................
Application:......................................
Checked on: ....................................
values
test
Test value after
test
ments
65
5
C see page
10.02.12
C C
DieseI engine RPM
Low idle RPM min
-1
850
30
min
-1
min
-1
High idle RPM min
-1
2450
50
min
-1
min
-1
2
G bar bar
ReguIation begin-Var. DispI. pump
Regulating valve 33
High pressure bar 50 MB(MA) 50 bar 50 bar
-1
1050
50
min
-1
min
-1
2
Pst bar bar
High pressure
Twist screw 17
-1
1850
50
min
-1
min
-1
2
Pst bar bar
25 forward bar 450
10
MB bar bar
26 reverse bar 450
10
MA bar bar
Pressure cut off
5
MB(MA) bar bar
Engine reduction,max. difference
-1
50 min
-1
min
-1
2
Pst bar bar
1. Var. dispI. motor A6VM 107 DA
ReguIation begin bar 0 M1
(Travel 1.travel range)
Adjustment screw A
+1
Pst bar bar
+20
MB bar bar
MB = forward
values
Test
Test value after
adjustment
2. Var. dispI. motor A6VMN 107
HD1D
ReguI. begin HD1 Q
max
Q
min
bar 0 M2
(Travel 2.Travel range)
Adjustment screw B
1
Pst bar bar
Pressure reguIation D
Adjustment screw C
End of reguIation Q
min
Q
max
5
MB bar bar
Setting pressure bar 50
20
M2 bar bar
Adjustment screw E
Correct adjustment: no
Screw in adjustment screw to block change neces-
sary
then turn out by 1/4 turn
Working hydrauIic:
60 Primary vaIve bar 190
+5
37 bar bar
+5
37 bar bar
+5
37 bar bar
64 Tilt cyl. (tilt out) Z-bar geometry bar 210
+5
37 bar bar
65 Tilt cyl. (tilt in) Z-bar geometry bar 210
+5
37 bar bar
66 Lift cylinder (down) bar 210
+5
37 bar bar
67 Lift cylinder (lift up) bar 210
+5
37 bar bar
(at full throttle)
min
-1
150 min
-1
min
-1
Working hydraulik
(Primary valve)
bar 190
+5
37 bar bar
Important:
Additional functions may not be actuated when adjusting the secondary pressure relief valves
(Additonal functions are limited by the primary pressure relief valve 60 ).
Notes:
Signature:
05.97
Adjustment Chart
L 512 152 - 263
7.02.12/1
Customer: L 512: S/N: 430/ ..............................
Operating Hours: .............................
Application:......................................
Checked on: ....................................
values
test
Test value after
test
ments
65
5
C see page
10.02.12/1
C C
DieseI engine RPM
low idle RPM min
-1
850
30
min
-1
min
-1
high idle RPM min
-1
2450
50
min
-1
min
-1
2
G bar bar
ReguIation begin-Var. dispI. pump
Regulating valve 33
-1
1050
50
min
-1
min
-1
2
Pst bar bar
High pressure
Twist screw 17
-1
1850
50
min
-1
min
-1
2
Pst bar bar
25 forward bar 450
10
MB bar bar
26 reverse bar 450
10
MA bar bar
Pressure cut off
5
MB(MA) bar bar
-1
50 min
-1
min
-1
2
Pst bar bar
(Travel 1. travel range)
Adjustment screw A
+1
Pst bar bar
+20
MB bar bar
MB = forward
values
test
Test value after
adjustment
HD1D
ReguI. begin HD1 Q
max
Q
min
bar 0 M2
Adjustment screw B
1
Pst bar bar
Adjustment screw C
End of reguIation Q
min
Q
max
5
MB bar bar
20
M2 bar bar
Adjustment screw E
sary
Working hydrauIic:
+5
37 bar bar
+5
37 bar bar
+5
37 bar bar
64 Tilt cyl. (tilt out ) Z-bar geometry bar 210
+5
37 bar bar
65 Tilt cyl. (tilt in ) Z-bar geometry bar 210
+5
37 bar bar
67 Lift cylinder (up) bar 210
+5
37 bar bar
(at full throttle)
min
-1
150 min
-1
min
-1
Working hydraulik
(Primary valve)
bar 190
+5
37 bar bar
Important:
When adjusting the valves, function lift arms down, do not run to block (This function is only limited
by the primary pressure relief valve 60 ).
Notes:
Signature:
05.97
Adjustment Chart
L 512 264
7.02.12/2
Customer: L 512: S/N: 430/ ..............................
Operating Hours: .............................
Application:......................................
Checked on: ....................................
values
test
Test value after
test
ments
65
5
C see page
10.02.12/2
C C
DieseI engine RPM
low idle RPM min
-1
850
30
min
-1
min
-1
high idle RPM min
-1
2450
50
min
-1
min
-1
2
G bar bar
Regulating valve 33
High pressure bar 50 MA(MB) 50 bar 50 bar
-1
1050
50
min
-1
min
-1
2
Pst bar bar
High pressure
Twist screw 17
-1
1850
50
min
-1
min
-1
2
Pst bar bar
26 forward bar 450
10
MA bar bar
25 reverse bar 450
10
MB bar bar
Pressure cut off
5
MA(MB) bar bar
-1
50 min
-1
min
-1
2
Pst bar bar
Adjustment screw A
Control pressure till S/N 274 bar 12
+1
Pst bar bar
Control pressure from S/N 275 bar 10
+1
Pst bar bar
+20
MA bar bar
MA = forward
values
test
Test value after
adjustment
HD1D
ReguI. begin HD1 Q
max
Q
min
bar 0 M2
Adjustment screw B
1
Pst bar bar
Adjustment screw C
End of reguIation Q
min
Q
max
5
MA bar bar
20
M2 bar bar
Working hydrauIic:
+5
37 bar bar
+5
37 bar bar
+5
37 bar bar
64 Tilt cyl. (tilt out ) Z-bar geometry bar 210
+5
37 bar bar
65 Tilt cyl. (tilt in ) Z-bar geometry bar 210
+5
37 bar bar
+5
37 bar bar
(at full throttle)
min
-1
150 min
-1
min
-1
Working hydraulik
(Primary valve)
bar 190
+5
37 bar bar
Important:
When adjusting the valves, function lift arms down, do not run to block (This function is only limited
by the primary pressure relief valve 60 ).
Notes:
Signature:
05.97
Adjustment Chart
L 522 101-233
7.02.22
Customer: L 522: S/N.: 422/ .............................
Operating hours:..............................
Application:......................................
Checked on: ....................................
values
Test point Test point at
test
Test value after
adjustment
ments
65
5
C see page
10.02.22/3
C C
DieseI engine RPM
low idle RPM min
-1
850
30
min
-1
min
-1
high idle RPM min
-1
2450
50
min
-1
min
-1
2
G bar bar
Regulating valve 33
-1
1050
50
min
-1
min
-1
2
Pst bar bar
high pressure
Twist screw 17
-1
1850
50
min
-1
min
-1
2
Pst bar bar
25 forward bar 450
10
MB bar bar
26 reverse bar 450
10
MA bar bar
Pressure cut off
5
MB(MA) bar bar
-1
50 min
-1
min
-1
2
Pst bar bar
Adjustment screw A
+1
Pst bar bar
+20
MB bar bar
MB = forward
values
test
Test value after
Adjustment
HD1D
ReguI. begin HD1 Q
max
Q
min
bar 0 M2
Adjustment screw B
1
Pst bar bar
Adjustment screw C
End of reguIation Q
min
Q
max
5
MB bar bar
20
M2 bar bar
Pressure reducing vaIve
(Travel 2. Travel range, at full throttle)
Adjustment screw D
2
M3 bar bar
Speed km/h 18
2
km/h km/h
Adjustment screw E
Correct Adjustment: no
sary
Working hydrauIic:
60 Primary reIief vaIve bar 220
+5
37 bar bar
+5
37 bar bar
+5
37 bar bar
+5
37 bar bar
+5
37 bar bar
66 Lift cylinder (down) bar 245
+5
37 bar bar
+5
37 bar bar
(at full throttle)
min
-1
150 min
-1
min
-1
Working hydraulik
(Primary valve)
bar 220
+5
37 bar bar
Important:
Additional functions may not be actuated when adjusting the secondary pressure relief valves.
(Additional functions are limited by the primary pressure relief valve 60 ).
Notes:
Signature:
05.97
Adjustment Chart
L 522 234 - 321
7.02.22/1
Customer: L 522: S/N.: 422/ .............................
Operating hours:..............................
Application:......................................
Checked on: ....................................
values
test
Test value after
Adjustment
ments
65
5
C see page
10.02.22/3
C C
DieseI engine RPM
low idle RPM min
-1
850
30
min
-1
min
-1
high idle RPM min
-1
2450
50
min
-1
min
-1
2
G bar bar
Regulating valve 33
-1
1050
50
min
-1
min
-1
2
Pst bar bar
High pressure
Twist screw 17
-1
1850
50
min
-1
min
-1
2
Pst bar bar
25 forward bar 450
10
MB bar bar
26 reverse bar 450
10
MA bar bar
Pressure cut off
5
MB(MA) bar bar
-1
50 min
-1
min
-1
2
Pst bar bar
Adjustment screw A
+1
Pst bar bar
+20
MB bar bar
MB = forward
values
Test
Test value after
Adjustment
HD1D
ReguI. begin HD1 Q
max
Q
min
bar 0 M2
Adjustment screw B
1
Pst bar bar
Adjustment screw C
End of reguIation Q
min
Q
max
5
MB bar bar
20
M2 bar bar
(Travel 2. Travel range)
Adjustment screw D
2
M3 bar bar
Speed km/h 18
2
km/h km/h
Adjustment screw E
sary
Working hydrauIic:
+5
37 bar bar
+5
37 bar bar
+5
37 bar bar
+5
37 bar bar
+5
37 bar bar
+5
37 bar bar
(at full throttle)
min
-1
150 min
-1
min
-1
Working hydraulik
(Primary valve)
bar 220
+5
37 bar bar
Important:
When adjusting the valves, function lift arms down, do not run on block (this function is only limited
by the primary relief valve 60 ).
Notes:
Signature:
05.97
Adjustment Chart
L 522 322 - 385
7.02.22/2
Customer: L 522: S/N.: 422/ .............................
Operating hours:..............................
Application:......................................
Checked on: ....................................
values
test
Test value after
Adjustment
ments
65
5
C see page
10.02.22/2
C C
DieseI engine RPM
low idle RPM min
-1
850
30
min
-1
min
-1
high idle RPM min
-1
2450
50
min
-1
min
-1
2
G bar bar
Regulating valve 33
-1
1050
50
min
-1
min
-1
2
Pst bar bar
High pressure
Twist screw 17
-1
1850
50
min
-1
min
-1
2
Pst bar bar
25 forward bar 450
10
MB bar bar
26 reverse bar 450
10
MA bar bar
Pressure cut off
5
MB(MA) bar bar
-1
50 min
-1
min
-1
2
Pst bar bar
Adjustment screw A
+1
Pst bar bar
+20
MB bar bar
MB = forward
values
Test
Test value after
Adjustment
HD1D
ReguI. begin HD1 Q
max
Q
min
bar 0 M2
Adjustment screw B
1
Pst bar bar
Adjustment screw C
End of reguIation Q
min
Q
max
5
MB bar bar
20
M2 bar bar
Adjustment screw E
lnsert adjustment screw to block change neces-
sary
Working hydrauIic:
+5
37 bar bar
+5
37 bar bar
+5
37 bar bar
+5
37 bar bar
+5
37 bar bar
+5
37 bar bar
(at full throttle)
min
-1
150 min
-1
min
-1
Working hydraulik
(Primary valve)
bar 220
+5
37 bar bar
Important:
Notes:
Signature:
05.97
Adjustment Chart
L 522 386
7.02.22/3
Customer: L 522: S/N.: 422/ .............................
Operating hours:..............................
Application:......................................
Checked on: ....................................
values
test
Test value after
Adjustment
ments
65
5
see page
10.02.22/3
DieseI engine RPM
low idle RPM min
-1
850
30
min
-1
min
-1
high idle RPM min
-1
2450
50
min
-1
min
-1
2
G bar bar
Regulating valve 33
-1
1050
50
min
-1
min
-1
2
Pst bar bar
High pressure
Twist screw 17
-1
1850
50
min
-1
min
-1
2
Pst bar bar
26 forward bar 450
10
MA bar bar
25 reverse bar 450
10
MB bar bar
Pressure cut off
5
MA(MB) bar bar
-1
50 min
-1
min
-1
2
Pst bar bar
Adjustment screw A
+1
Pst bar bar
+1
Pst bar bar
+20
MA bar bar
MA = forward
values
Test
Test value after
Adjustment
2. Var. dispI. motor A6VM 160 HD1D
ReguI. begin HD1 Q
max
Q
min
bar 0 M2
Adjustment screw B
1
Pst bar bar
Adjustment screw C
End of reguIation Q
min
Q
max
5
MA bar bar
20
M2 bar bar
Working hydrauIic:
+5
37 bar bar
+5
37 bar bar
+5
37 bar bar
+5
37 bar bar
+5
37 bar bar
+5
37 bar bar
(at full throttle)
min
-1
150 min
-1
min
-1
Working hydraulik
(Primary valve)
bar 220
+5
37 bar bar
Important:
Notes:
Signature:
05.97
TechnicaI Data
L 504 0101
7.06.04
GENERAL S/N 0101 - 0246 from S/N No. 0501
Operating weight with standard bucket 0.6 mt kg 3410 3680
Total length with bucket mm 4450 4450
Bucket width mm 1600 1600
Overall width with tires mm 1540 1540
Total height with tires 11,5 / 80 - 15,3 mm 2410 2410
Ground clearance with tires 11,5 / 80 - 15,3 mm 225 225
Wheel base mm 1600 1600
Tread gauge mm 1280 1270
Turning radius with bucket in transport position mm 3580 3580
Dumping height at 40 max. mm 2290 2290
Penetration depth mm 42 80
Traction kg 2720 2720
Travel speed, max. travel range l / ll km/h 5/20 5/20
DIESEL ENGINE
KHD Diesel engine Type F3L 1011 F3L 1011 F
Output kW 27,5 (37,4 PS) 29 (39,4 PS)
Nominal speed min
-1
2500
high idle RPM min
-1
2680
low idle RPM min
-1
900
Torque, max. ( at 1800 RPM ) Nm 113 118
Oil quantity (with filter change) l 7
Displacement cmt 2049
Stroke / bore mm 105 / 91
Firing order 1-2-3
Valve play, cold - lnlet / exhaust mm 0,3 / 0,5
Begin of delivery kW v.OT 20
lnjection pressure bar 250
+8
Fuel tank capacity l 42
Permissible inclination left / right 25
Uphill - downhill 35
HYDRAULIC TANK
Hydraulic system capacity (complete system ) l 40
Hydraulic tank capacity l 29
Hydraulic oil change intervals Hrs. 2000
Combination return - suction filter (10 Qm absolute) Type SK 3229-1
Return strainer Qm 63
TRAVEL HYDRAULIC
VariabIe dispIacement pump Type A4VG 28 DA
Output kW 26
Pump flow, max. l/min 70
Operating pressure, max. bar 410
10
Replenishing pump displacement cmt 6,1
Replenishing pressure, max. bar 28
Control pressure at begin of regulation bar 7
VariabIe dispIacement motor Type A6VM 55 HA1U A6VM 55 HA1R1
(from 0520)
Displacement volume, max. cmt 55 55
Displacement volume, min. cmt 13 13
Torque, max. ( = 380 bar) Nm 330 330
WORKING HYDRAULIC S/N 0101 - 0246 from S/N 0501
Fixed displacement pump with priority flow divider Type Ultra 1 PX 140 Ultra 1 SX 170 C
Output kW 12 12
Pump flow, max. l/min 35 42,5
Displacement cmt 14 17
Primary pressure relief bar 260
+5
210
+5
Control valve block 3-way Type SM 12 SM 12
Control direct controlled direct controlled
Diameter / lift cylinder cyl. / rod mm 80 / 40 90 / 50
Diameter / tilt cylinder cyl. / rod mm 80 / 4 80 / 40
Hoist speed sec. 4,7 4,9
TRAVEL GEAR
Gear Type ZF 1 AVG - 95
Gear ratio 1 : 1,816
Universal drive shaft, max. RPM min
-1
2770
50
Oil quantity l 0,2
Oil viscosity SAE 90 LS
Oil change intervals Hrs. 1000
AXLES
Planetary steering axle rear with self locking differential Type ZF APL - 2010
Planetary steering axle front with self locking differential Type ZF APL - 2010
Gear ratio, complete 1 : 21
Oil quantity , differential rear/ front l 3,0 / 3,5
Oil quantity per wheel hub rear/ front l 0,2 / 0,2
Oil viscosity / quality SAE 90 LS
Tires (Standard) 11.5 / 80 - 15.3
Tightening torque / wheel lugs Nm 330
STEERING
Steering unit (Servostat) Type Eaton 263 - 4062
Displacement cmt 95
Pilot flow l/min 3
Pressure relief, primary bar 180
Pressure relief, secondary bar 240
Steering cylinder- cyl. / rod mm 60/32
BRAKES
Service brake, hydraulic on front axle Drum brake
Brake pressure / service brake, max. bar 120
Brake light - pressure switch bar 3
Parking brake, mechanical, on front axle Drum brake
Brake fluid SAE 10 W
ELECTRICAL SYSTEM
Operating voltage V 12
Battery Ah / V 88 / 12
Alternator V / A 14 / 60
Starter V / kW 12 / 2,2
08.99
TechnicaI Data
L 506 2501
7.06.06
GENERAL P - geometry Z - geometry
Operating weight with standard bucket 0,7 mt(0,8 mtfrom 4308) kg 4410 (4570) 4600 (4810)
Total length with bucket (from 4308) mm 5230 (5435) 5200 (5502)
Width over tires mm 1770 1770
Total height with tires 12,5 - 18 mm 2670 2670
Ground clearance with tires 12,5 - 18 mm 300 300
Turning radius with bucket in transport position (from 4308) mm 3750 (3730) 3670 (3625)
Dumping height at 42 max. (from 4308) mm 2500 (2450) 2480 (2490)
Scraping depth mm 85 100
Traction with tires 335/80 R20 kg 3350 3350
Travel speed max. travel range l / ll km/h 6 / 20 6 / 20
DIESEL ENGINE
KHD - Diesel engine Type F 4L 1011 F4L 1011F (from 3008)
BFL 1011F (from 4308)
Output kW / hp 40 / 54 44 / 60 (from 4308)
Nominal speed min
-1
2600
High idle RPM min
-1
2700
50
Low idle RPM min
-1
850
50
Torque max. ( at 1800 min
-1
) Nm 154
Oil Quantity (with filter change) l 8,5
Firing order 1-3-4-2
Valve play cold - lntake / Discharge mm 0,3 / 0,5
Compression ratio 17:1
+8
permissible incline / left - right 25
Uphill - Downhill 35
HYDRAULIC TANK
Hydraulic tank capacity (System complete) l 61
Combination return-suction filter (10 Qm absolute) Type SR 110L
Return filter strainer Qm 40
TRAVEL HYDRAULIC
Output kW 36
Pump flow max. l/min 98
Secondary pressure relief bar 460
10
Pressure cut off bar 425
+5/-10
2
Control pressure at regulation begin bar 7
VariabIe dispIacement motor Typ A6VM 80 HA1U A6VM 80 HA1R1 (from 3096)
Displacement volume max. cmt 80
Displacement volume min. cmt 22 20 (from 2705)
Torque max. ( = 380 bar) Nm 485
WORKING HYDRAULIC
Fixed displacement pump with priority flow divider Type 1 SX 250 C 1 SX 260 C (from 3362)
Output kW 21,4 22,2
Pump flow max. l/min 62,5 65
Pump displacement cmt 25 26
+5/-10
Control valve block 3-way Type SM 12
Control hydraulic - servo controlled
Pilot control valve Type 4 THF 6
Diameter Lift cylinder Bore / Rod P - geomtry mm 100 / 50
Diameter Tilt cylinder Bore / Rod P - geomtry mm 100 / 50
Diameter Lift cylinder Bore / Rod Z - geomtry mm 80 / 40
Diameter Tilt cylinder Bore / Rod Z - geomtry mm 80 / 40
Hoist speed sec. 4,5
TRAVEL GEAR
Gear Type Hurth 302
Gear ratio 1 : 2,27 (from 2705 1 : 2,54)
-1
1860
50
Oil quantity l 0,5
AXLES
Steered Planetary axle, rear, with self-locking differential # Hurth 302 / 271 / 167
and transfer gearbox
Planetary axle, front, with self-locking differential Hurth 171 / 202
Ratio, complete 1 : 16,92
Oil quantity Differential rear/front l 4,7 / 3,7
Oil quantity Wheel hub rear/front l 2 x 1,0
Oil viscosity / Quality SAE 90 LS
Tires (Standard) 335/80 R20
Tightening torque, wheel lugs Nm 450
STEERING
Pilot flow l/min 3
Pressure relief primary bar 180
Pressure relief secondary bar 240
Steering cylinder- Bore / Rod mm 70/30
BRAKE
Service brake, hydraulic, on front axle Drum brake
Brake pressure / Service brake, max. bar 120
ELECTRICAL SYSTEM
08.99
TechnicaI Data
L 507 0101
7.06.07
Operating weight with standard bucket 0,8 mt
(
0,9 mtfrom 4299) kg 4670 (4770) 4870 (4930)
Total length with bucket (from (4299) mm 5230 (5480) 5200 (5260)
Total height with tires 335/80 R20 mm 2700 2700
Ground clearance with tires 335/80 R20 mm 325 325
DIESEL ENGINE
KHD - Diesel engine Type BF 4L 1011/T BF 4L 1011 FT (ab 2904)
Output kW / hp 44 / 60 46 / 63 (from 4299)
Nominal speed min
-1
2500
High idle RPM min
-1
2700
50
Low idle RPM min
-1
850
50
-1
) Nm 185
+8
HYDRAULIC TANK
Combination return-suction filter (10 Qm absolute) Type E 084 - 10 E SR 110L (from 2501)
Return filter strainer Qm 63 40(from 2501)
TRAVEL HYDRAULIC
Output kW 40
10
+5/-10
2
Displacement volume min. cmt 22 20 (from 2705)
WORKING HYDRAULIC
Fixed displacement pump with priority flow divider Type 1 PX 250
1 SX 250C (from 2501) 1 SX 260C (from 3362)
Output kW 21,4 22,2
Pump flow max. l/min 62,5 65
Pump displacement cmt 25 26
+5/-10
Diameter Lift cylinder Bore / Rod P - geomtry mm 100 / 50
Diameter Tilt cylinder Bore / Rod P - geomtry mm 100 / 50
Diameter Lift cylinder Bore / Rod Z - geomtry mm 80 / 40
Diameter Tilt cylinder Bore / Rod Z - geomtry mm 80 / 40
TRAVEL GEAR
Gear Type Hurth 302
Gear ratio 1 : 2,27 1 : 2,54 (from 2705)
-1
1860
50
Oil quantity l 0,5
AXLES
Steered Planetary axle, rear, with self-locking differential Hurth 302 / 271 / 167
and transfer gearbox
Ratio, complete 1 : 16,92
Oil quantity Wheel hub rear/front l 2 x 1,0
STEERING
Pilot flow l/min 3
BRAKE
ELECTRICAL SYSTEM
08.99
TechnicaI Data
L 508 2501
7.06.08
(
1,0 mtfrom 4368) kg 4980 (5210) 5135 (5310)
Dumping height at 42 max. (from (4368) mm 2705 2500 (2480)
DIESEL ENGINE
KHD - Diesel engine Type BF 4L 1011 BF 4L 1011 FT (from 3001)
Output kW / hp 46 / 63 49 / 67 (from 4368)
Nominal speed min
-1
2500
High idle RPM min
-1
2700
50
Low idle RPM min
-1
900
50
-1
) Nm 200
+8
HYDRAULIC TANK
Combination return-suction filter (10 Qm absolute) Type SR 110L
TRAVEL HYDRAULIC
Output kW 42
10
+5/-10
2
Displacement volume min. cmt 26,5
WORKING HYDRAULIC
Fixed displacement pump with priority flow divider Type 2 SR 033
Output kW 26
Pump flow max. l/min 82,5
Pump displacement cmt 33
+5/-10
Diameter Lift cylinder Bore / Rod P - geometry mm 120 / 50
Diameter Tilt cylinder Bore / Rod P - geometry mm 120 / 50
Diameter Lift cylinder Bore / Rod Z - geometry mm 90 / 50
Diameter Tilt cylinder Bore / Rod Z - geometry mm 90 / 50
TRAVEL GEAR
Gear (from 4085) Type Hurth 302 (ZF - 1AVG 185)
Gear ratio (from 4085) 1 : 1,867 (1 : 2,48)
Universal drive shaft, max. RPM (from 4085) min
-1
2700
50
(2030
50
)
Oil quantity (from 4085) l 0,5 (1,0)
AXLES
and transfer gearbox ZF from 4085 APL-R725
ZF from 4085 AP-R725
Ratio, complete (from 4085) 1 : 27 (1 : 20,66)
Oil quantity Differential rear/front (from 4085) l 4,7 / 3,7 (4,0 / 5,0)
Oil quantity je Wheel hub rear/front (from 4085) l 1,0 (0,7)
STEERING
Pilot flow l/min 3
BRAKE
ELECTRICAL SYSTEM
08.99
TechnicaI Data
L 509 0101
7.06.09
(
1,1 mtfrom 4322) kg 5355 (5580) 5510 (5740)
DIESEL ENGINE
KHD - Diesel engine Type BF 4L 1011 BF 4L 1011 F (from 2925)
Output kW / hp 49 / 67 52 / 71 (from 4322)
Nominal speed min
-1
2500
High idle RPM min
-1
2700
50
Low idle RPM min
-1
900
50
-1
) Nm 230
+8
HYDRAULIC TANK
Combination return-suction filter (10 Qm absolute) Type E 084 - 10 E SR 110L (from 2501)
Return filter strainer Qm 63 40 (from 2501)
TRAVEL HYDRAULIC
Output kW 45
10
+5/-10
2
Displacement volume min. cmt 26,5
WORKING HYDRAULIC
Fixed displacement pump with priority flow divider Type 2 PX 330 (from 2501 2 SR 033)
Output kW 26
Pump flow max. l/min 82,5
Pump displacement cmt 33
+5/-10
Diameter Lift cylinder Bore / Rod P - geometry mm 120 / 50
Diameter Tilt cylinder Bore / Rod P - geometry mm 120 / 50
Diameter Lift cylinder Bore / Rod Z - geometry mm 90 / 50
Diameter Tilt cylinder Bore / Rod Z - geometry mm 90 / 50
TRAVEL GEAR
Gear (from 4089) Type Hurth 302 (ZF - 1AVG 185)
Gear ratio (from 4089) 1 : 1,867 (1: 2,48)
Universal drive shaft, max. RPM (from 4089) min
-1
2700
50
(2030
50
)
Oil quantity (from 4089) l 0,5 (1,0)
AXLES
and transfer gearbox ZF from 4089 APL-R725
ZF from 4089 AP-R725
Ratio, complete (from 4089) 1 : 27 (1 : 20,66)
Oil quantity Differential rear/front (from 4089) l 4,7 / 3,7 (4,0 / 5,0)
Oil quantity je Wheel hub rear/front (from 4089) l 1,0 (0,7)
STEERING
Pilot flow l/min 3
BRAKE
ELECTRICAL SYSTEM
11.93
TechnicaI Data
L 512 101-151
7.06.12
GENERAL
Basic weight with standard bucket 1,2 mt t 7,4
Total length with bucket mm 6150
Width mm 2400
Total height with tires 15,5 - 25 mm 2950
Ground clearance (with tires 15,5 - 25) mm 440
Wheel base mm 2650
Thread gauge mm 1850
Turning radius mm 5280
Dumping height at 45 max. mm 2790
Traction kN 62
Travel speed, max. km/h 32
Steering deflection max 40
DIESEL ENGINE
Type Deutz BF 4L 913
Output at 2300 min
-1
kW 69 (94 PS)
high idle RPM min
-1
2450
50
Torque, max. Nm 342 at 1600 min
-1
Oil quantity l 10,0
Valve play, cold - lntake / Discharge mm 0,15
Begin of fuel delivery KW 27
+1
v. OT
+8
HYDRAULIC TANK
Hydraulic tank capacity (Oil quantity / Tank capacity) l 80
Additional circuit l 40
Oil quality / Viscosity see Operating Fluids, Section 6
Combination Return-Suction filter Type SK 3229-2
Filtration (2 Filters ) Qm 10 absolute
TRAVEL HYDRAULIC
Var. dispI. pump Type A4VG 90 DA Series 3.1
Output kW 64
High pressure, max. bar 450
10
5
Pump flow, Replenishing pump (theor.) l/min 43
Replenishing and control pressure, max. bar 34/20
Control pressure at Regulation begin bar 7
1. Var. dispI. motor Type A6VM 107 DA
Displacement volume, max. cmt/U 107
Torque, max. Nm 570
Gear ratio in travel gear 1,829
2. Var. dispI. motor Type A6VMN 107 HD1D
Torque, max. Nm 570
WORKING HYDRAULIC
Fixed displacement pump Type JSB G25-58-B6 F1-10-R
Output kW 42
+5
Secondary pressure relief- Lift / tilt cylinder bar 210
+5
Secondary relief
Extend tilt cylinder only with parallelogram geometry bar 150
+5
Control valve block Z / P - Geometry 3-way standard Type SM 18 (227 897 02 / 227 615 02)
Diameter / Lift cylinder Bore / Rod mm 110 / 60
Diameter / Tilt cylinder Bore / Rod Z bar geometry mm 130 / 70
Diameter / Tilt cylinder Bore / Rod Parallelogram geometry mm 160 / 80
TRAVEL GEAR
Gear box Type Hurth 310
Oil quantity l 2,4
AXLES
Planetary axle / rear Type 310 / 176 / 50
Planetary axle / front Type 176 / 114
Self locking differentials / Locking value 45 %
Oil quantity Wheel hub rear/front l 2x1,8 / 2x1,8
Oil viscosity/Quality SAE 90 LS
Tires 15,5-25 / 17,5-25
Brakes wet disk brakes
STEERING
Valve block with flow divider Type ZF 7760
Pump flow,-Steering and working hydraulic, max. l/min 133
Pilot flow l/min 5
Displacement volume of emergency steering pump cmt/U 16
Servostat Type ZF 8476
Servostat displacement volume cmt/U 492
BRAKE
Main brake cylinder / Change over pressure bar 15
Brake pressure/Service brake, max. bar 45
Parking brake, mech. on rear axle wet disk brake
06.94
TechnicaI Data
L 512 152
7.06.12/1
GENERAL
Width mm 2400
Total height with tires 15,5 - 25 mm 2950
Ground clearance (with tires 15,5 - 25) mm 440
Wheel base mm 2650
Traction kN 62
DIESEL ENGINE
Output at 2300 min
-1
kW 69 (94 PS)
high idle RPM min
-1
2450
50
-1
Oil quantity l 10,0
Valve play, cold - lntake / Discharge mm 0,15
+1
v. OT
+8
HYDRAULIC TANK
Hydraulic tank capacity (Oil quantity - tank capacity) l 80
Oil quality / Viscosity see Operating Fluids, section 6
Combination return - suction filter Type SK 3229-2
Filtration (2 filters ) Qm 10 absolute
TRAVEL HYDRAULIC
Output kW 64
10
5
Pump flow of replenishing pump (theor.) l/min 43
Replenishing and Control pressure, max. bar 34/20
Torque, max. Nm 570
Torque, max. Nm 570
WORKING HYDRAULIC
Output kW 42
+5
Secondary pressure relief - Lift / tilt cylinder bar 210
+5
Secondary pressure relief
+5
Control valve block 2-way standard Type SM 18 (228 313 01)
Servo control Type 4 THF6
Accumulator Servo control cmt 320
Fill pressure bar 15
Diameter / lift cylinder Bore / Rod mm 110 / 60
Diameter / tilt cylinder Bore / Rod Z-bar geometry mm 130 / 70
Diameter tilt cylinder Bore / Rod Parallelogram geometry mm 160 / 80
TRAVEL GEAR
Oil quantity l 2,0
AXLES
Self locking differentials / locking value 45 %
Oil quantity / Differential rear / front l 8,3 / 8,3
Oil quantity / wheel hub rear / front l 2x2,0 / 2x2,0
Tires 15,5-25 / 17,5-25
Brakes wet disk brake
STEERING
Pump flow - Steering and working hydraulic, max. l/min 133
Pilot flow l/min 5
Pressure relief - primary bar 180
Pressure relief , secondary bar 240
Servostat Displacement volume cmt/U 492
BRAKE
Gear pump Type 1 PF 2 G2
Displacement volume cmt/U 4
Accumulator charge valve Type LT 06
Accumulator PB 210 cmt 750
Service brake valve Type LT 05
Brake pressure, max. bar 60
5
Parking brake, mech. on drum front axle
11.93
TechnicaI Data
L 522 101 - 233
7.06.22
GENERAL
Width mm 2440
Total height with tires 20 - 24 mm 2990
Ground clearance (with tires 20 - 24) mm 480
Wheel base mm 2650
Traction kN 72
DIESEL ENGINE
Output at 2300 min
-1
kW 74 (101 PS)
high idle RPM min
-1
2450
50
-1
Oil quantity l 10,0
Valve play cold - lntake / Discharge mm 0,15
+1
v. OT
+8
HYDRAULIC TANK
Hydraulic tank capacity ( oil quantity - tank capacity) l 80
Filtration (2 Filters) Qm 10 absolute
TRAVEL HYDRAULIC
Output kW 69
10
5
Replenishing and Control Pressure, max. bar 34/20
Torque, max. Nm 569
Torque, max. Nm 850
Gear ration in travel gear 1,641
WORKING HYDRAULIC
Output kW 49
+5
Secondary relief / lift - tilt cylinder bar 245
+10
Secondary relief
+5
Control valve block Z / P- geometry 3-way standard Type SM 18 (227 897 02 / 227 615 02)
Diameter lift cylinder Bore / Rod mm 110 / 60
Diameter tilt cylinder Bore / Rod Z-bar geometry mm 130 / 70
TRAVEL GEAR
Oil quantity l 2,4
AXLES
Oil quantity / differential rear / front l 12,5 / 12,5
Oil quantity - wheel hub rear/ front l 2x1,8 / 2x1,8
Oil viscosity / quality SAE 90 LS
Tires 17,5-25 / 20-24
STEERING
Pump flow - steering and working hydraulic, max. l/min 133
Pilot flow l/min 5
BRAKE
Main brake cylinder / Change over pressure bar 15
Brake pressure / service brake, max. bar 45
Manual brake, mechanical, on rear axle wet disk brake
06.94
TechnicaI Data
L 522 234
7.06.22/1
GENERAL
Width mm 2440
Total height with tires 20 - 24 mm 2990
Ground clearance (with tires 20 - 24) mm 480
Wheel base mm 2650
Traction kN 72
DIESEL ENGINE
Output at 2300 min
-1
kW 74 (101 PS)
high idle RPM min
-1
2450
50
-1
Oil quantity l 10,0
Valve play cold - lntake / Discharge mm 0,15
+1
v. OT
+8
permissible incline left -right 25
HYDRAULIC TANK
Hydraulic tank capacity (Oil quantity tank capacity) l 80
Filtration (2 Filters) Qm 10 absolute
TRAVEL HYDRAULIC
Output kW 69
10
5
Replenishing and Control Pressure, max. bar 34/20
Torque, max. Nm 569
Torque, max. Nm 850
WORKING HYDRAULIC
Output kW 49
+5
Secondary pressure relief lift / tilt cylinder bar 245
+10
Secondary relief
+5
Control valve block 2-wary standard Type SM 18 (228 313 01)
Servo control Type 4 THF6
Accumulator servo control cmt 320
Filling pressure bar 15
Diameter lift cylinder Bore / Rod mm 110 / 60
Diameter tilt cylinder Bore / Rod Z-bar geometry mm 130 / 70
TRAVEL GEAR
Oil quantity l 2,0
AXLES
Oil quantity - differential rear/ front l 12,5 (13,5 from S.N. 298) / 12,5
Oil quantity wheel hub rear / front l 2x1,8 / 2x1,8
Tires 17,5-25 / 20-24
STEERING
Pump flow - steering and working hydraulic, max. l/min 133
Pilot flow l/min 5
Pump displacement volume of emergency steering pump cmt/U 16
BRAKE
Gear pump Type 1 PF 2 G2
Pump flow cmt/U 4
Accumulator charge valve Type LT 06
Accumulator PB 210 cmt 750
Service brake valve Type LT 05
Brake pressure, max. bar 60
5
Parking brake, mech. on rear axle wet disk brake till Sr. No. 297
Parking brake, mech. on drum front axle from Sr. No. 298
05.97
Maintenance and
Inspection ScheduIe
L 504 0101
7.14.01
DEUTZ DIESEL ENGINE
Q Q Q Q Q Q Q Oil level and oil pressure - Check OM
Q Q Q Q Q Dust ejector on air filter - empty OM
S Q Q Fuel filter element - replace OM
S Q Q Q Engine oil - replace 1) 2) 3) OM
S Q Q Q Lube oil filter element - replace OM / SM
Q Q Q V-belt and tension - check OM / SM
Q Q Q Q Engine and cooling system for contamination - check / clean OM
Q Q Q Q Oil and fuel system for leaks - check OM / SM
Q Q Q Q Air intake and exhaust system for mounting and leaks - check OM / SM
Q Q Q All screws and nuts -
especially on oil pan and engine mount for tightness - check OM / SM
S Q Q Valve play - cold intake / exhaust - check / adjust 0,3 / 0,5 OM / SM
Q Q Q RPM - check / adjust 2680 SM
Toothed-belt and tension pulley - replace 4) OM / SM
Flame glow system - check (before begin of cold season) OM
Air filter insert - replace / annually if necessary OM
Fuel injectors - check / adjust - if necessary OM / SM
TRAVEL AND WORKING HYDRAULIC SYSTEM
Q Q Q Q Q Q Q Oil level in hydraulic tank - check OM
Q Q Q Return - suction filter insert - replace OM
Q Q Q Q Hydraulic system for function and leaks - check OM / SM
Q Q Q Q Hose assembly for scrapes - check OM
Q Q Q Hydraulic tank - condensation and contaminants - drain OM
(at least every 6 months)
Q Q Q Oil cooler for contamination and leaks - check / clean OM
Q Q Q All hydraulic pressure according to adjustment guidelines - check / adjust SM
Q Q Q Control spool - control mechanism - check / grease
Q Q Q Mounting and screw fittings for tightness - check OM / SM
Q Q Bleeder filter on hydraulic tank - replace OM / SM
Q Hydraulic oil in tank - change 1) 2) OM
Q Q Q lnching device - check / adjust OM / SM
Q Q Q Q Proper use of brake / inching pedal - explain / note OM
ELECTRICAL SYSTEM 12V
Q Q Q Q Q Q Q lndicator lights and lighting - check OM / SM
Q Q Battery - terminals and battery poles - check / clean OM
Q Q Batteries - electrolyte level - check OM
Q Q Q Function of complete system and components - check OM / SM
HEATER / VENTILATION
Q Q Q Q System for function and leaks - check OM / SM
Q Q Fresh air filter in cab - replace / if necessary OM
TRAVEL GEAR
Q Q Q Q Oil level - check OM / SM
Q Q Q Q Leaks - screw fittings for tightness - check OM / SM
Q Q Mounting - gear, oil motor and gear shaft - check SM
Q Q Q Q Q Q Lube points - drive shaft - check / grease OM
S Q Q Gear oil - change 1) 2) OM / SM
AXLES
Q Q Q Q Oil level and leaks - check OM / SM
Q Q Mounting of axles - check OM / SM
Q S S Q Q Q Mounting of wheel lugs - 330 Nm ( S also at 100 hrs.) - check 5) OM / SM
S Q Q Gear oil / Differential - front - change 1) 2) OM
S Q Q Gear oil / Differential - rear - change 1) 2) OM
S Q Q Gear oil / wheel hub - front / rear - change 1) 2) OM
Q Q Q Q Q Q Bearing and lube points of steering axles - check / grease OM / SM
STEERING
Q Q Q Q Q Q Function and for leaks on system - check SM
Q Q Mounting tightness of components and steering cylinder - check SM
INCHING / BRAKE SYSTEM
Q Q Q Q Q Q Q Service and parking brake for function and effectiveness - check OM / SM
Q Q Q Q System for leaks / fluid level in reservoir - check OM / SM
Q Q Q Brake pad play (wear check every 2000 hrs.) - check / adjust 0,3 mm OM / SM
Q Q Q Brake light switch for function - check SH
Q Q Overlap of inching / brake system - check / adjust 150 bar SH
MAIN FRAME - CAB
Q Q Q Q Q Q Bearing and lube points / oscillating axle - check / grease OM
Q Q Door, window and cover hinges - check / lubricate
Q Q Vehicle frame for cracks - check
LIFT ARMS - WORKING ATTACHMENT
Q Q Q Q Q Q Bearing and lube points - check / grease OM
Q Q Q Q Float position for function - check OM / SM
Q Q Q Lift arms and bucket stops - check OM / SM
Q Q Lift arms and bucket for cracks - check
Q Q Q Q Proper use of attachment - explain / note OM
GENERAL
Q Have the operator lubricate the machine according to the lubrication plan: OM
explain proper maintenance and correct operation.
Q Daily maintenance by the operator also includes visual inspection of the machine:
Check engine, hydraulic system, gear and axles for leaks.
1) Lube and service fluid quality / viscosity, see section 6
2) Quantities - see LUBRlCATlON CHART - in Operation and Maintenance Manual for corresponding
machine
3) The quantities given in the lubrication plan apply for oil change with filter change.
4) Replace toothed - belt with tension pulley every 5 years or every 4500 hrs!
5) Perform the intervals marked with S also after every wheel change:
08.99
Maintenance and
Inspection ScheduIe
L 506 / L 507
L 508 / L 509
2501 / 0101
2501 / 0101
7.15.01
08.99
Maintenance and
Inspection ScheduIe
L 506 / L 507
L 508 / L 509
2501 / 0101
2501 / 0101
7.15.02
05.97
Maintenance and
Inspection PIan
L 512 / L 522 101
7.16.01
DEUTZ DIESEL ENGINE
Q Q Q Q Q Q Q Oil level and oil pressure - check OM
Q Q Q Q Q Dust collector on air filter - clean / empty if necessary OM
Q Q Q Fuel strainer on fuel pump - clean / if necessary OM
S Q Q Fuel - filter element 1. stage - replace OM
S Q Q Q Engine oil - change 1) 2) 3) OM
S Q Q Q Lube oil filter element - replace OM / SM
Q Q Q V-belt and tension - check OM / SM
Q Q Q Q Engine and cooling system for contamination - check / clean OM
Q Q Q Q Oil and fuel system for leaks - check OM / SM
Q Q Q Q Air intake and exhaust system for mounting and leaks - check OM / SM
Q Q Q All screws and nuts -
especially on oil pan and engine mount for tightness - check OM / SM
Q Q Q Valve play - cold intake / exhaust - check / adjust 0,15 OM / SM
Q Q Q RPM - check / adjust 2450 SM
Q Fuel - filter element 2. stage - replace OM
Flame glow system - check (before start of cold season) OM
Air filter inserts - replace / if necessary - annually OM
Fuel injectors - check / adjust - if necessary OM / SM
Air filter hose - replace / at 4000 hrs.
or every 3 years
OM / SM
TRAVEL AND WORKING HYDRAULIC SYSTEM
Q Q Q Q Q Q Q Oil level in hydraulic tank - check OM
Q Q Q Return - suction filter insert - replace OM
Q Q Q Q Hydraulic system for function and leaks - check OM / SM
Q Q Q Q Hose assembly for scrapes - check OM
Q Q Q Hydraulic tank - condensation and contaminants - drain OM
(at least every 6 months)
Q Q Q Oil cooler for contamination and leaks - check / clean OM
Q Q Q All hydraulic pressures according to adjustment guidelines - check / adjust SM
Q Q Q Mounting and screw fittings for tightness - check OM / SM
Q Return strainer collector tube - clean / 1 x a year OM
Q Hydraulic oil in tank - change 1) 2) OM
Q Q Bleeder filter on hydr. tank - replace OM / SM
Q Q Q lnching device - check / adjust OM / SM
Q Q Q Q Proper use of brake / inching pedal - explain / note OM
ELECTRICAL SYSTEM 24 V
Q Q Q Q Q Q Q lndicator lights and lighting - check OM / SM
Q Q Batteries - electrolyte level, terminals and battery poles - check OM
Q Q Q Function of complete system and components - check OM / SM
HEATER / VENTILATION
Q Q Q Q System for function and leaks - check OM / SM
Q Q Fresh air filter in cab - replace / if necessary OM
TRAVEL GEAR
Q Q Q Q Oil level - check OM / SM
Q Q Q Q Leaks - screw fittings for tightness - check OM / SM
Q Q Mounting - gear, oil motors and gear shaft - check SM
Q Q Q Q Q Q Lube points - drive shaft - check / grease OM
Q Q Gear oil - change 1)2) OM / SM
AXLES
Q Q Q Q Oil level and leaks - check OM / SM
Q Q Mounting of axles - check OM / SM
Q S S Q Q Q Mounting of wheel lugs - 650 Nm ( S also at 100 hrs.) - check 4) OM / SM
Q Q Gear oil / Differential - front - change 1) 2) OM
Q Q Gear oil / Differential - rear - change 1) 2) OM
Q Q Gear oil / wheel hubs -front / rear- change 2 x 1) 2) OM
STEERING
Q Q Q Q Q Q Bearing and lube points of steering cylinder - check / grease OM / SM
Q Q Q Q Flow indicator for function - check OM / SM
Q Q Moutning tightness of components and steering cylinder - check SM
BRAKES
Q Q Q Q Q Q Q Service and parking brake for function and effectiveness - check OM / SM
Q Q Q Q Q Q System for leaks - check OM / SM
Q Q Brake disk play - check / adjust SM
Q Brake pad - wear check (replace at s 4.5 mm) SM
MAIN FRAME - CAB
Q Q Q Q Q Q Bearing and lube points / articulation linkage - check / grease OM
Q Q Q Q Q Q Bearing and lube points / oscillating axle - check / grease OM
Q Q Door, window and covering hinges / quick closures - check
Q Q Front and rear section for crack formation - check
LIFT ARMS - WORKING ATTACHMENT
Q Q Q Q Q Q Bearing and lube points - check /grease OM
Q Q Q Q Float position for function - check OM / SM
Q Q Q Q Hoist limit switch for function - check SM
Q Q Q Q

Automatic bucket return - check SM
Q Q Q Lift arms and bucket stops - check OM / SM
Q Q Lift arms and bucket for cracks - check
Q Q Q Q Proper use of attachment - explain / note OM
GENERAL
Q Have the operator lubricate the machine according to the lubrication plan: OM
Proper maintenance and correct operation.
Q Daily maintenance by the operator also includes visual inspection of the machine :
Check engine, hydraulic system, gear and axles for leaks.
1) Lube and service fluid quality / viscosity, see section 6
2) Quantities - see LUBRlCATlON CHART - in Operation and Maintenance Manual for corresponding
machine!
3) The quantities given in the lubrication plan apply for oil change with filter change.
4) Perform the intervals marked with S also after every wheel change.
11.93
SoIenoid
Engine shut off
101
8.20.01
Task
The solenoid replaces the cable to shut the Diesel
engine off.
When the keyed switch is turned on, the solenoid pulls
the shut off lever from Stop to normal operation (regu-
lator rod position at added starting quantity)
When the keyed switch is turned off, the solenoid is
released and turn the shut off lever to engine stop
(zero flow)
Test and adjustment
lf the solenoid is energized (key on position l), play X"
must be about 0.5 mm.
lt can be adjusted on Pos. 3
Current intake ( holding current) is about 0.5 A when
play X is adjusted correctly.
The energizing current (pick up current) is about 20 A,
the solenoid shifts automatically to holding current when
the magnetic anchor is fully energized
The solenoid is polarized, it only works if the + con-
nection is correct
the auxiliary connection is not used.
Sub Group lndex
05.97
TraveI HydrauIic
10.
10. 02. Operating pressures
10. 04. Travel drive L 504 ................................................................................................
10. 05. Travel drive L 506 / L 507 ......................................................................................
L 508 / L 509
10. 06. Travel drive L 512 / L 522 ......................................................................................
10. 29. Variable displacement pump A4VG ... DA L 504 .................................................
10. 30. Variable displacement pump A4VG ... DA L 512 / L 522 .......................................
10. 34. Performance diagram L 504 ................................................................................
10. 35. Performance diagram L 506 / L 507 ......................................................................
L 508 / L 509
10. 36. Performance diagram L 512 / L 522 ......................................................................
10. 47. Variable displacement motor A6VM ... HA 1U / HA 1R1 L 504 ...........................
L 506 / L 507
L 508 / L 509
10. 48. Variable displacement motor A6VM ... DA L 512 / L 522 ......................................
10. 49. Variable displacement motor A6VMN ... HD1 D L 512 / L 522 ..............................
10. 50. Hydraulic tank L 504 ............................................................................................
10. 55. Hydraulic tank L 506 / L 507 ..................................................................................
L 508 / L 509
10. 60. Hydraulic tank L 512 / L 522 ..................................................................................
10. 90. Towing procedure
10. 91. Variable Displacement Motors - Restrictor Overview
05.97
Operating Pressures
L 504 0101
10.02.04
1
Check / adjustment Adjustment
values
Test point
must remain constant during all tests 65
5
C see
reverse page
DieseI engine Speed
low idle RPM min
-1
900
30
high idle RPM min
-1
2680
50
(see note, reverse page)
at high idle bar 28
2
G
ReguIation begin - Var. dispIacement pump
Regulating valve 33
High pressure bar 50 MB
-1
1050
50
2
Pst
Pump performance at 380 bar
High pressure
Adjustment screw 17
-1
2100
100
2
Pst
High pressure reIief vaIve
(at full throttle)
25 forward bar 410
10
MB
Var. dispI. motor HA ReguIation begin
Adjustment screw A
+5
MB
Q min Q max bar 50
10
M1
= BIocked machine - 2. traveI range
to S/N 0519
MB = forward
2
NOTE:
Pressures above 215 bar can onIy be checked as
foIIows:
Apply the parking brakes to block the machine (press
switch -parking brake) and drive against some resi-
stance - the wheels may not spin.
or increase regulation begin of var. displ. motor (turn
out the screw A by about 3 turns and block the
machine with the parking brake.
3
4
from S/N 0520
5
Check / Adjustment Adjustment
values
Test point
20
MB
Slowly release brake pedal
at full throttle
Adjustment on threaded rod 1
Description:
Select travel range 2 and forward travel direction
Actuate inching / brake pedal all the way
Slowly release inching / brake pedal at full throttle
At 150
20
bar high pressure, the machine should start
to drive
The pedal height in resting position should be 180
+5
mm, measu-
red from the floor of the cab to the upper edge of the pedal.
Adjustment on screw 2.
6
The repIenishing pressure reIief vaIve 31 is permanently adju-
sted. The adjustment value can only be changed with shims. (0.5
mm shim = 2 bar increase in pressure)
7
Operating temperature:
The operating temperature can be checked as follows:
On connection R (Pos. R) with dip gauge and screw
coupling (Tool No. 5).
On suction line of replenishing pump (Pos. B) with
wire gauge. Mount the gauge with a hose clamp.
NOTE:
When checking temperatures "outside" on lines, the test
value is at least 5C lower than when checking it directly
in the hydraulic oil.
8
08.99
Operating Pressures
L 506 / L 507 2501 / 0101
10.02.07
1
values
Test point
5
C see reverse
page
DieseI engine speed
low idle RPM min
-1
850
50
high idle RPM min
-1
2700
50
Replenishing pressure valve 31
2
G
Regulating valve 33
-1
1050
50
2
Pst
Adjustment screw 17
-1
1850
100
2
Pst
(at full throttle)
25 forward bar 460
10
MB
Pressure cut off (at full throttle)
Cut off valve 27 bar 425
+5/-10
MB
RPM drop from high idle max. min
-1
50
2
Pst
Adjustment screw A
10
MB
Q min Q max bar 50
10
M1
to S/N 3095
= BIocked machine - 2. TraveI range
MB = forward
2
NOTE:
foIIows:
3
from S/N 3096
4
5
values
Test point
20
MB
at full throttle
Description:
At 150
20
to drive
+5
mm, measu-
6
7
The high pressure reIief vaIves 25/26 are permanently adjusted.
The adjustment value cannot be changed!
The adjustment screw on the valve is used for towing and is
adjusted as follows:
ln normal wheel loader operation (pos. A), the adjust-
ment screw of valve 25/26 is turned out to the stop
and is secured with the lock nut.
When towing the wheel loader (pos. B), the adjust-
ment screw of valves 25/26 is turned in until the
adjustment screw is flush with the lock nut.
After towing, return the valves to normal operating
position
8
On Return and suction filter (Pos. A) with dip gauge
and screw coupling (Tool No. 5).
On suction line of replenishing pump with wire gauge.
Mount the gauge with a hose clamp.
NOTE:
08.99
Operating Pressures
L 508 / L 509 2501 / 0101
10.02.09
1
values
Test point
5
C see reverse
page
DieseI engine speed
low idle RPM min
-1
900
50
high idle RPM min
-1
2700
50
2
G
Regulating valve 33
-1
1050
50
2
Pst
Adjustment screw 17
-1
1850
100
2
Pst
(at full throttle)
25 forward bar 460
10
MB
+5/-10
MB
-1
50
2
Pst
Adjustment screw A
10
MB
Q min Q max bar 50
10
M1
to S/N 3024
MB = forward
2
NOTE:
foIIows:
3
from S/N 3025
4
5
values
Test point
20
MB
at full throttle
Description:
At 150
20
to drive
+5
mm, measu-
6
7
The high pressure reIief vaIves 25/26 are permanently adjusted.
The adjustment value cannot be changed!
The adjustment screw on the valve is used for towing and is
adjusted as follows:
ln normal wheel loader operation (pos. A), the adjust-
ment screw of valves 25/26 is turned out to the stop
and is secured with the lock nut.
When towing the wheel loader (pos. B), the adjust-
ment screw of valve 25/26 is turned in until the adjust-
ment screw is flush with the lock nut.
position
8
NOTE:
05.97
Operating Pressures
L 512 101 - 151
10.02.12
1
Values
Test point
5
C Hydr.Tank
DieseI engine speed
low idle RPM min
-1
850
30
high idle RPM min
-1
2450
50
1
G
ReguIation begin -
Var. dispIacement pump
Regulating valve 33
High pressure bar 50 MB(MA)
-1
1050
50
2
Pst
Adjustment screw 17
-1
1850
50
2
Pst
(at full throttle)
25 forward bar 450
10
MB
26 reverse bar 450
10
MA
Pressure cut off
(at full throttle)
5
MB(MA)
-1
50
2
Pst
2
NOTE:
To check pressures in bIocked condition:
Drive the machine against a solid resistance and block
it with the parking brake (bypassing the travel lock).
Or (if no solid resistance is available):
Turn in the adjustment screw C on the pressure regu-
lator by 3 turns.
Release the ball joint from the inching valve and block
the machine with the service brake and the parking
brake (bypassing the travel lock).
Preselect the 2. travel range
3
4
5
values
Test point
ReguIation beginQ
max
Q
min
bar 0 M1
(Travel 1.Travel range )
Adjustment screw A
+1
Pst
+20
MB
HD1D
ReguI. begin HD1 Q
max
Q
min
bar 0 M2
(Travel 2. Travel range )
Adjustment screw B
1
Pst
Adjustment screw C
End of reguIation Q
min
Q
max
5
MB
Control chamber bar 50
20
M2
Adjustment screw E
(no change necessary)
Correct adjustment
Screw in adjustment screw to block
6
7
MB = forward
MA = reverse
8
NOTE:
05.97
Operating Pressures
L 512 152 - 263
10.02.12/1
1
values
Test point
5
C see reverse
page
DieseI engine speed
low idle RPM min
-1
850
30
high idle RPM min
-1
2450
50
2
G
ReguIation begin -
Regulating valve 33
-1
1050
50
2
Pst
Adjustment screw 17
-1
1850
50
2
Pst
(at full throttle)
25 forward bar 450
10
MB
26 reverse bar 450
10
MA
Pressure cut off
(at full throttle)
5
MB(MA)
-1
50
2
Pst
MB = forward
MA = reverse
2
NOTE:
Close off the hose line and connection on the inching
valve (Closure components Tool No. 35, 36).
Block the machine with the service brake.
3
4
5
values
Test point
ReguIation beginQ
max
Q
min
bar 0 M1
Adjustment screw A
+1
Pst
+20
MB
HD1D
ReguI. begin HD1 Q
max
Q
min
bar 0 M2
Adjustment screw B
1
Pst
Adjustment screw C
End of reguIation Q
min
Q
max
5
MB
20
M2
Adjustment screw E
Correct adjustment
6
7
8
NOTE:
05.97
Operating Pressures
L 512 264
10.02.12/2
1
values
Test point
5
C see reverse
page
DieseI engine speed
low idle RPM min
-1
850
30
high idle RPM min
-1
2450
50
2
G
ReguIation begin -
Regulating valve 33
High pressure bar 50 MA (MB)
-1
1050
50
2
Pst
Adjustment screw 17
-1
1850
50
2
Pst
(at full throttle)
26 forward bar 450
10
MA
25 reverse bar 450
10
MB
Pressure cut off
(at full throttle)
5
MA (MB)
-1
50
2
Pst
MA = forward
MB = reverse
2
NOTE:
3
4
5
values
Test point
ReguIation begin Q
max
Q
min
bar 0 M1
Adjustment screw A
+1
Pst
+1
Pst
+20
MA
ReguI. begin HD1 Q
max
Q
min
bar 0 M2
Adjustment screw B
1
Pst
Adjustment screw C
End of reguIation Q
min
Q
max
5
MA
20
M2
6
7
8
NOTE:
05.97
Operating Pressures
L 522 101 - 233
10.02.22
9
values
Test point
5
C see page
10.02.22/2
DieseI engine speed
low idle RPM min
-1
850
30
high idle RPM min
-1
2450
50
2
G
ReguIation begin -
Var. dispI. pump
Regulating valve 33
-1
1050
50
2
Pst
Adjustment screw 17
-1
1850
50
2
Pst
(at full throttle)
25 forward bar 450
10
MB
26 reverse bar 450
10
MA
5
MB(MA)
-1
50
2
Pst
10
NOTE:
To check pressure in bIocked condition:
with parking brake (bypassing travel lock).
Turn in the adjustment screw C on the pressure regu-
lator by 3 turns.
Release the ball joint from the inching valve and block
the machine with the service brake and the parking
brake (bypassing the travel lock).
Preselect the 3. Travel range
11
12
13
values
Test point
ReguIation begin Q
max
Q
min
bar 0 M1
Adjustment screw A
+1
Pst
+20
MB
HD1D
ReguIation begin HD1 Q
max
Q
min
bar 0 M2
Adjustment screw B
1
Pst
Adjustment screw C
End of reguIation Q
min
Q
max
5
MB
20
M2
(Travel 2. Travel range, at full throttle)
Adjustment screw D
2
M3
Speed km/h 18
2
Adjustment screw E
Correct adjustment
then turn out by 1/4 turn.
The maximum traveI speed in the 2. traveI range depends on:
Adjustment of pressure reducing valve 43
Adjustment of regulation begin on 2. var. displ. motor
( this adjustment 6
1
bar is also in direct relation to
the final speed, which can be reached in the 2nd
travel range)
14
15
MB = forward
MA = reverse
16
05.97
Operating Pressures
L 522 234-321
10.02.22/1
17
values
Test point
5
C see page
10.02.22/2
DieseI engine speed
low idle RPM min
-1
850
30
high idle RPM min
-1
2450
50
2
G
ReguIation begin -
Var. dispI. pump
Regulating valve 33
-1
1050
50
2
Pst
Adjustment screw 17
-1
1850
50
Steuerdruck bar 14
2
Pst
(at full throttle)
25 forward bar 450
10
MB
26 reverse bar 450
10
MA
5
MB(MA)
-1
50
2
Pst
MB = forward
MA = reverse
18
NOTE:
valve.
19
20
21
values
Test point
ReguIation begin Q
max
Q
min
bar 0 M1
Adjustment screw A
+1
Pst
+20
MB
HD1D
ReguIation begin HD1 Q
max
Q
min
bar 0 M2
Adjustment screw B
1
Pst
Adjustment screw C
End of reguIation Q
min
Q
max
5
MB
20
M2
Adjustment screw D
2
M3
Speed km/h 18
2
Adjustment screw E
Correct adjustment
The maximum traveI speed in the 2. traveI range depends on:
Adjustment of pressure reducing valve 43
Adjustment of regulation begin on 2. var. displ. motor
( this adjustment 6
1
bar is also in direct relation to
the final speed, which can be reached in the 2nd
travel range)
22
23
24
05.97
Operating Pressures
L 522 322 - 385
10.02.22/2
1
values
Test point
5
C see reverse
page
DieseI engine speed
low idle RPM min
-1
850
30
high idle RPM min
-1
2450
50
2
G
ReguIation begin -
Var. dispI. pump
Regulating valve 33
-1
1050
50
2
Pst
Adjustment screw 17
-1
1850
50
Steuerdruck bar 14
2
Pst
(at full throttle)
25 forward bar 450
10
MB
26 reverse bar 450
10
MA
5
MB(MA)
-1
50
2
Pst
MB = forward
MA = reverse
2
NOTE:
3
4
5
values
Test point
ReguIation begin Q
max
Q
min
bar 0 M1
Adjustment screw A
+1
Pst
+20
MB
HD1D
ReguI. begin HD1 Q
max
Q
min
bar 0 M2
Adjustment screw B
1
Pst
Adjustment screw C
End of reguIation Q
min
Q
max
5
MB
20
M2
Adjustment screw E
Correct adjustment
Screw in adjustment screw to the block,
6
7
8
NOTE:
05.97
Operating Pressures
L 522 386
10.02.22/3
1
values
Test point
5
C see reverse
page
DieseI engine speed
low idle RPM min
-1
850
30
high idle RPM min
-1
2450
50
2
G
ReguIation begin -
Var. dispI. pump
Regulating valve 33
-1
1050
50
2
Pst
Adjustment screw 17
-1
1850
50
Steuerdruck bar 14
2
Pst
(at full throttle)
26 forward bar 450
10
MA
25 reverse bar 450
10
MB
Pressure cut off
(at full throttle)
5
MA (MB)
-1
50
2
Pst
MA = forward
MB = reverse
2
NOTE:
3
4
5
values
Test point
ReguIation begin Q
max
Q
min
bar 0 M1
Adjustment screw A
+1
Pst
+1
Pst
+20
MA
ReguI. begin HD1 Q
max
Q
min
bar 0 M2
Adjustment screw B
1
Pst
Adjustment screw C
End of reguIation Q
min
Q
max
5
MA
20
M2
6
7
8
NOTE:
05.95
Components of the
TraveI Drive
L 504 0101
10.04.01
1 Front axle
2 Rear axle
3 Travel gear
4 Var. displ. motor A6VM 55 HA1U
5 Var. displ. pump A4VG 28 DA 3.1
6 Gear pump with priority flow divider
(Steering and working hydraulic)
7 Diesel engine F3L 1011
8 Drum brake
05.97
TraveI Drive
System Description
L 504 0101
10.04.02
StepIess hydrostatic traveI drive
VariabIe dispIacement motor with high pressure dependent (HA) reguIation and override
eIectric controI
Due to the large regulating range, the variable displa-
cement motor fulfills the requirement for high speed
and high torque.
ln case the swivel angle is reduced (in direction of Vg
min), the RPM increases and the possible torque de-
creases.
ln case the angle is increased (in direction Vg max), the
torque increases and the possible RPM decreases.
Vg max =
maximum output volume at maximum swivel angle
Vg min =
minimum output volume at minimum swivel angle
The output of the variable displacement pump depends on the Diesel engine RPM and the
operating pressure.
TraveI range I: Speed 0 - 5 km/hr.
AppIication:
- if limited maximum travel speed is desired,
- tractive force is available up to the maximum value.
Due to an electrical signal on the shift solenoid, the
high pressure dependent regulation is overridden and
the variable displacement motor moves to maximum
swivel angle. max. swivel angle
TraveI range II: Speed 0 - 20 km/h
AppIication:
- normal travel and loading operation
ln case of low pull force requirement, the variable
displacement motor is on minimum swivel angle, and
maximum speed can be reached.
ln travel range ll, the adjustment of the swivel angle
occurs automatically depending on the operating pres-
sure (HA regulation).
The regulating unit measures the operating pressure
internally and as soon as the adjusted nominal pressure
value of Vg min is reached on the regulator, the motor
moves to Vg max, which means the maximum tractive
force is available. regulates from minimum swivel
angle to maximum swivel angle
and reverse.
Parts Listing for Schematic 10.04.06
1 Hydraulic tank
2 Returnand suction filter, complete
3 Filter element 10 m
4 Bypass valve 2 bar
5 Pretension valve 0.5 bar
6 Bleeder filter
7 Drain valve
10 Diesel engine
12 Oil cooler
13 Thermo switch - oil cooler 70 / 65
14 Thermo switch - hydraulic oil 100/95
(suction connection)
16 Return - control valve block
17 Return run - Servostat
18 Check valve 3 bar
20 Pump component, complete
21 Hydraulic var. displacement pump
22 Travel direction valve
24 Control cylinder
25 High pressure limiting and
replenishing valve B
replenishing valve A
28 Restrictor 0.8 mm
(pump limiter)
30 Replenishing pump
31 Replenishing pressure relief valve
33 Regulating valve
34 Orifice 3,2 mm
36 Check valve, 2 bar
37 lnching valve
50 Hydraulic var. displ. motor
51 Axial piston motor
52 Control piston
53 Control piston
54 Shifting solenoid, travel range 1
55 Check valve
56 Restrictor, size 3
58 lntegrated flushing valve
80 Travel direction switch
Test connections
Var. dispI. pump:
MB Test connection for high pressure (for-
ward)
MA Test point for high pressure (reverse)
G Test connection for replenishing pres-
sure
Pst Test connection for control pressure
Var. dispI. motor:
M1 Test connection for regulating
pressure (Q-max)
05.97
TraveI HydrauIic System
L 504 0101 - 0519
10.04.06
1 Hydraulic tank
2 Return and suction filter, complete
6 Bleeder filter
7 Drain valve
10 Diesel engine
12 Oil cooler
14 Thermo switch - hydraulic oil 100/95
(suction connection)
21 Hydraulic var. displacement pump
24 Control cylinder
(pump limiter)
33 Regulating valve
34 Orifice 3,2 mm
37 lnching valve
52 Control piston
53 Control piston
55 Check valve
57 Orifice
59 Pressure limiting valve (flushing)
60 Control piston
61 Shifting solenoid / travel direction re-
cognition
Test connections
Var. dispI. pump:
ward)
G Test connection for replenishing
pressure
Var. dispI. motor:
pressure
05.97
TraveIIing hydrauIic
L 504 0520
10.04.07
03.95
TraveI drive
Components
L 506 / L 507
L 508 / L 509
2501 / 0101
2501 / 0101
10.05.01
1 Front axle
2 Rear axle
3 Travel gear
4 Var. displacement motor
A6VM 80 HA1U
5 Var . displacement pump
A4VG .. DA 3..
(Steering and working hydraulic)
7 Diesel engine BF 4L 1011T
8 Drum brake
05.97
TraveI Drive
System Description
L 507 / L 509
L 506 / L 508
0101
2501
10.05.02
StepIess hydrostatic traveI drive
VariabIe dispIacement motor with high pressure dependent (HA) reguIation and eIectric
override controI
Due to the large regulating range, the variable displa-
cement motor fulfills the requirement for high speed
and high torque.
ln case the angle is reduced (in direction of Vg min),
the RPM increases and the possible torque decrea-
ses.
ln case the swivel angle is increased (in direction Vg
max), the torque increases and the possible RPM de-
creases.
Vg max =
maximum output volume at maximum swivel angle
Vg min =
minimum output volume at minimum swivel angle
The output of the variable displacement pump depends on the Diesel engine RPM and the
operating pressure.
TraveI range I: Speed 0 - 6 km/hr.
AppIication:
- if limited maximum travel speed is desired,
- tractive force is available up to the maximum value.
Due to an electrical signal on the shift solenoid, the
high pressure dependent regulation is overridden and
the variable displacement motor moves to maximum
swivel angle. max. swivel angle
TraveI range II: Speed 0 - 20 km/hr.
AppIication:
- normal travel and loading operation
ln case of low pull force requirement, the variable
displacement motor is on minimum swivel angle, and
maximum speed can be reached.
ln travel range ll, the adjustment of the swivel angle
occurs automatically depending on the operating pres-
sure (HA regulation).
The regulating unit measures the operating pressure
internally and as soon as the adjusted nominal pressure
value of Vg min is reached on the regulator, the motor
moves to Vg max, which means the maximum tractive
force is available. regulates from minimum swivel
angle to maximum swivel angle
and reverse.
1 Hydraulic tank
2 Return and suction filter
(Combi filter) 10 m
3 Return filter 63 m
4 Collector tube
5 Pretension valve, 0.6 bar
6 Bleeder filter
7 Collection point / return lines
9 Drain valve
10 Diesel engine
12 Oil cooler
14 Thermo switch - hydraulic oil 100
15 Gear pump with
priority flow divider
18 Return - pilot control
19 Pilot control - working hydraulic
21 Hydraulic var. displ. pump
24 Control cylinder
27 Pressure cut off
(pump limiter)
33 Regulating valve
34 Orifice
36 Orifice 1,5 mm
37 lnching valve
52 Control piston
53 Control piston
54 Control valve - travel stage
55 Check valve
56 Restrictor valve
Test connections
Var. dispI. pump:
ward)
sure
Var. dispI. motor:
M1 Test connection for control pressure
(No control pressure:
Motor is at Q min)
05.95
FahrhydrauIik AnIage
HydrauIique de transIation
L 507
L 509
0101 - 0340
0101 - 0172
10.05.06
1 Hydraulic tank
(Combi filter) 10 m
3 Safety filter 40 m
4 Bypass valve 2.5 bar
6 Bleeder filter
9 Drain valve
10 Diesel engine
12 Oil cooler
14 Thermo switch - hydraulic oil 100
15 Gear pump with
17 Return - Servostat
24 Control cylinder
27 Pressure cut off
(pump limiter)
31 Replenihsing pressure relief valve
33 Regulating valve
34 Orifice
36 Orifice 1,5 mm
37 lnching valve
50 Hydraulic var, displ. motor
52 Control piston
53 Control piston
54 Control valve - travel stage
55 Check valve
56 Restrictor valve
Test connections
Var, dispI. pump:
MB Test connection for high pressure
(forward)
sure
Var. dispI. motor:
(No control pressure:
Motor is at Q min)
05.97
L 506 / L 507
L 508 / L 509
2501 - 3095
2501 - 3024
10.05.07
1 Hydraulic tank
(Combi filter) 10 m
6 Bleeder filter
9 Drain valve
10 Diesel engine
12 Oil cooler
14 Thermo switch - hydraulic oil 100 /
105
15 Gear pump with
17 Return - Servostat
24 Control cylinder
27 Pressure cut off
(swivel time)
31 Replenihsing pressure relief valve
33 Regulating valve
34 Orifice
36 Orifice 1,5 mm
37 lnching valve
50 Hydraulic var, displ. motor
52 Control piston
53 Control piston
54 Control valve - travel range 1
55 Check valve
57 Restrictor 1,4 mm L 506 / L 507
Restrictor 1,8 mm L 508 / L 509
59 Pressure limiting valve (flushing)
60 Control piston
61 Shifting solenoid / Travel direction re-
cognition
80 travel direction switch
Test connections
Var, dispI. pump:
ward)
pressure
Var. dispI. motor:
pressure
05.97
L 506 / L 507
L 508 / L 509
3096
3025
10.05.08
11.93
TraveI Drive
Components
L 512 / L 522 101
10.06.01
1 Front axle
2 Rear axle
3 Travel gear
4 Emergency steering pump
5 on the L 512 - Var. displ. motor
A6VMN 107 HD1 D
5 on the L 522 - Var. displ. motor
A6VMN 160 HD1 D
6 Var. displacement motor A6VM 107
DA
7 Diesel engine BF 4L 913
8 Var. displ. pump A4VG 90 DA 3.1
9 Gear pump / working - steering hy-
draulic
10 Gear pump / suction
11 Gear pump / brake system (depends
on machine model)
07.94
TraveI Drive
System Description
L 512 / L 522 101 / 322
10.06.02
1. StepIess hydrostatic traveI drive
The advanced hydrostatic travel drive with 2 variable displacement motors, with 2 selected maximum
speed ranges accelerates or decelerates the machine without shifting jerks.
Wear and maintenance efforts are reduced, because instead of the usual transmission, a simple spur
gear box is used.
VariabIe dispIacement motor 2
VariabIe dispIace-
ment motor 1
VariabIe dispIace-
ment motor 2
VariabIe
dispIacement motor
1
1. TraveI range : Travel speed 0 - 8 km/h
Var. displ. motor 2 is on max. angle
Var. displ. motor 1 regulates
At maximum tractive force demand :
Both variable displacement motors are on maxi-
mum swivel angle.
max. swivel angle regulates
Both variable displacement motors regulate over
the total range.
At highest speed:
Var. displ. motor 2 is on zero angle
Var. displ. motor 1 is on smallest angle
regulates regulates
mum swivel angle.
2. Description - TraveI Drive
2.1 Drive units:
Variable displacement pump: A4V 90 DA 3.1
Variable displacement motor 1: A6VM 107 DA
Variable displacement motor 2: A6VMN 107 HD1D (L 512) / A6VMN 160 HD1D (L 522)
2.2 Drive concept:
The variable displacement pump actuates the two variable displacement motors 1 and 2.
The travel range is selected via the travel range switch on the control lever, the electronic unit and a
2-way valve .
2.3 TraveI behavior:
TraveI 1. TraveI range :
The two way valve for the travel range is on position l (P-connection is closed).
- The variable displacement motor 1 regulates according to the engine RPM (DA Regulation )
- The variable displacement motor 2 is held on maximum angle,
TraveI 2. TraveI range:
The two way valve for the travel range is on position ll (P-A), and the RPM dependent control pressure
is also available for regulation on the variable displacement motor 2.
lf control pressure increases, variable displacement motor 2 regulates steplessly towards zero angle.
Variable displacement motor 2 is then driven along by variable displacement motor 1.
The flow from the pump now actuates only variable displacement motor 1.
lf the load momentum increases (increasing operating pressure), then the variable displacement motor 2
and 1 steplessly move towards maximum pangle, which means full tractive orce, even in the 2. travel
range.
NOTE:
Since the control of the travel range changes the variable displacement motor 2, it is possible to
change travel ranges while driving downhill at full speed.
The machine decelerates as much as possible without any shifting jerks.
05.97
Function Description
TraveI range
L 512 / L 522 101 / 322
10.06.03
Function description - TraveI range:
From the variable displacement pump A4VG, the RPM dependent control pressure is applied to the
variable displacement motor 50 on X1 or X2 connection (depending on direction of travel). This control
pressure is used to regulate the variable displacement motor 50 and is also applied via channels to the
X3 connection . From there, control pressure is directed via the directional valve 44 to the X-connection
on the variable displacement motor 60.
1. TraveI range:
The directional valve 44 remains in position l , and no control pressure is available to the variable
displacement motor 60. The variable displacement motor 60 remains on maximum angle.
The variable displacement motor 50 regulates, depending on control pressure and high pressure, over
the complete range. Maximum obtainable travel speed = 8 km/h.
2. TraveI range :
The directional valve 44 shifts to position ll , and the full control pressure (dependent on engine speed)
is available to the variable displacement motor 60. The variable displacement motor 60 operated
(steplessly), depending on control pressure and high pressure, between the maximum angle of 25 and
the minimum angle of 0.
The variable motor 50 regulates, depending on control pressure and high pressure, over the complete
swivel angle. Maximum obtainable travel speed = 32 km/h.
07.94
TraveI Drive
System Description
L 522 101 - 321
10.06.04
1. StepIess hydrostatic traveI drive
The advanced hydrostatic travel drive with 2 variable displacement motors, with 3 selected maximum
speed ranges accelerates or decelerates the machine without shifting jerks.
Wear and maintenance effort are reduced, because of the usual transmission, a simple spur gear box is
used.
VariabIe dispIacement motor 2
VariabIe dispIace-
ment motor 1
VariabIe dispIace-
ment motor 2
VariabIe
dispIacement motor
1
Variable displacement motor 2 is on maximum
angle
Variable displacement motor 1 regulates
mum swivel angle.
max. swivel angle regulates
Variable displacement motor 2 regulates bet-
ween 25 and 15 angle
Variable displacement motor 1 regulates
Both variable displacement motors are on
maximum swivel angle.
regulates regulates
3. TraveI range: Travel speed 0 - 32 km/h
Both variable displacement motors regulate over
the total range.
At highest speed:
Variable displacement motor 2 is on zero angle
Variable displacement motor 1 is on smallest
angle
regulates regulates
At maximum tractive force demand:
mum swivel angle.
2. Description - TraveI Drive
2.1 Drive units:
Variable displacement pump: A4V 90 DA 3.1
Variable displacement motor 1: A6VM 107 DA
Variable displacement motor 2: A6VMN 160 HD1D
2.2 Drive concept:
The variable displacement pump actuates the two variable displacement motors 1 and 2.
The travel range is selected via the travel range switch on the control lever, the electronic unit and a
3-way valve.
2.3 TraveI behavior:
The 3-way valve 44 for the travel range is on position l (P-connection is closed).
- The variable displacement motor 1 regulates according to the engine RPM (DA Regulation )
- The variable displacement motor 2 is held on maximum angle,
The 3-way valve is shifted to position ll (P-A)
- The variable displacement motor 1 regulates depending on engine speed (DA Regulation )
- The variable displacement motor 2 is returned by the control pressure of about 12 bar (Pressure
reducing valve 43) to an angle of 15.
- lf the load momentum increases (increasing operating pressure), then the variable displacement motor
1 and therefore also variable displacement motor 2 move to maximum angle, which means full tractive
force, even in the 2. travel range.
TraveI 3. TraveI range :
The 3-way valve is shifted to position lll (P-B)
- The RPM dependent control pressure is fully available also for regulation on variable displacement
motor 2.
- lf pressure increases (almost to maximum), the variable displacement motor 2 returns steplessly to
zero angle.
- Variable displacement motor 2 is driven along by variable displacement motor 1.
- The pump flow now actuates only variable displacement motor 1.
- As the load momentum increases (increasing operating pressure), the variable motor 1 and 2 (as in
the 2. travel range) moves to maximum angle, which means full tractive force also in the 3. travel
range.
NOTE:
Since the control of the travel range changes the variable displacement motor 2, it is possible to
change travel ranges while driving downhill at full speed.
The machines decelerates as much as possible without shifting jerks.
11.94
Function Description
TraveI Range
L 522 101 - 321
10.06.05
Function description - TraveI range:
From the variable displacement pump A4VG, the RPM dependent control pressure, is applied to the
variable displacement motor 50 on X1 or X2 connection (depending on direction of travel). This control
pressure is used to regulate the variable displacement motor 50 and is also directed via channels to the
X3-connection. From there control pressure is directed via the pressure reducing valve 43, directional
valve 44 and 2-way check valve 35 to the X-connection on the variable displacement
motor 60.
1. TraveI range:
The directional valve 44 remains in center position l , and no control pressure is available to the variable
displacement motor 60. The variable displacement motor 60 remains on maximum angle.
The variable displacement motor 50 regulate, depending on the control pressure and high pressure, over
the total output range. Maximum obtainable travel speed = 8 km/h.
2. TraveI range :
The directional valve 44 shifts to position ll , and reduced control pressure is available to the variable
displacement motor 60. This reduced control pressure can be adjusted on the pressure reducing valve
43, adjustment screw D. The variable displacement motor 60 moves (steplessly), depending on control
pressure and high pressure, between a max. swivel angle of 25 and a defined swivel angle of about
15.
the total output range. Maximum obtainable travel speed = approx. 18 km/h.
3. TraveI range :
The directional valve 44 shifts to position lll , and the full control pressure (depending on engine speed)
is available to the variable displacement motor 60. The variable displacement motor 60 moves (stepless-
ly), depending on control pressure and high pressure, between a maximum angle of 25 and a minimum
angle of 0.
the total swivel angle. Maximum obtainable travel speed = 32 km/h.
Parts Iisting for schematic 10.06.11
1 Hydraulic tank
(Combination filter) 10 m
3 Return strainer 63 m
4 Collector tube
5 Bypass valve 2,5 bar
6 Pretension valve 0,6 bar
7 Bleeder filter
8 Oil cooler
10 Diesel engine
11 Thermo switch / oil cooler 70 / 65
15 Gear pump
(Working and steering hydraulic)
20 Pump travel, complete 10.30 ...............
21 Hydraulic variable displacement pump
22 Directional control valve
24 Regulating cylinder
25 High pressure relief and
27 Pressure cut off valve
32 Gear pump - suction
33 Regulating valve
34 Orifice 7 mm
37 lnching valve
41 Orifice 1,5 mm
44 Control valve (Travel range)
48 to working hydraulic
49 from working hydraulic
50 Hydraulic variable displacement
motor 1, complete 10.48 ......................
52 Regulating piston
53 Control valve
54 Spool valve
55 Check valve
56 Time restrictor
57 Orifice 1,5 mm
motor 2, complete 10.49 ......................
63 Control valve (control pressure actua-
ted)
66 Time restrictor
67 Orifice 1,5 mm
68 Control valve (high pressure actuated)
Test connections
VariabIe dispIacement pump:
ward)
MA Test connection for High pressure
(reverse)
sure
VariabIe dispIacement motor 1:
M1 Test connection for regulating pressu-
re
pressure
11.94
HydraIique de transIation
L 512 101 - 119
10.06.11
1 Hydraulic tank
4 Collector tube
7 Bleeder filter
8 Oil cooler
10 Diesel engine
15 Gear pump
33 Regulating valve
34 Orifice 7 mm
37 lnching valve
41 Orifice 1,5 mm
44 Control valve (Travel range )
motor 1, complete 10.48 ......................
53 Control valve
54 Spool valve
55 Check valve
56 Time restrictor
57 Orifice 1,5 mm
58 Discharge valve
59 Pressure relief valve / 18 bar
motor 2, complete 10.49 ......................
ted)
66 Time restrictor
67 Orifice 1,5 mm
Test connections
ward)
MA Test connection for high pressure
(reverse)
sure
re
pressure
11.94
L 512 120 - 151
10.06.12
1 Hydraulic tank
4 Collector tube
7 Bleeder filter
8 Oil cooler
10 Diesel engine
15 Gear pump
(working and steering hydraulic)
replenishing pump B
33 Regulating valve
34 Orifice 7 mm
37 lnching valve (Pressure reducing val-
ve)
38 Bleeder valve
41 Orifice 1,5 mm
42 Orifice 1,5 mm
45 to Servo control - working hydraulic
46 Accumulator - servo control
47 Check valve
motor 1, complete 10.48 ......................
53 Control valve
54 Spool valve
55 Check valve
56 Time restrictor
57 Orifice 1,5 mm
58 Discharge valve
59 Pressure relief valve 18 bar
motor 2, complete 10.49 ......................
ted)
66 Time restrictor
67 Orifice 1,5 mm
100 from accumulator charge valve
110 Brake accumulator
115 Service brake valve
120 Rear axle
121 Front axle
Test connections
VariabIe dispIacement pump :
(forward)
MA Test connection for high pressure (re-
verse)
sure
pressure
re
03.95
L 512 152 - 263
10.06.13
1 Hydraulic tank
4 Collector tube
7 Bleeder filter
8 Oil cooler
10 Diesel engine
15 Gear pump
replenishing pump B
33 Regulating valve
34 Orifice 7 mm
ve)
38 Bleeder valve
41 Orifice 1,5 mm
42 Orifice 1,5 mm
47 Check valve
motor 1, complete 10.48 ......................
53 Control valve
54 Spool valve
55 Check valve
56 Time restrictor
57 Orifice 1,5 mm
58 Discharge valve
motor 2, complete 10.49 ......................
63 Control valve (control pressure
actuated)
66 Time restrictor
67 Orifice 1,5 mm
120 Rear axle
121 Front axle
Test connections
MA Test connection for high pressure (for-
ward)
MB Test connection for high pressure (re-
verse)
pressure
re
re
03.95
L 512 264
10.06.14
1 Hydraulic tank
4 Collector tube
7 Bleeder filter
8 Oil cooler
10 Diesel engine
15 Gear pump
33 Regulating valve
34 Orifice 7 mm
35 2-way check valve
37 lnching valve
41 Orifice 1,5 mm
43 Pressure reducing valve
motor 1, complete 10.48 ......................
53 Control valve
54 Spool valve
55 Check valve
56 Time restrictor
57 Orifice 1,5 mm
motor 2, complete 10.49 ......................
actuated)
66 Time restrictor
67 Orifice 1,5 mm
Test connections
ward)
verse)
pressure
re
re
ControI vaIve 44:
Travel range ll and lll
11.93
L 522 101 - 192
10.06.21
1 Hydraulic tank
4 Collector tube
7 Bleeder filter
8 Oil cooler
10 Diesel engine
15 Gear pump
33 Regulating valve
34 Orifice 7 mm
35 Two way check valve
37 lnching valve
41 Orifice 1,5 mm
motor 1, complete 10.48 ......................
53 Control valve
54 Spool valve
55 Check valve
56 Time restrictor
57 Orifice 1,5 mm
58 Discharge valve
motor 2, complete 10.49 ......................
actuated)
66 Time restrictor
67 Orifice 1,5 mm
Test connections
ward)
verse)
pressure
re
re
ControI vaIve 44:
11.93
L 522 193 - 233
10.06.22
1 Hydraulic tank
4 Collector tube
7 Bleeder filter
8 Oil cooler
10 Diesel engine
15 Gear pump
33 Regulating valve
34 Orifice 7 mm
35 Two way check valve
37 lnching valve (pressure reducing
valve)
38 Bleeder valve
41 Orifice 1,5 mm
42 Orifice 1,5 mm
47 Check valve
motor 1, complete 10.48 ......................
53 Control valve
54 Spool valve
55 Check valve
56 Time restrictor
57 Orifice 1,5 mm
58 Discharge valve
motor 2, complete 10.49 ......................
ted)
66 Time restrictor
67 Orifice 1,5 mm
120 Rear axle
121 Front axle
Test connections
VariabIe dispIacement pump
ward)
MA Test connection for high pressure
(reverse)
G Test connection of replenishing pres-
sure
re
pressure
ControI vaIve 44:
11.94
L 522 234 - 321
10.06.23
1 Hydraulic tank
4 Collector tube
7 Bleeder filter
8 Oil cooler
10 Diesel engine
15 Gear pump
replenishing pump B
33 Regulating valve
34 Orifice 7 mm
ve)
38 Bleeder valve
41 Orifice 1,5 mm
42 Orifice 1,5 mm
47 Check valve
motor 1, complete 10.48 ......................
53 Control valve
54 Spool valve
55 Check valve
56 Time restrictor
57 Orifice 1,5 mm
58 Discharge valve
motor 2, complete 10.49 ......................
ted)
66 Time restrictor
67 Orifice 1,5 mm
120 Rear axle
121 Front axle
Test connections
(forward)
verse)
sure
pressure
re
03.95
L 522 322 - 385
10.06.24
1 Hydraulic tank
4 Collector tube
7 Bleeder filter
8 Oil cooler
10 Diesel engine
15 Gear pump
replenishing pump B
33 Regulating valve
34 Orifice 7 mm
ve)
38 Bleeder valve
41 Orifice 1,5 mm
42 Orifice 1,5 mm
47 Check valve
motor 1, complete 10.48 ......................
53 Control valve
54 Spool valve
55 Check valve
56 Time restrictor
57 Orifice 1,5 mm
58 Discharge valve
motor 2, complete 10.49 ......................
actuated)
66 Time restrictor
67 Orifice 1,5 mm
120 Rear axle
121 Front axle
Test connections
MA Test connection for high pressure (for-
ward)
MB Test connection for high pressure (re-
verse)
pressure
re
re
03.95
L 522 386
10.06.25
11.93
Modification Kit
Discharge vaIve
L 512 / L 522 101-120/101-192
10.06.30
Modification Kit Discharge vaIve:
Description Pos. Id. No. Qty.
Discharge valve 1 7618 803 1
Fitting Ge 15 LM 2 7003 570 1
Allen screw M 12 x 70 10.9 3 4600 505 8
Fitting Kor 28 / 15L 4 7617 002 1
Fitting EL 28L 5 7407 120 1
Hose 6 7618 800 1
The complete modification kit is available with ld. No. 9517 252 .
05.97
VariabIe DispIacement Pump
A4VG 28 DA 3
10.29.01
TechnicaI Data Machine ModeI L 504
SeriaI number from 0101
Series 3
Design No. 244.13.02.21
DispIacement voIume max. cmt 28
FIow max. (at 2500 min-1) l/min 70
SwiveI angIe (both sides) max. 20
min. 0
Speed max. min
-1
2680
Output kW 26
RepIenishing pump dispIacement cmt 6,1
Inching vaIve , integrated no
RepIenishing pressure reIief vaIve fix adjusted
High pressure reIief and repIenishing vaIves adjustable
ReguIating vaIve - orifice mm 3,3
Restrictor (swiveI time) mm 0,8
05.97
A4VG 28 DA 3
L 504 0101
10.29.02
1. Description of variabIe dispIacement pump
The A4VG is a swashplate type pump for hydrostatic drives in a closed circuit. All necessary valves and
a replenishing pump are integrated.
The displacement volume is changed by an adjusting piston, which swivels the swashplate.
As the pump angle increases, the pump flow and the necessary driving torque increases.
lf the pump angle decreases, the flow and driving torque also decrease.
ln 0- position, the pump flow is also zero. As it passes 0, the flow changes flow direction smoothly. lf
no control signals are applied, the springs in the control cylinder keeps the swashplate at 0, or, if
there is a lack of control signals, it returns the swashplate safety to 0 position. This 0-position is
mechanically adjustable.
The maximum pump angle is 20 and is permanently set.
The pump is controlled by the engine speed, operating pressure and electrically via two solenoids.
The control energy is taken from the auxiliary circuit.(Speed related control pressure)
14 Thermo switch 100 / 95 C
17 Adjustment screw
24 Control cylinder
25 High pressure and replenishing valve
31 Replenishing valve
33 Regulating valve
1.1 DA-ReguIation (speed reIated hydrauIic controI)
The drive speed of the pump is transferred into control pressure by routing the speed dependent flow of
the replenishing pump 30 via a orifice 34. ln the regulating valve, control pressure is then formed from
the flow dependent pressure difference of the orifice. ( )
The travel direction valve 22 determines the direction of pump output by directing the control pressure
into one of the two control chambers of the adjusting cylinder 24 , while the opposite chamber remains
connected with the leak oil area.
The operating pressure, created by the load, acts upon the pistons of the drive gears and on the
swashplate. The result is a reaction force, which swivels the pump back towards zero flow.
The adjustment of the regulating valve 33 is set in such a way that the control pressure created at low
idle RPM does not go above the force of the control spring. The pump is therefore in 0-position, even
at low idle RPM. Only when the speed is increased, does the pump swivel out of zero, the drive is put
in motion. Continued increase of speed increases the control pressure until the pump swivels all the
way and puts out its full flow. The drive moves at maximum speed.
lncreasing travel resistance increases the operating pressure and therefore the necessary drive torque
of the pump. When the torque limit on the engine is reached, its speed drops and therefore also the
control pressure. The control pressure can no longer hold the swashplate against the force of the
piston (return force) and the pump is swiveld back. lt reduces its flow, the drive is getting slower.
This regulating procedure prevents that too much power is taken from the Diesel engine. The same
regulating procedure is also applied when the load on the engine is coming from another user.
05.97
A4VG 28 DA 3
L 504 0101
10.29.03
1.2 RepIenishing pump 30
lnternal gear pump, on an extension of the drive shaft. The drive is carried out directly via a coupling
sleeve via the drive shaft.
1.3 Pressure reIief vaIve 31 of the repIenishing pump
Fix adjusted, direct acting valve. Connected with the pressure connection of the replenishing pump
through internal channels. The draining oil is returned to the pump housing to cool the pump.
1.4 High pressure reIief and repIenishing vaIves 25, 26
Pilot controlled, adjustable valve, which is connected with the corresponding high pressure side, and is
reliefed to the opposite side. The replenishing function is obtained when the main piston lifts off against a
spring.
The high pressure relief and replenishing valves 25/26 secure the variable displacement pump and circuit
in both directions and equalize the leak oil losses in the circuit by adding replenishing oil from the suction
side of the pump.
25 High pressure valve
26 High pressure valve
31 Replenishing valve
33 Regulating valve
1 Drive shaft
2 Roller bearing
3 Swashplate
4 Glide shoe
5 Cup springs
6 Piston
7 Cylinder
8 Control plate
9 Connector housing
10 Shaft seal ring
11 End ring
12 Circlip
13 Retainer for bearing cage
14 Swashplate bearing
24 Control cylinder, complete
28 Restrictor (swivel time)
05.97
A4VG 28 DA 3
L 504 0101
10.29.04
23 Control piston
24 Adjusting cylinder, complete
28 Restrictor
35 O-ring
36 Bushing
37 Adjusting piston
38 Spring
39 Spring
40 Cover
41 Cup spring
42 Circlip
43 Adjustment screw / pump zero posi-
tion
44 Safety element
45 O-ring
46 Shim
05.97
VariabIe dispIacement pump
A4VG ... DA 3
10.30.01
TechnicaI Data Machine ModeI L 506 / L 507 L 508 / L 509
SeriaI number from 2501 / 0101 from 2501 / 0101
VariabIe dispIacement pump Type A4VG 40 DA A4VG 56 DA
Series 3 Series 3
Design No. 244.15.07.25 244.17.07.28
DispIacement voIume max. cmt 40 56
FIow max. (at 2500 min-1) l/min 98 138
SwiveI angIe (both sides) max. 20 20
min. 0 0
Speed max. min
-1
2700 2700
Output kW 36 / 40 42 / 45
RepIenishing pump dispIacement cmt 8,4 11,1
Inching vaIve , integrated no no
RepIenishing pressure reIief vaIve fix adjusted fix adjusted
High pressure reIief and repIenishing vaIves fix adjusted fix adjusted
ReguIating vaIve - orifice mm 4,8 5,5
Restrictor mm 0,7 0,8
SeriaI number 101-151/101-233 152 / 234
VariabIe dispIacement pump Type A4VG 90 DA A4VG 90 DA
Series 3.1 Series 3.1
Design No. 244.20.08.03 244.20.08.09
DispIacement voIume max. cmt 90 90
FIow max. (at 2300 min-1) l/min 204 204
SwiveI angIe (both sides) max. 20 20
min. 0 0
Speed max. min
-1
2450 2450
Output kW 64 / 69 64 / 69
RepIenishing pump dispIacement cmt/U 18,7 18,7
Inching vaIve, integrated no yes
RepIenishing pressure reIief vaIve adjustable adjustable
High pressure reIief and repIenishing vaIves adjustable adjustable
ReguIating vaIve - orifice mm 7,0 7,0
Restrictor mm 1,0 1,0
11.93
A4VG DA 3.1
10.30.02
1. Description of variabIe dispIacement pump
The A4VG is a swashplate type pump for hydrostatic drives in a closed circuit. All necessary valves and
a replenishing pump are integrated.
The displacement volume is changed by an adjusting piston, which swivels the swashplate.
As the pump angle increases, the pump flow and the necessary driving torque increases.
lf the pump angle decreases, the flow and driving torque also decrease.
ln 0- position, the pump flow is also zero. As it passes 0, the flow changes flow direction smoothly. lf
no control signals are applied, the springs in the control cylinder keeps the swashplate at 0, or, if
there is a lack of control signals, it returns the swashplate safety to 0 position. This 0-position is
mechanically adjustable.
The maximum pump angle is 20 and is permanently set.
The pump is controlled by the engine speed, operating pressure and electrically via two solenoids.
The control energy is taken from the auxiliary circuit.(Speed related control pressure)
17 Adjustment screw
24 Adjustment cylinder
27 Pressure shut off valve
33 Regulating valve
1.1 DA-ReguIation (speed reIated hydrauIic controI)
The drive speed of the pump is transferred into control pressure by routing the speed dependent flow of
the replenishing pump 30 via a orifice 34. ln the regulating valve, control pressure is then formed from
the flow dependent pressure difference of the orifice. ( )
The travel direction valve 22 determines the direction of pump output by directing the control pressure
into one of the two control chambers of the adjusting cylinder 24 , while the opposite chamber remains
connected with the leak oil area.
The operating pressure, created by the load, acts upon the pistons of the drive gears and on the
swashplate. The result is a reaction force, which swivels the pump back towards zero flow.
The adjustment of the regulating valve 33 is set in such a way that the control pressure created at low
idle RPM does not go above the force of the control spring. The pump is therefore in 0-position, even
at low idle RPM. Only when the speed is increased, does the pump swivel out of zero, the drive is put
in motion. Continued increase of speed increases the control pressure until the pump swivels all the
way and puts out its full flow. The drive moves at maximum speed.
lncreasing travel resistance increases the operating pressure and therefore the necessary drive torque
of the pump. When the torque limit on the engine is reached, its speed drops and therefore also the
control pressure. The control pressure can no longer hold the swashplate against the force of the
piston (return force) and the pump is swiveld back. lt reduces its flow, the drive is getting slower.
This regulating procedure prevents that too much power is taken from the Diesel engine. The same
regulating procedure is also applied when the load on the engine is coming from another user.
05.97
A4VG DA 3
10.30.03
1.2 RepIenishing pump 30
lnternal gear pump, on an extension of the drive shaft. The drive is carried out directly via a coupling
sleeve and via the drive shaft.
1.3 Pressure reIief vaIve 31 of the repIenishing pump
Adjustable, direct acting valve. ls connected with the pressure connection of the replenishing pump by
internal channels. The draining oil is led into the pump housing to cool the pump.
1.4 Pressure cut off vaIve 27
The pressure cut off, controlled by operating pressure, limits the operating pressure by taking back the
pump flow, so that the adjusted maximum pressure is just held, and the high pressure relief valves
25/26 do not actuate.
1.5 High pressure reIief and repIenishing vaIves 25, 26
Pilot controlled, adjustable valve, which is connected with the corresponding high pressure side and is
relieved to the opposite side. The replenishing function is obtained when the main piston lifts off against
a spring .
The high pressure relief and replenishing valves 25/26 secure the variable displacement pump and the
circuit in both directions and equalize the loss of oil in the circuit by adding replenishing oil from the
suction side of the pump.
NOTE:
High pressure relief valves in closed circuits also function as safety or shock valves. Make sure that
the adjustment value of the high pressure relief valves is at least 30 bar higher than the adjustment
value of the pressure cut off. A longer actuation time (for example, because the adjustment value is
too low) would lead to overheating in the closed circuit.
23 Control piston
35 O-ring
36 Bushing
38 Spring
42 Circlip
43 Adjustment screw / pump zero posi-
tion
B Control oil intake
R Tank connection / housing
05.97
A4VG DA 3
10.30.04
3 Connector housing
4 Control plate
5 Piston
6 Cylinder
7 Glide shoe
8 Swashplate
9 Roller bearing
10 Shaft seal ring
11 Drive shaft
12 End ring
13 Retainer ring
14 Swashplate bearing
15 Retainer for bearing cage
16 Cup spring
24 Adjusting cylinder
1 Travel direction valve, complete
2 Solenoid, reverse
3 Solenoid, forward
4 Control piston
5 Spring cup
6 Spring
10 Brake/lnching valve, complete
11 Bleeder valve
12 Brake piston
14 Guide rod
15 Valve piston
16 Adjustment spring
17 Spring cup
18 Adjustment spring
19 Spring cup
20 Adjustment screw
A Brake connection
B Control oil intake
R Tank connection / housing
C to control cylinder - forward
D to control cylinder - reverse
E Test surface
F Test surface
11.93
TraveI Direction VaIve with
Inching Device
L 512 / L 522 152 / 234
10.30.11
Function of traveI direction vaIve with brake inching vaIve:
The inching valve, hydraulically adjustable, is installed between the travel direction valve and the
control cylinder.
lf, for example, solenoid 2 is actuated, control oil (pressure) flows from the DA-regulating valve
(channel B) into channel D to the control piston and swivels the pump. Channel C is relieved to the
tank. Control oil (pressure) is also applied on test surface F of valve piston 15, against the force of
adjustment spring 16. The tank connection R is closed.
lf the brake pedal is now depressed, brake pressure builds up, in proportion to the pedal stroke, and
is applied onto channel A to the test surface E of brake piston 12, and acts itself against the
adjustment spring 18, which is adjusted to a certain value on adjustment screw 20.
lf the hydraulic force of the brake pressure now becomes higher than the adjusted spring force, the
position of brake piston 12 and the guide rod 14 against the adjustment spring 18 changes.
This causes a reduction of the set value of spring 16 by control pressure on the valve piston.
Hydraulic force on test surface F surpasses the spring force 16, the vale piston 15 opens to the tank
(channel R). Control oil (pressure) is lowered until the hydraulic force and the spring force are equal
again.
Due to the different (lower) control pressure in channel D, the pump returns to zero direction .
Adjustment of inching device:
The adjustment of adjustment spring 18 has been preadjusted by the manufacturer on screw 20. This
setting should not be changed.
The adjustment spring 18 is not pretensioned in resting position.
The adjustment screw 20 is screwed in until it touches spring cup 19 and then secured.
05.97
Performance Diagram /
TraveI HydrauIic
L 506 / L 507
L 508 / L 509
2501 / 101
2501 / 101
10.35.01
P
HD
High pressure
DieseI engine
RPM
P
ST
ControI pres-
sure
50 1050
50
6
2
380 1850
100
13
2
425 2700 17
2
05.95
Performance Curve /
TraveI HydrauIic
L 512 / L 522 101
10.36.01
P
HD
High pressure
DieseI engine
RPM
P
ST
ControI
pressure
50 1050
50
6
2
380 1850
100
14
2
05.97
VariabIe DispIacement Motor
A6VM ... HA1U
A6VM ... HA 1R1
10.47.01
TechnicaI Data Machine ModeI L 504 L 504
SeriaI number 0101 - 519 from 520
VariabIe dispIacement motor Type A6VM 55 HA1U A6VM 55 HA 1R1
Series 60 Series 63
Design No. 225.20.76.90 262.20.76.96
DispIacement max. 55 cmt 55 cmt
min. 13 cmt 13 cmt
SwiveI angIe max. 25 25
min. 5,7 5,7
Restrictor (swivel time) size 3 3
Speed (max.) min-1 5030 5030
Torque ( =380 bar) Nm 330 330
Mass (about) kg 26 26
Measurement X on Q-min adjustment screw mm 14,8 11,6
at a screw length of mm 50 60
TechnicaI Data ModeI / Sr. No. L 506 / 2501-2704 L 506 / 2705-3095
ModeI / Sr. No. L 507 / 0101-2704 L 507 / 2705-3095
VariabIe dispIacement motor Type A6VM 80 HA1U A6VM 80 HA1U
Series 60 Series 60
Design No. 225.22.46.90 225.22.46.90
min. 22 cmt 20 cmt
min. 6,7 6
Speed (max.) min-1 4220 4725
Torque ( =380 bar) Nm 485 485
Mass (ca.) kg 34 34
Measurement X on Q-min adjustment screw mm 20,2 19.1
TechnicaI Data Machine ModeI L 506 / L 507
SeriaI No. from 3096
VariabIe DispIacement motor Type A6VM 80 HA 1R1
Series 63
Bau - Nr. 262.22.46.96
DispIacement max. 80 cmt
min. 20 cmt
SwiveI angIe max. 25
min. 6
Restrictor (swivel time) size 3
Speed (max.) min-1 4725
Torque ( =380 bar) Nm 485
Mass (ca.) kg 34
Measurement X on Q-min adjustment screw mm 14
at a screw length of mm 70
TechnicaI Data ModeI / Sr. No. L 508 / 2501-3024 L 508 / from 3025
ModeI / Sr. No. L 509 / 0101-3024 L 509 / from 3025
VariabIe DispIacement motor Type A6VM 80 HA1U A6VM 80 HA 1R1
Series 60 Series 63
Design No. 225.20.46.90 262.22.46.96
min. 26,5 cmt 26,5 cmt
min. 8 8
Speed (max.) min-1 5040 5040
Torque ( =380 bar) Nm 485 485
Mass (ca.) kg 34 34
Measurement X on Q-min adjustment screw mm 17,7 10,2
05.97
A6VM... HA1U
10.47.02
1. VariabIe dispIacement motor with high pressure dependent reguIation, eIectricaI
override and integrated fIushing vaIve
1.1 VariabIe dispIacement motor:
with axial piston drive in bent axis design for hydrostatic drives in open and closed circuits.
The motor is suitable for use in mobile applications, such as axle drives.
The variable displacement motor is able to fulfill the requirements for high speed and high torque due
to its large regulating range.
lf the angle is reduced, the
speed increases and the
possible torque is decreased.
lf the angle is increased, the
torque
increases and the possible
speed
is decreased.
Vg max = maximum displacement
Vg min = minimum displacement
1.2 HA Automatic adjustment, high pressure dependent:
ln high pressure dependent, automatic adjustment, the displacement is set depending on the operating
pressure .
This unit measures the operating pressure internally
at A or B (no control line required) and, if the adjusted
pressure has been reached, it swivels from Vg min to Vg max .
HA 1
Version almost without increase in pressure from
regulation begin to end of regulation.
Pressure increase (Vg min to Vg max) = 10 bar
Regulation begin adjustable between 80 - 350 bar
A =Regulation begin - adjustment range
1.3 U EIectricaI override of nominaI pressure adjustment
ln HA1 version, the high pressure de-
pendent regulation can be overridden
by an electrical signal to an shifting
solenoid 54.
ln override, the variable displacement
motor moves to maximum swivel an-
gle.
Shifting solenoid 54 without current =
no override
Shifting solenoid actuated = Var. displ.
motor at Vg max
Shifting solenoid: DC current 12V,
30W
1.4 FIushing vaIve 58
The flushing valve, which is integrated into the control lens of the variable displacement motor is
utilized in the closed circuit to prevent increased temperatures.
The flushing valve is actuated by the high pressure side, whereby a defined quantity of oil is
removed from the corresponding low pressure side and directed to the tank. The pressurized fluid,
which is removed from the circuit, is replaced by the replenishing pump with cooled oil.
1. Operating condition of wheeI Ioader : Travel range 2
Machine drives at high
Diesel engine speed against
resistance or larger incline
High pressure increases due
to the load momentum above
the adjustment value of the
HA1 regulation
due to the high pressure
(operating pressure), the
control spool 53 is pushed
against the spring and high
pressure is acting on the large
surface of the piston.
The variable displacement
motor moves in direction
Vg max
1. Operating condition of
wheeI Ioader:
Travel range 1
the electric override
is activated (current is added)
the control spool 53 is pushed against the regulating spring by the shifting solenoid 54 and high
pressure actuates the large piston surface.
The variable motor moves in direction Vg max.
05.97
A6VM... HA1U
10.47.03
2. Operating condition of wheeI Ioader:
The machine is standing still or drives against a slight resistance (level route or slight incline)
High pressure is low (below the adjustment value of the HA1 regulation).
The variable displacement motor is at Vg min
VariabIe dispIacement motor A6VM... HA1U
1 Drive shaft
2 Shaft seal ring
3 Housing
4 Connection T
5 Cylinder
6 Adjustment screw (Q min.)
7 Cover
8 Piston
9 Control lens (with flushing valve)
10 End plate
11 Control pin
12 Spring
13 Adjustment bushing
14 Regulating spring
15 Valve bushing
16 Control piston
17 Shifting solenoid
18 Adjustment screw
19 Spring plates
20 Piston
21 Center pin
22 Connection T
23 Tapered roller bearing
25 Lock ring
26 Support ring
27 O-ring
28 Lock ring
29 End ring
31 O - ring
32 Check valve
33 O - ring
34 O - ring
35 O - ring
36 Control housing
11.94
Var. dispIacement motor
A6VM... HA1U
10.47.04
05.97
A6VM... HA 1R1
10.47.05
1. VariabIe dispIacement motor with high pressure dependent reguIation, eIectric
override, eIectric traveI direction vaIve and discharge vaIve
with axial piston drive in bent axis design for hydrostatic drives in open and closed circuit.
The motor is suitable for use in mobile applications, such as axle drives.
The variable displacement motor fulfills the requirement for high speed and high torque due to the
large regulating range.
lf the angle is reduced, the
speed increases and the
possible torque is decreased.
lf the angle is increased, the
torque
increases and the possible
speed
is decreased.
Vg max = maximum displacement
Vg min = minimum displacement
1.2 HA Automatic controI, high pressure dependent:
ln case of automatic control, high pressure dependent,
the adjustment of the intake volume occurs automatically,
depending on the operating pressure.
This control unit measures the operating pressure internally
at A or B (no control line is required) and, as soon as
the nominal pressure, which has been set on the regulator,
is reached, it moves from Vg min to Vg max .
HA 1
Version, almost without increase in pressure from
begin of regulation to end of regulation.
Pressure increase (Vg min to Vg max) = 10 bar
Regulation begin adjustable between 80 - 350 bar
A = Regulation begin - Adjustment range
1.3 U1 EIectric override of nominaI pressure adjustment
ln version HA1, the high pressure de-
pendent regulation can be overridden
by an electrical signal to an shifting
solenoid 54.
ln override, the variable displacement
motor moves to maximum swivel an-
gle.
Shifting solenoid 54 without current =
No override
Shifting solenoid actuated = Variable
displacement motor at Vg max
Shifting solenoid: DC current 12V,
26W
1.4 TraveI direction vaIve 60
With the electric travel direction valve it is assured that even in case of a change of high pressure
side (for example travel drive going down hill), the preselected pressure side of the variable
displacement motor regulates the swivel angle. This valve prevents a non-desired move of the
variable displacement motor to a larger displacement.
Depending on the travel direction, the travel direction valve 60 is actuated either by the spring or the
shifting solenoid 61.
Travel direction forward - channel B open / Channel A closed
Travel direction reverse - channel A open / Channel B closed (shifting solenoid not energized)
1.5 Discharge vaIve 58 and repIenishing vaIve 59
The discharge valve is utilized in the closed circuit to prevent increased temperatures. The valve is
installed on the variable displacement motor.
A predetermined (through the orifice) amount of oil, is taken from the corresponding low pressure
side and directed into the tank. The pressurized fluid taken from the circuit is replaced by the
replenishing pump with cooled oil.
The repIenishing vaIve 59 is used to secure the minimum replenishing pressure.
1.6 Operating condition of the wheeI Ioader: Travel range 1, travel direction forward (fig. 1)
The travel direction recognition valve 60 connects the channel B with the regulating unit.
The electric override (shifting solenoid) is actuated (current is added).
The control piston 53 is pushed by the shifting solenoid 54 against the regulating spring and high
pressure actuates the large control piston surface in the control cylinder 52.
The variable displacement motor moves in direction of maximum angle.
1.7 Operating condition of wheeI Ioader :Travel range 2, travel direction forward (fig. 1)
The travel direction recognition valve 60 connects the channel B to the regulating unit.
The electric override (shifting solenoid) is not actuated.
The machine drives at high Diesel engine RPM against a resistance or a steep hill.
High pressure increases due to the load momentum above the adjustment valve of the HA1
regulation.
The control piston 53 is pushed due to the high pressure (operating pressure) against the regulating
spring and high pressure actuates the large control piston surface in the control cylinder 52.
The variable displacement motor moves in direction of maximum angle.
05.97
A6VM... HA 1R1
10.47.06
Fig. 1
1.8 Operating condition of wheeI Ioader: (Fig. 2)
Machine drives in travel range 2, travel direction forward and downhill. The high pressure changes
from B to A (push operation). The travel direction recognition valve 60 closes off the channel A to
the regulating unit and therefore no high pressure dependent regulation (HA1) occurs, the variable
displacement motor remains on minimum angle.
Fig. 2
9 Pressure relief valve
10 Orifice
25 Valve piston
35 Discharge valve, complete
36 Valve piston
37 Check valve
38 O-ring
39 O-ring
40 Shifting solenoid - travel direction val-
ve
42 Spring
43 O-ring
44 Control housing
05.97
A6VM... HA 1R1
L 504 / L 506 / L 507 520 / 3096 / 3096
L 508 / L 509 3025 / 3025
10.47.07
1 Drive shaft
2 Connection U
3 Housing
4 Connection T
5 Cylinder
6 Adjustment screw (Q-min.)
7 Shim
8 Spring
9 Pressure valve
10 Orifice
11 O-ring
12 Socket head screw
13 Control piston seal
14 Threaded pin
15 Adjusting piston
16 Adjusting pin
17 Control lens
18 Spring
21 Control piston
22 Valve bushing
23 Adjustment screw (regulation begin)
24 Shifting solenoid - travel range 1
25 Valve piston
26 O-ring
27 Adjustment screw (Q-max)
28 Piston
29 Connection T
30 Center pin
33 Shaft seal ring
34 Circlip
05.97
A6VM ... DA
L 512 / L 522
10.48.01
TechnicaI Data ModeI Machine L 512 L 522
SeriaI number 101 - 274 101 - 401
VariabIe dispIacement motor Type A6VM 107 DA A6VM 107 DA
Series 60 Series 60
Design No. 225.25.10.69 225.25.10.69
min. 43 cmt 43 cmt
min. 9,8 9,8
Speed (max.) min-1 4485 4485
Torque ( =380 bar) Nm 645 645
Measurement X
on Q-min adjustment screw
mm 20 20
SeriaI number from 275 from 402
VariabIe dispIacement motor Type A6VM 107 DA A6VM 107 DA
Series 63 Series 63
Design No. 262.25.74.34 262.25.74.34
min. 43 cmt 43 cmt
min. 9,8 9,8
Speed (max.) min-1 4485 4485
Torque ( =380 bar) Nm 645 645
Measurement X
mm 12 12
07.94
A6VM DA
10.48.02
2. DA HydrauIic ControI , RPM dependent
with axial - tapered - piston rotary group in bend axis design for hydrostatic drives, in closed circuit.
Due to the large regulating range, (max. swivel angle 25, min. 5) the variable displacement motor
fulfills the requirement for high speed and high torque.
Reducing the angle gives
higher speed and lower tor-
que.
lncreasing the angle gives
higher t orque and l ower
speed.
2.2 DA HydrauIic ControI (RPM dependent)
The variable displacement motor A6VM with hydraulicregulation , RPM dependent, is used primarily
for hydrostatic travel drives, together with a variable displacement pump A4VG with DA - control.
ReguIation begin:
servo pressure dependent at Vg max (towards Vg min)
high pressure dependent at Vg min (towards Vg max)
(Vg =geometric displacement per rev. in cm
3
)
InitiaI position :
at Vg max (high torque)
The control pressure which is determined by the RPM of the variable displacement pump A4VG and
the operating pressure (high pressure) regulate the angle of the variable motor.
The control pressure is applied to connection X1 or X2 , depending on the direction of travel.
lncreasing engine speed, which means increasing control pressure and depending on existing opera-
ting pressure, causes a change to small angle (decreased torque, higher speed).
lf the operating pressure increases above the pressure value, which has been set on the regulator,
then the variable displacement motor changes to large angle (higher toque, lower speed).
2.3 Function of variabIe dispIacement motor:
The pressurized oil from the hydraulic pump is forwarded via pressure connection A or B on end plate 20
and kidney shaped slot in the control lens 10 to cylinder 7. Three cylinder bores are connected with the
pressure side of the oil motor, three bores with the return side and one bore is always at dead center,
i.e. at the point of reversing direction.
The axially moving tapered pistons in the cylinder are sealed by two piston rings each.
By actuating the three piston surfaces on the pressure side with oil, a resulting radial force is created on
the pistons 8, which creates a output torque on the radius of drive shaft 3.
ln idle and during starting procedure, the cylinder 7 is pushed onto control lens 10 by the cup springs on
the center pin 9. When pressure increases, the cylinder 7 is so well balanced by hydraulic forces, that an
oil film always remains between the control surface of cylinder 7 and the control lens 10, even at high
loads, and the leak oil is held to a minimum. The leak oil lubricates the center pin, pistons and the drive
shaft bearing.
Via two check valves 34 and internal bore holes in the end plate 20, pressurized oil is applied on the
corresponding high pressure side A or B on the ring surface of the control piston. The adjusting piston
23 is thereby held at large angle = large output torque.
Control pressure of the variable displacement pump actuates the variable displacement motor via
connections X1/X2. ln order to eliminate any influence onto the regulation in case the pressure direction
is reversed, but the output direction remains the same, for example when changing from driving to
braking, the control pressure of the corresponding drive side (travel direction) is routed via an integrated,
control pressure actuated spool 25 onto the measuring surface of the control piston 27.
The control pressure force acts via the control piston 27 onto the pretensioned spring 29. lf the control
pressure is increased (by increasing the Diesel engine RPMs) the control piston 27 moves against the
spring 29.
This releases the path for the high pressure oil to flow via the control edge of the control piston 27 and
an integrated oil channel to the large control piston surface. Due to the larger piston surface, the
adjusting piston 23 pushes the cylinder 7 via the pin 24 and control lens 10 in direction of the smaller
angle = larger output speed, i.e. the wheel loader drives faster. The minimum angle and therefore the
maximum speed is limited by adjustment screw 11.
The corresponding operating pressure (high pressure) acts against the control piston 27 at a certain ratio
( 3/100 bar) via a surface difference. Which means the control procedure is also influenced by the
operating pressure. lf pressure increases, according to the regulator adjustment, the oil motor swivels to
large angle.
The regulation begin of the oil motor is determined by the adjustment screw 31. Optimum performance
(drawbar pull or speed) can be obtained at any travel range.
2 Motor housing
3 Drive shaft
4 Drive shaft bearing
5 End ring
6 Shaft seal ring
7 Cylinder
8 Tapered piston, complete
9 Center pin with tension elements
10 Control lens
11 Adjustment screw
12 Circlip
13 O-ring
14 Seal
20 Connector plate, complete
21 Control housing
22 Cover
23 Adjusting piston, complete, with seal
24 Adjusting pin
25 Spool
26 Control bushing
27 Control piston
28 Pin
30 Spring bushing
31 Adjustment screw for regulation begin
32 Return spring
34 Check valves
35 Restrictor (Retarding throttle)
37 O-ring
38 O-ring
40 Connection U (with orifice 1,5 mm)
NOTE:
When changing the motor, make sure to reinstall the orifice 1,5 mm (ld. No. 9518 186) in the
U-connection Pos. 40 !
05.95
A6VM ... DA/60
L 512 / L 522 101-274 / 101-401
10.48.03
Parts Iisting for page 10.48.03/1
2 Motor housing
3 Drive shaft
4 Drive shaft bearing
5 Retainer ring
6 Shaft seal ring
7 Cylinder
8 Piston
9 Center pin with spring
10 Control lens
11 Adjustment screw (Q min)
12 Adjustment screw (Q max)
13 O-ring
14 O-ring
20 Cover plate, complete
21 Control housing
22 Cover
23 Control piston, complete with seal
24 Control pin
25 Control spool
26 Control bushing
27 Control piston
28 Spring pin
30 Spring bushing
31 Adjustment screw for regulation begin
32 Return spring
33 Valve insert with O-ring
34 Check valve
35 Restrictor valve
36 O-ring
37 O-ring
38 O-ring
39 O-ring
40 Connection U (with orifice 1.5 mm)
NOTE:
When replacing the motor, reinstall orifice Pos. 40 1.,5 mm (ld. No. 9518 186) in U - connection,
again!
05.95
A6VM ... DA4/63
L 512 / L 522 275 / 402
10.48.03/1
11.93
A6VM DA
10.48.04
Operating condition of iIIustrated schematic:
low control pressure, or operating pressure overcomes control pressure
the control piston 27 connects the large adjusting piston side to the tank
The variable displacement motor is on maximum angle (large displacement volume)
large torque, low output speed
05.95
A6VMN ... HD1D/60
A6VM ... HD1D/63
10.49.01
SeriaI number 101 - 274 101 - 401
VariabIe dispIacement motor Type A6VMN 107 HD1D A6VMN 160 HD1D
Series 60 Series 60
Design No. 225.25.00.08 225.28.00.09
DispIacement max. 107 cmt/U 160 cmt/U
min. 0 cmt/U 0 cmt/U
min. 0 0
Speed min-1 4485 (max.) 4020 (max.)
Torque ( =380 bar) Nm 645 844
Measurement X
mm 21,2 20
SeriaI number from 275 from 402
VariabIe dispIacement motor Type A6VM 107 HD1D A6VM 160 HD1D
Series 63 Series 63
Design No. 262.25.00.05 262.28.00.03
DispIacement max. 107 cmt/U 160 cmt/U
min. 0 cmt/U 0 cmt/U
min. 0 0
Speed min-1 4485 (max.) 4020 (max.)
Torque ( =380 bar) Nm 645 844
Measurement X
mm 21.2 20
11.93
A6VMN HD1D
10.49.02
1. HD - HydrauIic controI, controI pressure dependent (with pressure reguIation D)
with axial tapered piston rotary group in bent axis design for hydrostatic drives in closed circuits.
The motor is suitable for applications, where it must return to - 0 - (for example in axle drives).
Due to the large regulating range (max. swivel angle 25; min 0), the variable displacement motor is
able to fulfill the requirement for high speed and high torque.
The displacement volume
(swivel angle) can be chan-
ged steplessly from Vg max
= 25 to Vg min = 0.
(Vg =geometric displacement
per rev. in cm
3
)
Reducing the angle gives
higher speed and lower tor-
que.
lncreasing the angle gives
higher t orque and l ower
speed.
1.2 HD HydrauIic controI , controI pressure dependent:
makes it possible to adjust the displacement volume according to the control pressure signal. The
control is done proportionally to the control pressure on connection X.
Standard version :
Rbg. = Regulation begin at Vg max
(max. torque, min. speed)
End of regulation at Vg min
(min. torque, max. speed)
ReguIator adjustment:
HD 1
Control pressure increase (Vg max - Vg 0) = 10 bar
Rbg. = Regulation begin, adjustable from 2 to 20 bar
Ebr. = Adjustment range
The required regulating oil is taken from the high pressure
side via connection G1.
1.3 Pressure reguIation (D)
The pressure regulation overrides the
HD1 function.
lf operating pressure (on connection
G1) increases due to the load mo-
mentum (or due to reduction of the
motor angle), the motor start to swivel
to a larger angle as soon as the adju-
sted nominal value on the pressure
regulation has been reached.
The regulating deviation is averted by
and increase in the displacement vo-
lume and a resulting pressure reduc-
tion. The motor supplies a larger
torque, at the same operating pressu-
re, due to the increase in the displa-
cement volume (larger angle).
1. Operating condition of the wheeI Ioader :
The vehicle increases speed with high Diesel engine RPM
high control pressure, and operating pressure is less than 250 bar
Variable displacement motor swivels steplessly in direction of Vg min (towards 0 angle)
11.93
A6VMN HD1D
10.49.03
Vehicle drives at high Diesel engine RPM against a resistance
high control pressure, and operating pressure increases to 400 bar
Variable displacement motor swivels in direction Vg max (towards 25 angle)
Vehicle slows down from full speed (Diesel engine RPM drops)
Control pressure drops and low operating pressure
Variable displacement motor swivels in direction Vg max (towards 25 angle)
1 Drive shaft
2 Shaft seal ring
3 Housing
4 Connection T
5 Cylinder
6 Adjustment screw (Q max.)
7 Cover
8 Adjusting piston
9 Control lens
10 Cover plate
11 Adjusting pin
12 Spring
13 Spring cup
14 Spring
17 Adjustment screw (not in use)
18 Control piston
19 Adjustment screw (Regulation begin)
20 Adjustment screw (Q min.)
21 Control housing
22 Adjustment screw (pressure
regulation)
23 Cup springs
24 Piston
25 Center pin
26 Connection T ( housing suction )
29 Connection U (with orifice 1,5 mm)
30 Lock ring
31 Prop ring
32 O-ring
33 Lock ring
34 End ring
35 Seal
(path closed)
36 O - ring
38 O - Ring
39 Restrictor (Retarding throttle)
40 O - ring
11.93
A6VMN HD1D
10.49.05
NOTE:
When changing the motor, make sure to reinstall the orifice 1,5 mm (ld. No. 9518 186) in the
U-connection pos. 29 !
05.97
A6VMN HD1D
10.49.06
Check / adjustment - variabIe dispIacement motor A6VM ... HD1D
Adjustment values, see page 10.02 Operating pressures.
1. Adjustment - reguIation begin HD1:
(Q max Q min)
Connect a 40 bar pressure gauge, test connection Pst
and a 600 bar pressure gauge to variable displace-
ment motor, test connection M2.
Machine raised on supports, or travel on level ground
in highest travel range and in forward travel direction,
slowly increase the Diesel engine RPM.
When regulation begin is reached, a slight increase in
pressure is noticeable on the pressure gauge M2, and,
if the RPMs continue to increase, the variable displa-
cement motor moves to minimum angle.
lf the pressure values are not reached, then the regu-
lation begin can be set on the adjustment screw B .
Turn screw in = regulation begin lower
Turn screw out = regulation begin higher
Note:
Slowly increase the Diesel engine RPM! The regulation
begin will already occur when the pressure increases
slightly on test point M2.
2. Adjustment - pressure reguIation D:
(Q min Q max)
The adjustment of the pressure regulation D has a large
influence on acceleration, final speed and tractive force
of the machine. For that reason, the adjustment must be
exact.
Connect a 600 bar pressure gauge to variable displa-
cement pump, test connection MB or MA (forward)
and on variable displacement motor, test connection
M2.
Block the machine, select highest travel range and
forward travel direction.
lncrease the Diesel engine RPMs until the high pres-
sure on test point MB or MA is above 300 bar. Then
lower the RPMs slowly until the pressure on test con-
nection M2 reaches a value of 50
20
bar. The pressu-
re on test connection MB or MA should be 270
5
bar.
At these pressure values, the variable displacement
motor has reached the end of regulation and thereby
maximum angle.
lf the pressure value is not reached on test connection
MB or MA, then the end of regulation can be set on
adjustment screw C .
Turn screw in = to set end of regulation higher
Turn screw out = to set end of regulation lower
ResuIts of incorrect adjustment of pressure reguIation D:
a) If pressure reguIation D is set to Iow:
The variable displacement motor moves too soon to maximum angle.
The machine accelerates reluctantly.
Only a low final speed is reached.
The tractive force is o.k.
2. If the adjustment of pressure reguIation D is too high::
The variable displacement motor moves too late to maximum angle.
The maximum tractive force is reached too late or not at all.
The acceleration and final speed are o.k.
05.97
HydrauIic System
HydrauIic Tank
L 504 0101
10.50.01
Components:
1 Hydraulic tank
- capacity 29 liter
6 Oil strainer
7 Bleeder filter 10 m
Opening pressure:
- lntake 0.03 bar
- Outlet 0.35 bar
8 Oil filler port
9 Oil level sight gauge
10 Return / suction filter, complete
11 Filter housing with pressure retaining
valve
12 Filter housing
13 Plug
(Point for temperature measurement)
15 Oil drain valve
16 Pressure holding valve
A Return oil from control valve block / oil
cooler
B Suction connection - replenishing
pump
C Return oil - pressure holding valve
D Return oil - Bypass valve
1. SYSTEM DESCRIPTION:
A combination return and suction filter is used in the filter system of the hydraulic system.
1.1 Combined return and suction fiIter 10:
This filter is used as return filter and at the same time as suction filter for the replenishing pump of the
hydrostatic travel drive.
The oil returning from the working hydraulic and from the servostat is directed via connection A to the
return filter 10.
- Filtration occurs from 'outside to inside' in filter element 2.
The inside of filter 2 is connected to suction connection B of the replenishing pump.
- The filtered excessive oil is directed through the pressure holding valve 16 and return line C to the
tank.
1.2 Pressure hoIding vaIve 16:
Due to the valve, the suction side of the replenishing pump is pretensioned with 0.5 bar.
- lmproved suction behavior during cold start and thereby quicker pressure increase of control
pressure in regulating circuit of the hydrostatic drive.
MAINTENANCE
Description Pos. Maintenance
intervaI
Work to be carried out
Combination return and
suction filter
2 500 hrs. change
11.94
HydrauIic System
HydrauIic Tank
L 507
L 509
0101 - 0340
0101 - 0172
10.55.01
Components:
1 Hydraulic tank
- capacity 40 liter
2 Combination return and
suction filter 10 m(2 each)
4 Collector pipe
(Pretension pressure 0,6 bar)
(opening pressure:
lntake 0,03 bar; Outlet 0,35 bar)
8 Oil filter neck
10 Oil drain plug
(for drain hose)
ln the filter system of the hydraulic system, a combination return and suction filter is used.
1.1 Combination return and suction fiIter 2:
This filter serves as the return filter and at the same time as the suction filter for the replenishing
pump of the hydrostatic travel drive.
The returning oil from the working hydraulic system and from the Servostat is directed via connection
15 and 16 to the return filter 2.
- Filtration occurs from "outside to inside" in the filter.
The inside of the filter is connected with the suction connection 26 of the replenishing pump.
- The additional flow is filtered and then flows through the pressure holding valve 6 into the tank and
is available on suction connection 25.
- The pressure holding valve 6 is below the oil level.
The suction side of the replenishing pump is pretensioned with 0,6 bar.
- lmproved suction behavior during cold start and therefore quicker control pressure increase in the
hydrostatic regulating circuit.
Connection:
Return fIow from Suction to
connection
15 Working hydraulic SM 12 25 Working hydraulic pump
16 Servostat (Steering) 26 Travel pump (Replenishing
pump)
17 Var. displacement motor (Oil cooler)
18 Servo control - Working hydraulic
lnching valve
Travel pump T1
MAINTENANCE
IntervaI
Work to performed
suction filter
2 500 hrs. change
Return flow strainer 3 2000 hrs.
or once a year
clean / check for damage
05.97
HydrauIic System
HydrauIic Tank
L 506 / L 507
L 508 / L 509
2501
10.55.02
Components:
1 Hydraulic tank
- Capacity 40 liter
3 Safety strainer 40 m
(Pretension pressure, 0.5 bar )
Opening pressure:
lntake 0.03 bar
Outlet 0.35 bar
8 Oil filler port
11 Oil drain valve
12 Hose
13 Hose clamp
16 Filter housing (with magnetic rod)
17 Plug (point for temperature measure-
ment)
18 Magnetic rod
19 Filter housing
A Return oil from control valve block /
servostat
B Suction connection - replenishing
pump
C Return oil - bypass valve
D Return oil - pressure holding valve
A combination return and suction filter is used in the
filter system of the hydraulic system.
1.1 Combined return and suction fiIter 2:
This filter is used as return filter and at the same time
as suction filter for the replenishing pump of the hydro-
static travel drive.
The oil returning from the working hydraulic and from
the servostat is directed via connection A to the return
filter 15.
- Filtration occurs from 'inside to outside' in filter element 2.
The outside of the filter is connected to the suction
connection B of the replenishing pump.
- The filtered excessive oil is directed through the
pressure holding valve 6 into the tank.
Due to the valve, the suction side of the replenishing
pump is pretensioned with 0.5 bar.
- lmproved suction behavior during cold start and thereby quicker pressure increase of control
pressure in regulating circuit of the hydrostatic drive.
1.3 Bypass vaIve 4:
The installed bypass valve limuits the pressure in the return line system.
1.4 Return fIow strainer 9:
Return oils from the travel hydraulic pump and motor as well as the servo control of the working
hydraulic are filtered through the return flow strainer.
MAINTENANCE
intervaI
Work to be carried out
Combined return and
suction filter
2 500 h change
Return flow strainer 9 2000 h or
annually
Bleeder filter 7 1000 h change
07.94
HydrauIic System
HydrauIic Tank
L 512 / L 522 101-151/101-233
10.60.01
Components:
1 Hydraulic tank
- capacity 80 liter
4 Collector pipe with
return pipe
(split oil intake chambers)
5 Bypass valve
(opening pressure = 2.5 bar)
(Pretension pressure 0.6 bar)
( opening pressure :
lntake 0.03 bar; outlet 0.35 bar)
8 Oil filler neck
10 Oil drain plug
(for drain hose)
ln the filter system of the hydraulics, a combination return and suction filter is used.
The leak oil returning from the travel hydraulic pump, as well as the return oil from the working
hydraulic (via the oil cooler) is directed via connection 15 and 16 to the return filter 2.
The inside of the filter is connected with the suction connection 26 of the replenishing pump.
is available on suction connection 25 and 27.
- The pressure holding valve 6 is below the oil level .
The suction side of the replenishing pump is pretensioned with 0.6 bar.
hydrostatic regulating circuit .
1.3 FiIter bypass vaIve 5:
also serves as an overflow valve
- protects the return / suction filter element 2 against sudden pressure shocks in the return line.
1.4 CoIIector pipe 4:
with split chamber, return pipe and return flow strainer 3
Return oil to :
- Connection 17 (from suction pump / variable displacement motors)
- Connection 19 (from directional valve of travel range control)
- Connection 20 (from inching valve)
- Connection 21 (from variable displacement motor "T")
are routed via the return flow strainer 3 above the oil level into the tank
(any air is thereby released without causing the oil in the tank to foam up)
Return oil to :
- Connection 18 (from Servostat - Steering)
are routed via the return pipe and the return flow strainer 3 below the oil level into the tank .
Connection :
Return fIow from suction to
connection
15 Travel pump 25 Working pump
16 Working hydraulic (oil cooler) 26 Travel pump
17 Suction pump (variable (Replenishing pump)
displacement motors ) 27 Emergency steering pump
18 Servostat (Steering)
19 Directional valve (travel stages)
20 lnching valve
21 Var. displacement motors "T"
(function as aeration line)
MAINTENANCE
IntervaI
Work to be performed
suction filter
2 500 Hrs. change
Return flow strainer 3 2000 hrs.
or once a year
11.93
HydrauIic System
HydrauIic Tank
L 512 / L 522 152 / 234
10.60.02
Components:
1 Hydraulic tank
- capacity 80 liter
3 Return flow strainer 63 m
4 Collector pipe with
return pipe
(split oil intake chamber)
5 Bypass valve
(opening pressure 2.5 bar)
(Pretension pressure 0.6 bar)
(opening pressure:
lntake 0.03 bar; outlet 0.35 bar)
8 Oil filler neck
10 Oil drain plug
(for drain hose)
ln the filter system of the hydraulics, a combination return and suction filter is used.
The leak oil returning from the travel hydraulic pump, as well as the return oil from the working
hydraulic (via the oil cooler) is directed via connection 15 and 16 to the return filter 2.
The inside of the filter is connected with the suction connection 26 in the replenishing pump.
is available on suction connection 25, 27 and 28.
- Pressure holding valve 6 is below the oil level.
The suction side of the replenishing pump is pretensioned with 0.6 bar.
hydrostatic regulating circuit.
1.3 FiIter bypass vaIve 5:
also serves as an overflow valve
- protects the return / suction filter element 2 against sudden pressure shocks in the return line.
1.4 CoIIector pipe 4:
with split chamber, return pipe and return flow strainer 3
Return oil to:
- Connection 19 (from directional valve - travel stages and servo control)
- Connection 20 (from foot brake valve)
- Connection 21 (from variable displacement motor - aeration line)
- Connection 22 (from suction pump - variable displacement motors)
are routed via the return flow strainer 3 above the oil level into the tank
(any air is thereby released without causing the oil in the tank to foam up)
Return oil to :
- Connection 17 (from shut off valve - brake system)
- Connection 18 (from servostat - steering)
are routed via the return pipe and the return flow strainer 3 below the oil level into the tank .
Connections:
Return fIow from suction to
connection
15 Travel pump 25 Working pump
16 Working hydraulic ( oil cooler) 26 Travel pump
17 Shut off valve (brake system) (replenishing pump )
18 Servostat (Steering) 27 Emergency steering pump
19 Directional valve (travel stages)
Servo control
28 Gear pump (brake system)
20 Foot brake valve
21 Variable displacement motor "T"
(Functions as aeration line)
22 Suction pump (variable displacement
motors)
MAINTENANCE
IntervaIs
Work to be performed
suction filter
2 500 Hrs. change
Return flow strainer 3 2000 Hrs.
or once a year
05.97
Inching vaIve
L 504 / L 506 / L 507 0101 / 2501 / 0101
L 508 / L 509 2501 / 0101
10.80.01
Use:
- Hydrostatic brake function of the wheel loader
- Controlled travel or brake action, independent of engine speed
- Stepless regulation of speed or traction
Certain loading operations, such as loading material from a bank, require high performance from the
hydraulic system, but at the same time, low output (low speed and trction) from the travel hydraulic.
High performance of the working hydraulic (maximum speed = maximum output from the working pump)
can only be obtained through high engine speed. But high engine speed would also create high control
pressure, i.e. high output from the travel hydraulic.
To be able to regulate the control pressure and thus the travel power (speed or traction) at high engine
speed continuously from maximum to zero or reverse, a turn inching valve for full inching is installed in
the bypass line (pump regulator - hydraulic tank) of the control pressure circuit. The turn inching valve
acts as an adjustable restrictor valve.
Because the hydrostatic travel drive in the closed circuit also initiates a braking action when the pump is
at zero flow, the full inching valve can also be used to slow down and brake the wheel loader.
Function
The piston 3 is turned by lever 4 by about 65 via a
pedal with rod. During the turning movement, the restric-
tor (conical groove C in piston 3) opens and the cross
section (passage) from connection X to connection T
increases. This allows control oil to flow from the regula-
ting valve and also from the pump control cylinder via a
line (bypass line) back to the tank, which means the
control pressure of the regulator valve will be reduced
and the pump will shift to a smaller angle (less flow). lf
the inching pedal is fully depressed, the restrictor opens
fully and the pump moves to zero flow.
Adjustment: see section 17 Brake System
1 Valve, complete
2 Housing
3 Piston
4 Lever
5 Lock screw
6 Washer
7 Circlip
8 Stop pin (Valve closed)
9 Allan head screw
10 O-ring
11 O-ring
03.95
Towing Measures
Overview
10.90.01
1
High pressure reIief vaIves:
L 506 from S/N. 371/1242
L 506 from S/N. 426 2501
L 507 from S/N. 427 0101
L 508 from S/N. 428 2501
L 509 from S/N. 429 0101
The high pressure relief valves 25/26 are permanently
adjusted valves. The adjustment value cannot be chan-
ged!
The adjustment screw on the valve is for towing and has
the following adjustment:
2
ln normal wheel loader operation (fig. 1), the adjust-
ment screw for valves 25/26 is turned out to stop and
secured with the lock.
When towing the wheel loader(fig. 2), the adjustment
screw for valves 25/26 is turned in until the adjustment
screw is flush with the lock nut.
condition.
3
L 504 from S/N. 424 0101
L 506 up to S/N. 371/1241
L 508 from S/N. 372/501
The high pressure relief valves 25/26 are adjustable
valves.
When towing the wheel loader, turn the spring sleeve
SW 19 (arrow) out by 2 turns.
After towing, screw in the spring sleeve again ( 60 Nm
tightening torque)to return the high pressure relief val-
ve to its original adjustment value.
4
L 512 from S/N. 430/101
L 522 from S/N. 422/101
The high pressure relief valves 25/26 are adjustable
valves.
When towing the wheel loader, turn the spring sleeve
SW 19 (arrow) out by 2 turns.
After towing, screw in the spring sleeve again ( 30 Nm
tightening torque) to return the high pressure relief
valves to its original adjustment value.
08.99
VariabIe DispIacement Motors
SwiveI-Time Restrictor
Overview
10.91.01
Ma-
chine
S/N
from - to / from
Var. dispI. motor Serie Restrictor
size
Fig.
L 504 424 / 101 - 519 A6VM 55 HA1U
L 506 426 / 2501 - 3095
L 507 427 / 101 - 3095 A6VM 80 HA1U 60 3 A
L 508 428 / 2501 - 3024
L 509 429 / 101 - 3024
L 504 424 / 520 A6VM 55 HA1R1
L 506 426 / 3096
L 507 427 / 3096 A6VM 80 HA1R1 63 3 B
L 508 428 / 3025
L 509 429 / 3025
L 512 430 / 101 - 274 A6VM 107 DA 60 8 / 2 x 8 C
A6VM 107 HD1D 60 8 / 2 x 8 D
L 522 422 / 101 - 401 A6VM 107 DA 60 8 / 2 x 8 C
A6VM 160 HD1D 60 8 / 2 x 8 D
L 512 430 / 275 A6VM 107 DA 63 8 / 2 x 8 E
A6VM 107 HD1D 63 8 / 2 x 8 F
L 522 422 / 402 A6VM 107 DA 63 8 / 2 x 8 E
A6VM 160 HD1D 63 8 / 2 x 8 F
L 531 279 / 501 - 1372 A6VM 107 DA 60 3 G
L 541 289 / 501 - 1794
L 531 279 / 1373 - 1404 A6VM 107 DA 62 4 * G
L 541 289 / 1795 - 1872
L 531 279 / 1405 A6VM 107 DA 63 4 * H
L 541 289 / 1873
L 551 274 / 101 A6VM 250 DA 61 5 * G
Ma-
chine
S/N
from - to / from
Var. dispI. motor Serie Restrictor
size
Fig.
L 506 371 / 101 - 1473 A6VM 80 HA1T 60 3 A
L 508 232 / 101 - 240 A6VM 107 EZ 60 3 G
L 508 232 / 241 - 334 A6VM 107 HA1T 60 3 A
L 508 372 / 501 - 1097
L 510 340 / 101 - 282
L 511 212 / 101 - 217 A6VM 107 DA 60 3 G
L 521 211 / 101 - 545
Pos. Description Id. No.
Restrictor, size 3 7618 108
1 Restrictor, size 4 7618 155
Restrictor, size 5 7621 406
Restrictor, size 8 / 2 x 8 7621 729
2 lnner restrictor screw 7615 603
3 Outer restrictor screw 7615 604
Note:
The cross section of the restrictor as well as the restrictor screws can change. This can negatively
influence the regulating behavior of the variable displacement motor from Q
min.
to Q
max.
ln these cases, we recommend to replace the restrictor and restrictor screws. Possible installation
(replacement) of different, larger restrictors in case of insufficient regulating behavior - see chart
below.
Note:
* Different restrictors have been installed in series from the following machines:
Machine from S/N New restrictor RepIacement
possibIe
fromS/N
L 531 1569 Size 4 1373
L 541 2183 Size 4 1795
L 551 956 Size 5 101
Sub Group lndex
04.95
Working HydrauIic
11.
11. 02. Operating pressures
11. 04. Working hydraulic system L 504 ..........................................................................
11. 05. Working hydraulic system L 506 / L 507 ................................................................
L 508 / L 509
11. 06. Working hydraulic system L 512 / L 522 ................................................................
11. 28. Gear pump with priority flow divider L 504 ...........................................................
L 506 / L 507
L 508 / L 509
11. 30. Gear pump JSB G25 L 512 / L 522 .......................................................................
11. 50. Control valve block SM 18 - mechanical control L 512 / 101 - 151 .........................
L 522 / 101 - 233
11. 55. Control valve block SM 18 - hydraulic control L 512 / from 152 .............................
L 522 / from 234
11. 80. Servo control L 506 / L 507 ...................................................................................
L 508 / L 509
L 512 / from 152
L 522 / from 234
11. 84. Servo control valve 4 THF 6
11. 90. Cylinder
04.95
Working HydrauIic System
Operating Pressures
L 504 0101 - 0246
11.02.04
PRESSURE CHART / Working HydrauIic Adjustment
vaIues
Position
Pressure Iimitation (Primary)
Test connection 37 260
+5
bar Valve 60
Pressure Iimitation (Secondary)
Extend tilt cylinder (tilt out) 100
+5
bar Valve 64
Retract tilt cylinder (tilt in) 230
+5
bar Valve 65
Extend lift cylinder (lift) 275
+5
bar Valve 67
Important:
When adjusting the secondary pressure relief valves, the added functions and function "lift arms -
down" may not be actuated (this function is limited by primary pressure relief valve 60 ).
The adjustment should be done at approx. 1200 RPM and at operating temperature.
08.99
Operating Pressures
L 506 / L 507
L 508 / L 509
2501 / 0101
2501 / 0101
11.02.07
PRESSURE CHART / Working hydrauIic Adjustment
vaIues
Position
Pressure Iimitation (Primary relief) L 506 210
+5/-10
bar Valve 60
L 507 230
+5/-10
bar Valve 60
Test connection 37 L 508 190
+5/-10
bar Valve 60
L 509 210
+5/-10
bar Valve 60
Pressure Iimitation (Secondary relief)
Retract tilt cylinder (tilt in) P-kinematics 250
+5/-10
bar Valve 64
Extend tilt cylinder (tilt out) P-kinematics 150
+5/-10
bar Valve 65
Extend lift cylinder (lift) P-kinematics 250
+5/-10
bar Valve 66
Extend tilt cylinder (tilt in) Z-kinematics 280
+5/-10
bar Valve 64
Retract tilt cylinder (tilt out) Z-kinematics 280
+5/-10
bar Valve 65
Extend lift cylinder (lift) Z-kinematics 250
+5/-10
bar Valve 66
Added attachments 250
+5/-10
bar Valve 68
Added attachments 250
+5/-10
bar Valve 69
Servo pressure / repIenishing pressure A4VG
Test connection G 33
2
Valve 31
Important:
Function "Lift arms -down", when adjusting the
secondary pressure relief valves, may not be
actuated (this function is only limited by the
primary pressure relief valve 60 ).
approx. 1200 RPM and at operating temperature.
Important:
On the following machines, do not actuate
pressures above 255 bar:
L 506 / L 507 S/N 2501 - 3361
Valve adjustment, see reverse page!
Note:
From S/N 3622 the test connection 37 is situated on
the pressure hose near the working hydraulics pump.
Adjustment measures for Z- Kinematics for L 506 and L 507 machines, from S/N 2501 to S/N 3361
Step VaIve Movement Adjustment vaIue Adjustment
1 Turn in primary relief valve 60
by 1/2 turn
don't actuate - -
2 Turn out secondary pressure relief
valve 64 by 1/8 turn
tilt in 250
+5
bar Turn in
by 1/8turn
(=280 bar)
3 Turn out secondary pressure relief
tilt out 250
+5
bar Turn in
by 1/8 turn
(=280 bar)
4 Secondary pressure relief valve 66 Lift 250
+5
bar -
5 Second. press. relief valve 68, 69 Added functions 250
+5
bar -
6 Turn out primary pressure relief
Lift see front side -
Note:
For pump type 1 SX 250, installed in above machines, a pressure increase is only permissible to
255 bar .
Recognition of secondary vaIves:
Allan key 5 for pilot controlled valve (1/2 turn = 110 bar pressure change)
Allan key 6 for direct controlled valve (1/2 turn = 35 bar pressure change)
11.93
Operating Pressures
L 512 101 - 151
11.02.12
PRESSURE CHART / Working hydrauIic Adjustment
vaIues
Position
Pressure Iimitation (Primary relief)
Test connection 37 on control valve block 190
+5
bar Valve 60
Pressure Iimitation (Secondary relief )
Extend tilt cylinder (tilt out ) P- kinematics 150
+5
bar Valve 64
Retract tilt cylinder (tilt in ) P-kinematics 210
+5
bar Valve 65
Retract tilt cylinder (tilt out ) Z-bar kinematics 210
+5
bar Valve 64
Extend tilt cylinder (tilt in) Z-bar kinematics 210
+5
bar Valve 65
Retract lift cylinder (lift arms down) 210
+5
bar Valve 66
Extend lift cylinder (lift arms up) 210
+5
bar Valve 67
Pressure Iimitation
A3 and B3 connections for additional functions 190
+5
bar limited by
pressure relief
valve 60
Important:
Additional functions may not be actuated when adjusting the secondary pressure relief valves!
The adjustment must be done at high idIe RPM and at operating temperature!
11.93
Operating Pressures
L 512 152
11.02.12/1
vaIues
Position
Pressure Iimitation (Primary relief )
+5
bar Valve 60
Extend tilt cylinder (tilt out ) P-kinematics 150
+5
bar Valve 64
+5
bar Valve 65
Retract tilt cylinder (tilt out ) Z-bar kinematics 210
+5
bar Valve 64
Extend tilt cylinder (tilt in ) Z-bar kinematics 210
+5
bar Valve 65
Extend lift cylinder (lift arms up ) 210
+5
bar Valve 67
1
bar Valve 31
Important:
When adjusting the valves, do not run lift arms down function on block (this function is only limited
by primary pressure relief valve 60 )
11.93
Operating Pressures
L 522 101 - 233
11.02.22
PRESSURE CHART/ Working HydrauIic Adjustment
vaIues
Position
+5
bar Valve 60
Pressure Iimitation (Secondary)
Extend tilt cylinder (tilt out) P-kinematics 170
+5
bar Valve 64
+5
bar Valve 65
Retract tilt cylinder (tilt out) Z-bar kinematics 245
+5
bar Valve 64
Extend tilt cylinder (tilt in) Z-bar kinematics 245
+5
bar Valve 65
Retract lift cylinder (lift arms down) 245
+5
bar Valve 66
+5
bar Valve 67
Pressure Iimitation
A3 and B3 connections for additional functions 220
+5
bar limited by
pressure relief
valve 60
Important:
Additional functions may not be actuated when adjusting the secondary pressure relief valves!
11.93
Operating Pressures
L 522 234
11.02.22/1
vaIues
Position
+5
bar Valve 60
Extend tilt cylinder (tilt out) P- kinematics 170
+5
bar Valve 64
Retract tilt cylinder (tilt in) P- kinematics 245
+5
bar Valve 65
Retract tilt cylinder ( tilt out) Z-bar kinematics 245
+5
bar Valve 64
Extend tilt cylinder (tilt in ) Z-bar kinematics 245
+5
bar Valve 65
+5
bar Valve 67
1
bar Valve 31
Important:
When adjusting the valves for lift arm down function, do not run on block (this function is only limited
by primary pressure relief valve 60 ).
04.95
L 504 0101
11.04.05
1
1 Hydraulic tank
6 Bleeder filter
2
3
50 Control valve block SM 12
4
P- kinematics
80 Lift cylinder
81 Tilt cylinder
82 Cylinder for quick change system
Parts Listing for HydrauIic Schematic 11.04.06
1 Hydraulic tank
6 Bleeder filter
7 Drain valve
10 Diesel engine
15 Gear pump with
16 Flow divider valve (steering - priority
flow divider)
18 Orifice
19 Orifice
20 Orifice
21 Filter
30 Suction connection - Replenishing
pump
31 Return flow - inching valve
32 Return flow - var. displ. pump
33 Return flow - oil cooler
34 Return flow - Servostat
35 P and LS connection to Servostat
37 Test connection/ operating pressure
40 Control lever (Hydr. quick change sy-
stem or added attachment)
45 Control lever / lift - tilt cylinder
50 Control valve block SM 12 (three way)
52 Spool ( Hydr. quick change system or
added attachment)
53 Spool / tilt cylinder
54 Spool / lift cylinder
(with float position)
60 Primary pressure relief valve (pilot
controlled)
64 Secondary pressure relief valve and
suction valve A2 (pilot controlled)
65 Secondary pressure relief valve B2
(direct controlled)
67 Secondary pressure relief valve A1
(direct controlled)
80 Lift cylinder
81 Tilt cylinder
82 Cylinder for quick change adapter
83 Quick change adapter
04.95
Working hydrauIic system
L 504 0101
11.04.06
11.94
L 507
L 509
0101 - 0340
0101 - 0172
11.05.05
1 Hydraulic tank
50 Control valve block SM12 - 3 way
P- kinematics
80 Lift cylinder
81 Tilt cylinder
82 Cylinder for quick change coupler
83 Connection for additional attachment
85 Distributor block
86 Shut off valve
Z-bar kinematics
80 Lift cylinder
81 Tilt cylinder
Parts index for hydrauIic schematic 11.05.06
1 Hydraulic tank
(combination filter) 10 m
4 Collector tube
6 Bleeder filter
7 Collector point, return lines
9 Drain valve
10 Diesel engine
15 Gear pump with
flow divider)
18 Orifice
19 Orifice
20 Orifice
21 Filter
22 Return line - oil cooler
23 Return line - Servostat
24 Return line - inching valve
25 Return line - travel hydraulic pump
28 Temperature switch -
hydraulic oil 100
29 Travel hydraulic pump
32 Orifice 1,5 mm
33 Check valve / servo control
34 Accumulator
35 Two way directional valve
37 Test connection / working pressure
40 Pilot control valve (servo control)
41 Servo control unit / added attachment
50 Control valve block SM 12 (three
spools)
52 Spool / Hydr. quick change coupler or
added user
60 Primary pressure relief valve
64 Secondary pressure relief valve
80 Lift cylinder
81 Tilt cylinder
82 Cylinder for quick change device
83 Possible connection for additional in-
stallation
86 Shut off / Change over valve
P = Parallel - kinematics
Z = Z-bar kinematics
11.94
L 507
L 509
0101 - 0340
0101 - 0172
11.05.06
04.95
L 506 / L 507
L 508 / L 509
2501
11.05.07
1 Hydraulic tank
50 Control valve block SM12 - 3 way
P- Kinematics
80 Lift cylinder
81 Tilt cylinder
15 Gear pump with
83 Connections for added attachment
86 Shut off / change over valve
Z-bar Kinematics
80 Lift cylinder
81 Tilt cylinder
1 Hydraulic tank
(Combi filter) 10 m
6 Bleeder filter
9 Drain valve
10 Diesel engine
15 Gear pump with
flow divider)
17 Pressure limiting valve 180 bar
18 Orifice
19 Orifice
20 Orifice
21 Filter
25 Return flow - travel hydraulic pump
Hydraulic oil 100C
32 Orifice 1,5 mm
33 Check valve / pilot control
34 Accumulator
40 Pilot control valve
41 Pilot control valve / added attachment
52 Spool / Hydr. quick change adapter or
added user
80 Lift cylinder
81 Tilt cylinder
83 Connection for
added attachments
P = Parallel - Kinematics
Z = Z -bar Kinematics
05.97
Z - Kinematics
L 506 / L 507
L 508 / L 509
2501
11.05.08
1 Hydraulic tank
(Combi filter) 10 m
(Pretension pressure 0.5 bar
6 Bleeder filter
9 Drain valve
10 Diesel engine
15 Gear pump with
flow divider)
18 Orifice
19 Orifice
20 Orifice
21 Filter
25 Return flow - travel hydraulic pump
Hydraulic oil 100C
32 Orifice 1,5 mm
33 Check valve / pilot control
34 Accumulator
41 Pilot control valve / added attachment
52 Spool / Hydr. quick change adapter or
added user
80 Lift cylinder
81 Tilt cylinder
83 Connection for
added attachments
11.93
Z- bar Kinematics
P- Kinematics
L 512 / L 522 101
11.06.01
Z - bar Kinematics
P - Kinematics
Parts index for hydrauIic schematic 11.06.11
1 Hydraulic tank
2 Return and suction filter (combination
filter)
4 Collector pipe
7 Bleeder filter
8 Oil cooler
10 Diesel engine
11 Thermo switch for oil cooler 70/65
15 Gear pump
20 Valve block / steering system
22 Flow divider valve
23 Shifting valve
26 Flow indicator (steering function )
40 Control lever (for additional installa-
tions)
spools)
52 Spool
(for additional installation )
( Z-bar kinematics)
(with float position )
64 Secondary pressure relief and suction
valve A2
valve B2
valve B1
valve A1
80 Lift cylinder
81 Tilt cylinder
82 Cylinder for quick change device (ad-
ditional installation)
83 Possible connection for
additional installation
11.93
Z - bar Kinematics
L 512 / L 522 101-151/101-233
11.06.11
Parts Iisting for hydrauIic schematic 11.06.12
1 Hydraulic tank
filter)
4 Collector pipe
7 Bleeder filter
8 Oil cooler
10 Diesel engine
15 Gear pump
20 Valve block / Steering system
23 Shifting valve
26 Flow indicator (steering function)
32 Orifice 1,5 mm
34 Accumulator
35 Two-way valve
40 Pilot control
50 Control valve block SM 18 (2-spools)
valve A2
valve B2
valve B1
80 Lift cylinder
81 Tilt cylinder
11.93
Working HydrauIic System +
Z - bar Kinematics
L 512 / L 522 152 / 234
11.06.12
1 Hydraulic tank
filter)
4 Collector pipe
7 Bleeder filter
8 Oil cooler
10 Diesel engine
15 Gear pump
23 Shifting valve
26 Flow indicator ( steering function )
40 Control lever (for added installation )
spools)
52 Spool
(for added installation)
(with differential control)
valve A2
valve B2
valve B1
valve A1
80 Lift cylinder
81 Tilt cylinder
82 Cylinder for quick change device (ad-
ded installation)
83 Possible connection for
added installation
86 Shut off - change over valve
11.93
P - Kinematics
L 512 / L 522 101-151/101-233
11.06.21
1 Hydraulic tank
filter)
4 Collector pipe
7 Bleeder filter
8 Oil cooler
10 Diesel engine
15 Gear pump
23 Shifting valve
26 Flow indicator (steering function)
32 Orifice 1,5 mm
34 Accumulator
35 Two-way valve
40 Servo control
50 Control valve block SM 18 (2-spools)
valve A2
valve B2
valve B1
80 Lift cylinder
81 Tilt cylinder
11.93
P - Kinematics
L 512 / L 522 152 / 234
11.06.22
05.97
Gear Pump
with Priority FIow Divider
11.28.01
TechniaI Data Machine ModeI L 504 L 504
Type Ultra 1 PX 140 1 SX 170 C
Speed max. min
-1
2680 2680
Pump output kW 12 12
DispIacement voIume cmt 14 17
FIow, max. l/min 35 42,2
Operating pressure max. bar 260 210
TechniaI Data Machine ModeI L 507 L 509
SeriaI number 0101 - 0340 0101 - 0172
Type Ultra 1 PX 250 2 PX 330
Speed max. min
-1
2700 2700
Pump output kW 21,4 26
FIow, max. l/min 62,5 82,5
Operating pressure max. bar 230 210
Type Ultra 1 SX 250 2 SR 033
Speed max. min
-1
2700 2700
Pump output kW 21,4 26
FIow, max. l/min 62,5 82,5
Operating pressure max. bar 210 / 230 190 / 210
TechnicaI Data Machine ModeI L 506 / L 507
SeriaI number from 3362
Type Ultra 1 SX 260 C
Speed max. min
-1
2700
Pump output kW 22,2
DispIacement voIume cmt 26
FIow, max. l/min 65
Operating pressure max. bar 210 / 230
Connections:
P = Priority flow (Steering)
EF = Excess flow (working hydraulic)
LS = Load Sensing line
11.94
Gear pump
11.28.02
1 Steering unit
2 Load signal from steering unit to
pump
3 Control valve block for working hy-
draulic, open center position
Function
The gear pump utilizes the installed priority flow regulating valve to divide the pump flow into a priority
flow P and an excess flow EF . This division is made through the dynamic load sensing signal on
connection LS .
The priority flow is requested by actuating the steering. The priority flow is in proportion to the
actuated hydraulic steering function. The remaining flow is direct to the working hydraulic.
lf the steering is not actuated, the total pump output is available for the working hydraulic.
Function of dynamic Ioad signaIs LS:
lf the steering is not actuated, a small pilot flow flows through the load sensing line and through the
Servostat, it also keeps the steering warm and prevents temperature shocks.
When the steering is actuated, the dynamic load signal reports the requirement for the steering. The
oil flow flows from connection P (priority flow) to the steering unit
Due to the dynamic load signal, the steering is actuated quicker.
Priority fIow divider - Steering not actuated:
The gear pump supplies the required amount of oil, depending on the speed, via inlet channel P1 .
The system pressure acts via the orifice D onto the surface A of the piston . A small amount of oil
flows through the control orifice C , which is directed via the load sensing line LS and the Servostat to
the tank.
This creates a significantly lower pressure in the spring chamber B than on the piston surface A ,and
the piston is moved to the left.
Almost the total oil flow is available via connection EF to the working hydraulic.
11.94
Gear Pump
11.28.03
Priority fIow divider - steering actuated:
The gear pump supplies the required amount of oil, depending on the speed, via inlet channel P1 .
The system pressure acts via orifice D onto the surface A of the piston. When the steering is
actuated, pressure builds up through the load sensing line in the spring chamber B , which acts onto
the piston, together with the spring force, and moved the piston to the right.
Via connection P, the priority flow is directed to the steering, while the remaining flow is directed via
the EF connection to the working hydraulic.
InternaI pressure reIief vaIve:
The internal pressure relief valve limits the priority flow for the steering system to a preadjusted
pressure value.
When the pressure relief valve is actuated, the spring chamber B is relieved via the bore V to the
suction connection of the pump.
This moves the piston to the left (against the spring), and almost all of the hydraulic flow is available
for the working hydraulic, via EF.
The pressure limitation for the remaining flow EF is effected by the primary pressure relief valve in the
control valve block for the working hydraulic.
11.94
Gear pump PX
11.28.04
1 Screws
2 Lock ring
3 Valve housing
4 O-ring
5 Support ring
6 Bushing, seal
7 Bushing
8 Bushing
9 Housing
10 Gear
11 Drive shaft and gear
12 Flange
13 Seal ring
14 Lock ring
15 Plug
16 O-Ring
18 Spring
19 O-ring
20 Screw fitting with orifice
21 Spring
22 Valve poppet
23 O-ring
24 O-ring
26 Cover
3 Valve housing
15 Plug
16 O-ring
18 Spring
19 O-ring
21 Spring
22 Valve poppet
23 O-ring
24 O-ring
26 Cover
04.95
Gear pump SX
with priority fIow divider
11.28.05
1 Screw
2 Lock ring
3 Valve housing
4 O-ring
5 Prop ring
6 Bushing / seal
7 Bushing
8 Bushing
9 Housing
12 Flange
13 Seal ring
14 Lock ring
15 Plug
16 O-ring
18 Spring
19 O-ring
21 Spring
22 Valve poppet
23 O-ring
24 O-ring
25 Pressure limiting valve
26 Cover (Seal)
30 Gear
31 Pin
32 Drive shaft and gear
33 Gear
34 Shim
35 Gear
3 Valve housing
15 Plug
16 O-ring
18 Spring
19 O-ring
21 Spring
22 Valve poppet
23 O-ring
24 O-ring
25 Pressure limiting valve
26 Plug (Seal)
07.94
Gear Pump JSB G25
L 512 / L 522 101
11.30.01
TechnicaI data Machine ModeI L 512 L 522
SeriaI number 101 101
Gear pump Type G25-58-BF6F1 G25-58-BF6F1
Speed (engine speed) rpm 2450 2450
Pump output KW 41 48
DispIacement voIume cmt/rev. 58 58
FIow (at 2300 rpm) l/min 133 133
Operating pressure, max. bar 190 220
11.93
ControI VaIve BIock SM 18
MechanicaI ControI
L 512 / L 522 101-151/101-233
11.50.01
Description of function
1. The control valve blocks in the SM 18 series are assembled from various elements.
- Connector element
- Valve elements
- End element
a) Connector element contain the intake and return connection, and, depending on the type additional
connections for pressure gauge, pressure relief valve as well as for directional valve elements.
b) Valve elements are directional valves with different shifting modes, piston versions and control modes.
2. These directional valves are constructed according to the 6-way principle, and consist of a housing, control
piston, check valve, as well as control element, the return element, with or without catch (float position).
ln neutral position, the pump flow is routed through the system unpressurized to the tank. lf a control
piston is actuated, the connection from pump to user is opened via fine control grooves, while the
circulation is restricted via fine control grooves (negative overlap).
lf pump pressure rises above the user pressure, the fluid starts to flow via the check valve to the user.
As the control piston continues to shift, the pump flow is directed more and more from the circulation
channel to the user channel (fine control).
The piston stroke is divided into three phases:
30 % for overlap (tight in neutral position)
40 % fine control range (volume flow and pressure),
30 % for remaining stroke (complete opening) .
Due to the large fine control range of 40% , the user can be controlled sensitively and precisely.
Parts Iisting for page 10.50.02
1 Control valve block, complete
2 Housing (connector element)
4 O-ring
5 Housing (valve element)
6 Control piston - Up / down /
float position
7 O-ring
8 Scraper ring
9 Control element
10 Retainer plate
11 Allen head screw
12 O-ring
13 Spacer sleeve
14 O-ring
15 Spacer
16 Retainer plate
17 End cover
18 Catch element
19 Catch element
20 Ball
21 Spring
22 Spring cup
23 Spring
25 Housing (Valve element)
26 Control piston - tilt
30 Housing (Valve element)
31 Control piston - additional installation
35 Housing ( end element)
36 Plug
40 Check valve
41 Spring
42 Valve piston
43 O-ring
11.93
ControI VaIve BIock SM 18
MechanicaI ControI
L 512 / L 522 101-151/101-233
11.50.02
11.94
ControI vaIve bIock SM 18
HydrauIique ControI
L 512 / L 522 152 /234
11.55.02
11.93
Servo ControI
L 512 / L 522 152 / 234
11.80.01
30 Replenishing pump (Travel hydraulic)
33 Check valve
34 Accumulator
35 2 - way valve (Shut off valve)
36 Test connection (replenishing pressu-
re / servo pressure)
40 Servo control (with electro magnetic
lock for bucket return and mechanical
catch for float position )
11.94
PiIot ControI VaIve 4 THF 6
11.84.01
Characteristics
- Little force needed, resulting in good fine control
- Electro magnetic lock (can be cut in) with noticeable resistance point shortly before lever end position,
for automatic bucket return funktion.
- End position lock (mechanical notch) for float position.
The pilot control valve works on the basis of direct controlled pressure reducing valves. Every pressure
reducing valve consists of one regulating piston 2, a regulating spring 3, a return spring 4 and a
plunger 5.
lf it is not actuated, the lever is held in zero position by the return spring 4. The connections 1, 2, 3, 4
are connected via bore 8 with the tank connection T.
When the control lever is deflected, the plunger 5 pushes against the return spring 4 and the regulating
spring 3. The regulating spring 3 moves the regulating piston 2 first downward and closes the connection
between the corresponding connection and the tank connection T. At the same time, the corresponding
connection is connected with connection P via bore 8. The regulating phase begins as soon as the
regulating piston 2 finds its balance between the force of the regulating spring 3 and the force resulting
from the hydraulic pressure in the corresponding connection (connection 1, 2, 3 or 4).
Due to the cooperation between regulating piston 2 and regulating spring 3, the pressure in the
corresponding connections is in proportion with the stroke of plunger 5 and therefore with the position of
the control lever. This pressure regulation, depending o the position of the control lever and the
properties of the regulating spring makes the proportional hydraulic control of the directional valves.
1 Pilot control valve, complete
2 Regulating piston
3 Regualting spring
4 Return spring
5 Plunger
6 Housing
7 Spring
8 Bore
9 Rubber sleeve
10 Ring
11 Electro magnet
12 Spring plate
13 Balls
14 Universal joint
MechanicaI notch for fIoat position
The force of the spring plates 12 moves the balls 13 into the
grooves in the plunger, which creates a resistance point and
retains the lever in maximum deflection. The lever is released
through opposing action.
EIectro magnetic Iock for the automatic bucket return
An additional spring 7, under the plunger 5, gives a warning -
through reinforced resistance - that the stroke of plunger 5 is
almost at its end.
After overcoming this point, the ring 10 contacts the magnetic
anchor 11. lf the magnet is energized, then the control lever is
held in its end position by the magnetic force.
The lever is released automatically by turning the magnetic cur-
rent off via the proximity switch or by counteraction of the control
lever .
Sub Group lndex
05.95
EIectricaI System
12.
12. 01. General Guidelines
12. 04. Electrical System L 504 .......................................................................................
12. 05. Electrical System and Electronic Control L 506 / L 507 .........................................
L 508 / L 509
12. 10. Electrical System and Electronic Control L 512 / 101-151 .....................................
L 522 / 101-233
12. 11. Electrical System and Electronic Control L 512 / ab 152 .......................................
L 522 / ab 234
11.93
GeneraI GuideIines
12.01.01
1. GENERAL GUIDELINES FOR THE OPERATION OF THE WHEEL LOADER AND FOR
WORK ON THE ELECTRICAL SYSTEM
1.1 The electrical system must always remain in excellent condition. Burnt out fuses and bulbs must be
replaced immediately.
ln case of a burnt out fuse, always find and remedy the cause. Never repair a fuse! For that reason, make
sure that you always keep spare fuses handy.
A battery master switch is installed in the electrical system. ln case of damage of the electrical lines
between the battery, starter switch and starter, this switch prevents additional damage to the components,
and, if the handle is removed, it also serves as a theft deterrent.
The battery master switch may only be operated if the engine is not running, since voltage peaks could
destroy electronic components, if the battery is not connected..
1.2 AIways wear protective gIoves and safety gIasses when working on the battery.
Do not smoke and make sure there are no sparks or open fIames within the vicinity - battery fumes
are highIy fIammabIe and expIosive!
For the proper function of the battery, it is of utmost importance, that it is always kept clean. Clean
battery terminals and connections regularly and apply a thin coat of grease to prevent corrosion.
Check the electrolyte level of the batteries regularly. Fill the battery cells to the proper level = 10 - 15
mm ( 1/2 ") above the plates with distilled or salt free water (according to VDE 0510), never use regular
tap water. Proper care is essential for a long life expectancy of the battery, follow all guidelines, always
maintain the proper charge, and protect the battery from extreme temperatures and mechanical damage.
Constant overcharging as well as storing the battery in a discharged condition will reduce service life.
Discharged batteries may be charged with a battery charger.
1.3 Before performing any work on the electrical system, including any welding, make sure to disconnect the
negative connection via the battery master switch.
05.95
EIectricaI System
L 504 0101
12.04.00
05.97
Location of Components
L 504 0101
12.04.01
1
G2 Battery (in left entry box)
1 x 12 V 88 Ah
F Main fuses: (in battery box)
50 A Main fuse
25 A Added user (special equipment)
2
Fuses: (F1 - F14)
F1 30 A Oil cooler motor
F2 10 A Relay Preglow 40 sec., instruments, indica-
tor lights, solenoid slow travel
F3 10 A Brake lights, horn, blinker,
F4 10 A Emergency blinker system
F5 15 A Working floodlight
F6 15 A lnterior light, beacon, plug cigarette lighter
F7 15 A Windshield wiper
F8 15 A Solenoid engine stop, heater fan, travel
direction solenoids
F9 7,5 A Relay preglow / K2a, Relay oil cooler motor
/ K6
F10 7,5 A Tail light - right, parking light - left
F11 7,5 A Tail light - left, parking light - right
F12 7,5 A Low beam, left
F13 7,5 A Low beam, right
F14 15 A Headlight
3
4
ReIay:
K1 Blinker
K2 Preglow time, 40 sec.
K2a Preglow
K3 Starting lock
K4 * Travel direction recognition
K6 Oil cooler motor
V1 Central unit, diodes
(Diodes D4, D5, D6, D9, D10, D14)
* from S/N 0520
5
G1 Alternator 14V / 60A
6
M1 Starter motor
7
Y5 Solenoid - engine stop
8
B1 lndicator - engine oil temperature
B2 Thermo switch / engine overheat 130C
B7 Pressure switch / engine oil pressure
(B1 and B2 on engine block, near alterna-
tor, from Engine F3L 1011 F )
05.97
L 504 0101
12.04.02
9
R3 Glow plug
10
B4 Sensor, air filter contamination
11
B17 Thermo switch - oil cooler 70C / 65C
M6 Oil cooler motor
12
B6 Thermo switch - hydraulic oil
overheat 100C
Y2 Solenoid - travel direction forward
Y3 Solenoid - travel direction reverse
13
B5 Switch parking brake / travel lock
Function when parking brake is actuated:
lndicator light H11
Neutral position of travel direction
14
B12 Switch - brake light
15
S2 Switch - travel direction / neutral
F = Forward
N = Neutral
R = Reverse
Starter lock is actuated if switch S2 is not in
position N .
16
Y4 Solenoid travel direction recognition
valid from S/N 0520
is actuated when traveling in reverse
Current intake approx. 2.5 A
Y6 Solenoid travel range - slow travel
is actuated in travel range "sIow traveI"
via switch S5
05.95
L 504 0101
12.04.10
A3 Radio installation *
B5 Switch parking brake / travel lock /
starting lock
F1-14 Fuse base
K1-K6 Relay base
M5 Heater blower motor
M7 Compressor - operators seat *
S2 Switch - travel direction / neutral
V1 Central unit diodes
X41 Plug / cigarette lighter
H2 lndicator light - preglow "ON"
H3 lndicator light - forward travel
H4 lndicator light - engine oil pressure
H5 lndicator light -engine overheat
H6 lndicator light -battery charge
indicator
H7 lndicator light - air filter contamination
H9 lndicator light - reverse travel
H10 lndicator light - blinker
H11 lndicator light - parking brake "ON"
H12 lndicator light - headlight
H23 lndicator light - hydraulic oil overheat
P1 Hourmeter
P3 Fuel gauge
P5 Engine oil temperature gauge
S1 Keyed switch
S3 Steering column combination switch
S4 Switch - emergency blinker
S5 Switch - slow travel
S7 Switch - working floodlight
S11 Switch - heater blower
S12 Switch - wiper motor, front
S13 Switch - wiper motor, rear
* for added equipment
05.97
Item Listing
FunctionaI Schematic
L 504 0101
12.04.11
Pos. Description Step
A3 Radio * 18 .........................................................................................................................................................................................................
B1 lndicator - engine oil temperature 4 ........................................................................................................................................
B2 Thermo switch engine overheat 130 C 5 ........................................................................................................................
B4 Sensor - air filter contamination 5 .............................................................................................................................................
B5 Switch - parking brake / travel lock 7 .....................................................................................................................................
B6 Thermo switch - hydraulic oil overheat 100 C 5 .......................................................................................................
B7 Switch - engine oil pressure 5 ......................................................................................................................................................
B8 lndicator - fuel reserves (fuel gauge) 4 ................................................................................................................................
B10 Horn 12 ................................................................................................................................................................................................................
B11 Loud speaker* 18 ......................................................................................................................................................................................
B12 Switch - brake light 9 .............................................................................................................................................................................
B16 Back up warning * 8 ...............................................................................................................................................................................
B17 Thermo switch - oil cooler 70 / 65 C 4 .............................................................................................................................
B20 Buzzer 6 .............................................................................................................................................................................................................
D4 Diode (in V1) 6 .............................................................................................................................................................................................
D5 Diode (in V1) 6 .............................................................................................................................................................................................
D6 Diode (in V1) 6 .............................................................................................................................................................................................
D9 Diode (in V1) 6 .............................................................................................................................................................................................
D10 Diode (in V1) 6 .............................................................................................................................................................................................
D14 Diode (in V1) 6 .............................................................................................................................................................................................
E2 lnterior light with switch 14 ...............................................................................................................................................................
E3 Headlight, left 10 ........................................................................................................................................................................................
E4 Headlight, right 11 ....................................................................................................................................................................................
E6 Tail light, left 10 ...........................................................................................................................................................................................
E7 Tail light, right 11 .......................................................................................................................................................................................
E10 Working floodlight, left front 14 ....................................................................................................................................................
E11 Working floodlight, right front 14 .................................................................................................................................................
E13 Working floodlight, rear 14 ...............................................................................................................................................................
F Fuse box 50 A, 25 A
(main fuse in battery box) 1 ............................................................................................................................................................
F1 30 A Oil cooler motor 3 .......................................................................................................................................................................
F2 10 A Relay preglow 40 sec., instruments, indicator lights,
Solenoid - slow travel Y6 3 ..............................................................................................................................................................
F3 10 A Brake lights, horn, blinker 9 ..............................................................................................................................................
F4 10 A Emergency blinker system 12 .........................................................................................................................................
F5 15 A Working floodlight 14 ...............................................................................................................................................................
F6 15 A lnterior light, beacon, plug cigarette lighter 14 ...............................................................................................
F7 15 A Windshield wiper 16 .................................................................................................................................................................
F8 15 A Solenoid -engine stop, heater fan,
Travel direction solenoids Y2, Y3, Y4 2 ..............................................................................................................................
F9 7,5 A Relay Preglow / K2a, relay oil cooler motor / K6 3 ...................................................................................
F10 7,5 A Tail light, right, parking light, left 10 .........................................................................................................................
F11 7,5 A Taillight, left, parking light, right 11 ...........................................................................................................................
F12 7,5 A Low beam, left 10 ......................................................................................................................................................................
F13 7,5 A Low beam, right 11 ..................................................................................................................................................................
F14 15 A Headlight 11 .....................................................................................................................................................................................
F19 2 A Radio * 17, 18 ....................................................................................................................................................................................
G1 Alternator with regulator 2 ................................................................................................................................................................
G2 Battery 1 .............................................................................................................................................................................................................
H2 lndicator light -Preglow "ON" 3 ....................................................................................................................................................
H3 lndicator light - forward / Y2 7 .......................................................................................................................................................
H4 lndicator light - engine oil pressure 5 ....................................................................................................................................
H5 lndicator light - engine overheat 5 ............................................................................................................................................
H6 lndicator light - battery charge indicator 4 ........................................................................................................................
H7 lndicator light - air filter contamination 5 ............................................................................................................................
H9 lndictor light - reverse / Y3 7 ..........................................................................................................................................................
H10 lndicator light - blinker 12 ..................................................................................................................................................................
H11 lndicator light - parking brake "ON" 7 ....................................................................................................................................
H12 lndicator light - headlight 11 ............................................................................................................................................................
H15 Blinker, left front 12 .................................................................................................................................................................................
H16 Blinker, right front 12 ..............................................................................................................................................................................
H17 Blinker, left rear 12 ...................................................................................................................................................................................
H18 Blinker, right rear 12 ...............................................................................................................................................................................
H20 Brake light, left / B12 9 .........................................................................................................................................................................
H21 Brake light, right / B12 9 .....................................................................................................................................................................
H22 Beacon * 15 ....................................................................................................................................................................................................
H23 lndicator light - hydraulic oil overheat 100C 5 ............................................................................................................
K1 Relay - blinker 11, 12 ............................................................................................................................................................................
K2 Relay - preglow time 40 sec. 3 ....................................................................................................................................................
K2a Relay -preglow / R3 3 ...........................................................................................................................................................................
K3 Relay - starting lock 2 ...........................................................................................................................................................................
K4 ** Relay - Travel direction recognition (back up warning *) 7 ..............................................................................
K6 Relay -oil cooler motor / M6 3, 4 ................................................................................................................................................
M1 Starter motor 2 .............................................................................................................................................................................................
M2 Wiper motor, front 15 .............................................................................................................................................................................
M3 Wiper motor, rear 16 ..............................................................................................................................................................................
M4 Windshield washer motor 15, 16 ...............................................................................................................................................
M5 Heater blower motor 17 ......................................................................................................................................................................
M6 Oil cooler motor 3 .....................................................................................................................................................................................
M7 Compressor - Operator's seat * 18 ..........................................................................................................................................
P1 Hour meter 4 ..................................................................................................................................................................................................
P3 Fuel gauge 4 ..................................................................................................................................................................................................
P5 Engine oil temperature gauge 4 .................................................................................................................................................
R3 Glow plug 3 .....................................................................................................................................................................................................
05.97
Item Listing
L 504 0101
12.04.12
S1 Keyed switch 1, 2 .....................................................................................................................................................................................
S2 Switch - travel direction / neutral 7, 8 ....................................................................................................................................
S3 Steering column combination switch 10 .............................................................................................................................
S4 Emergeny blinker switch / K1 11, 12 ......................................................................................................................................
S5 Switch - slow travel 8 ............................................................................................................................................................................
S7 Switch - working floodlight / E10 / E11 / E13 14 .........................................................................................................
S9 Switch - beacon * 15 ..............................................................................................................................................................................
S11 Switch - heater fan / M5 17 ..............................................................................................................................................................
S12 Switch - wiper motor, front / M2 and M4 15 ....................................................................................................................
S13 Switch, Wiper motor, rear / M3 16 ............................................................................................................................................
V1 Central unit - diodes 6 ..........................................................................................................................................................................
V5 Diodes - solenoids Y2, Y3, Y6, 8 ...............................................................................................................................................
X01 Screw connection, 3-pole 1, 3 .....................................................................................................................................................
X1 Plug connection, 15-pole 1-7 .........................................................................................................................................................
X1a Plug connection, 9-pole 8, 9, 10, 11, 12, 15, 18 .........................................................................................................
X1b Plug connection, 2-pole 7, 8 ..........................................................................................................................................................
X2 Plug connection, 5-pole 10, 12 ....................................................................................................................................................
X2a Plug connection, 5-pole 11, 12 ....................................................................................................................................................
X3 Plug connection, 8-pole 3, 14, 15 .............................................................................................................................................
X3a Plug connection, 6-pole 14, 16 ....................................................................................................................................................
X4 Plug connection, 4-pole 17 ..............................................................................................................................................................
X5 Plug connection, 8-pole 3 .................................................................................................................................................................
X7 Plug connection, 14-pole 5, 6 .......................................................................................................................................................
X9 Plug connection, 3-pole 7 .................................................................................................................................................................
X11 Plug connection, 2-pole 17, 18 ....................................................................................................................................................
X17 Plug connection, 2-pole (license plate illumination) 11 ........................................................................................
X24 Plug connection, 3-pole / S2 7, 8 ..............................................................................................................................................
X25 Plug connection, 9-pole / S3 10 ..................................................................................................................................................
X33 Valve plug, 4-pole / Y2 7 ...................................................................................................................................................................
X41 Plug, 2-pole (cigarette lighter) 17 ..............................................................................................................................................
Y2 Solenoid, travel direction - forward 7 .....................................................................................................................................
Y3 Solenoid - travel direction - reverse 8 ...................................................................................................................................
Y4 ** Solenoid - travel direction recognition (on var. displ. motor) 7 .....................................................................
Y5 Solenoid - engine stop 2 ....................................................................................................................................................................
Y6 Solenoid - travel range - slow travel 8 ..................................................................................................................................
* = Special equipment
** from S/N 0520
CoIor chart for cabIe markings in functionaI schematic
rot
rt = red
rouge
gelb
ge = yellow
jaune
grau
gr = gray
gris
grn
gn = green
vert
schwarz
sw = black
noir
weiss
ws = white
blanc
hellblau
hbl = light blue
bleu clair
violett
vl = violet
violet
orange
or = orange
orange
rosa
ro = pink
rose
blau
bl = blue
bleu
braun
br = brown
brun
ExampIe - for additionaI cabIe markings
bI - ws = blau - weiss laengsgestreift
bI - ws = blue - white long stripe
bI - ws = bleu - blanc rayL en lang
bl / ws = blau / weiss quergestreift
bI / ws = blue / white diagonal stripe
bI / ws = bleu / blanc rayL en travers
05.97
L 504 0520
12.04.13
05.97
L 504 0520
12.04.14
05.97
L 504 0520
12.04.15
05.97
L 504 0520
12.04.16
TraveI hydrauIic with variabIe dispIacement motor A6VM .. HA 1R1 (reguIation with traveI direction
recognition)
Shifting function:
Y2 forward
Y3 reverse
Y4 Travel direction recognition
Y6 Travel stage l (slow)
Travel ranges Y2 Y3 Y4 Y6
Forward l
Reverse l
Forward ll
Reverse ll
05.95
EIectricaI System
L 506 / L 507
L 508 / L 509
2501 / 0101
2501 / 0101
12.05.00
A1 Electronic control
A3 Radio installation *
B5 Switch - parking brake
FA, FB Fuse base
K1-K10 Relay base
(K4 Near air intake)
M5 Heater blower motor
M7 Compressor - Operator's seat *
S2 Travel range switch
S10 Battery master switch
X41 Plug - cigarette lighter
05.97
L 506 / L 507
L 508 / L 509
2501 / 0101
2501 / 0101
12.05.01
17
G2 Battery (in left entry box)
1 x 12 V 88 Ah
18
F Main fuses: (in battery box)
50 A Main fuse
25 A Added user (special equipment)
19
FUSE BASE A, B in instrument paneI
20
FA1 10 A Solenoid - engine stop
FA2 30 A Oil cooler motor
FA3 15 A Working floodlight
FA4 15 A lnterior lighting, beacon, Radio, Plug ciga-
rette lighter, relay K6,
compressor -operator's seat
FA5 20 A Spare fuse
FA6 7,5 A Emergency blinker system
FA7 10 A Electronic control, gauges, indicator lights
FA8 10 A Brake light, blinker
FA9 15 A Blower motor - heater
FA10 15 A Windshield wiper, washer motor, horn
FA11 7,5 A Spare fuse
FB1 10 A Relay K3, K8
FB2 7,5 A Parking light, taillight, side light - left,
instrument lighting
FB3 7,5 A Parking light, taillight, side light - right,
license plate illumination
FB4 7,5 A Low beam, left
FB5 7,5 A Low beam, right
FB6 7,5 A High beam, left
FB7 7,5 A High beam, right
FB8 7,5 A Spare fuse
FB9 15 A Preglow, switch illumination
FB10 10 A Spare fuse
FB11 10 A Spare fuse
21
22
G1 Alternator 14 V / 60 A
23
M1 Starter motor
24
Y5 Solenoid - Engine stop
05.97
L 506 / L 507
L 508 / L 509
2501 / 0101
2501 / 0101
12.05.02
25
B1 lndicator - engine oil temperature
B2 Thermo switch - engine overheat 130 C
B7 Switch - engine oil pressure
(B1 and B2 on engine block near alternator
from engine F4L 1011 F)
26
B4 Sensor - air filter contamination
27
B17 Thermo switch - oil cooler 70C / 65 C
M6 Oil cooler motor (controlled via B17)
Fan speed 2650 min
-1
15 A current intake
28
B6 Thermo switch - hydraulic oil-
overheat 100C
(on suction line to travel pump)
29
B5 Switch parking brake / travel lock
Function when parking brake is actua-
ted:
lndicator light H11
Neutral position for travel direction
30
B12 Switch - brake light
31
F = Travel direction - forward
R = Travel direction - reverse
l = Travel range - slow (switched automatically
after engine start, valid to S/N 3127)
ll = Travel range - fast (automatically selected
after engine start, valid from S/N 3128)
N = Neutral position of travel direction (for elec-
tronic control, ld. No. 975796801)
Note:
Whenever the switch is actuated, an audible signal is
emitted (valid for electronic control, ld. No. 975796801)
32
Y4 Solenoid - travel direction recognition, valid
from:
L 506, L 507 from S/N 3096
L 508, L 509 from S/N 3025
is actuated when traveling forward
Y6 Solenoid - travel range l
is actuated in travel range l
05.97
L 506 / L 507
L 508 / L 509
2501 / 0101
2501 / 0101
12.05.03
33
Y2 Solenoid - Travel direction - forward
Y3 Solenoid - Travel direction - reverse
(Current consumption 2,5 A)
34
M5 Blower motor - heater
35
ReIay: (in instrument panel, right)
K1 Relay - blinker
K2 Relay - preglow time 40 sec.
K2a Relay - preglow
K3 Relay - engine stop
K5 Relay wiper - washer - intermittent
K6 Relay - oil cooler motor
K7 Relay - reverse travel warning signal *
K8 Relay - supply electronic control, instru-
ments
K10 Relay - bucket return *
* free for Special equipment
36
K4 Relay - additional starting quantity -
only L 509 S/N 0101 - 2924
(placed under air intake on right fender)
Note:
K4 not used with BF4L 1011 F engine
37
R3 Glow plug
38
39
40
05.95
L 506 / L 507
L 508 / L 509
2501 / 0101
2501 / 0101
12.05.10
Positions of pIug connections:
X1 under cab floor, right
X1b under cab floor, right
X1c under cab floor, right
X6 under cab floor, left
X11 under cab floor, left, or in radio
compartment
X17 in rear section, right
X22 in front section
P = Parking position
0 = 0 - position / engine shut off
l = Contact - Operational - preglow position
ll = Starting position
05.97
Item Listing
FunctionaI diagram
L 506 / L 507
L 508 / L 509
2501 / 0101
2501 / 0101
12.05.11
A1 Electronic control 4, 5, 6 .....................................................................................................................................................................
A3 Radio * 19, 20 ...............................................................................................................................................................................................
B1 Transmitter engine oil temperature 3, 4 .............................................................................................................................
B4 Contact transmitter air filter contamination 5 .................................................................................................................
B5 Switch parking brake / Starting lock 4 ..................................................................................................................................
B6 Thermo switch hydraulic oil overheat 100 C 5 ...........................................................................................................
B7 Switch / engine oil pressure 5 .......................................................................................................................................................
B8 Transmitter / fuel level 5, 6 ..............................................................................................................................................................
B10 Horn 13 ................................................................................................................................................................................................................
B11 Loudspeaker * 19, 20 ............................................................................................................................................................................
B12 Brake light switch 6 .................................................................................................................................................................................
B15 Proximity switch / bucket return / Y9 * 18 ..........................................................................................................................
B16 Reverse travel warning device * 10 .........................................................................................................................................
B17 Thermo switch oil cooler 70 / 65C 3 ..................................................................................................................................
E2 lnterior lighting with switch 15 .......................................................................................................................................................
E3 Head light / left 12, 13 ...........................................................................................................................................................................
E4 Head light / right 13 .................................................................................................................................................................................
E6 Tail light / left 12 .........................................................................................................................................................................................
E7 Tail light / right 13 ......................................................................................................................................................................................
E8 Profile light / left 12 ..................................................................................................................................................................................
E9 Profile light / right 12 ..............................................................................................................................................................................
E10 Working flood light / left front 14, 15 .......................................................................................................................................
E11 Working flood light / right front 14 .............................................................................................................................................
E12 Working flood light / left rear 15 ..................................................................................................................................................
E13 Working flood light / right rear 15 ...............................................................................................................................................
E14 License plate illumination 13, 14 ................................................................................................................................................
Fuses F, FA1-11, FB1-9
F Fuse box 50 A, 25 A
(Main fuse in battery box) 1 ............................................................................................................................................................
FA1 10 A Solenoid / engine stop 2 ......................................................................................................................................................
FA2 30 A Oil cooler motor 3 .......................................................................................................................................................................
FA3 15 A Working floodlight 15 ...............................................................................................................................................................
FA4 15 A lnterior lighting, beacon, plug, radio, relay K6 15 ........................................................................................
FA6 7,5 A Emergency blinker system 14 .......................................................................................................................................
FA7 10 A Electronic control lndicator lights 6 ............................................................................................................................
FA8 10 A Brake light, blinker, additional installations 10 ................................................................................................
FA9 15 A Heater blower motor 18 .........................................................................................................................................................
FA10 15 A Windshield wiper, horn, washer motor 17 ...........................................................................................................
FA11 7,5 A spare fuses 18, 19 ....................................................................................................................................................................
FB1 10 A Relay K3, K8 lndicator lights 2 .......................................................................................................................................
FB2 7,5 A Parking, tail, profile light / left
lnstrument lighting 12 ............................................................................................................................................................................
FB3 7,5 A Parking, tail, profile light / right
License plate illumination 13 ..........................................................................................................................................................
FB4 7,5 A Low beam / left 12, 13 ..........................................................................................................................................................
FB5 7,5 A Low beam / right 13 .................................................................................................................................................................
FB6 7,5 A High beam / left 12, 13 .........................................................................................................................................................
FB7 7,5 A High beam / right 13 ................................................................................................................................................................
FB9 15 A Switch illumination, preglow relay K2 18 ..............................................................................................................
G2 Battery 1 .............................................................................................................................................................................................................
H1 lndicator light Travel range l 4, 5, 6 .........................................................................................................................................
H2 lndicator light Preglow "ON" 4, 5, 6 .........................................................................................................................................
H3 lndicator light forward / Y2 4, 5, 6 .............................................................................................................................................
H4 lndicator light Engine oil pressure 3, 4, 5 ..........................................................................................................................
H5 lndicator light Engine overheat 3, 4, 5 ..................................................................................................................................
H6 lndicator light battery charge 3, 4, 5 .......................................................................................................................................
H7 lndicator light Air filter contamination 3, 4 ........................................................................................................................
H9 lndicator light reverse / Y3 4, 5, 6 .............................................................................................................................................
H10 lndicator light Blinker 4, 5, 6 ...........................................................................................................................................................
H11 lndicator light - Parking brake "APPLlED" 4, 5, 6 ......................................................................................................
H12 lndicator light High beam 4, 5, 6 .................................................................................................................................................
H13 lndicator light Travel range ll 4, 5, 6 .......................................................................................................................................
H15 Turn signal / left front 14 .....................................................................................................................................................................
H16 Turn signal / right front 14 .................................................................................................................................................................
H17 Turn signal / left rear 14 ......................................................................................................................................................................
H18 Turn signal / right rear 14 ..................................................................................................................................................................
H20 Brake light / left / B12 6 .......................................................................................................................................................................
H21 Brake light / right / B12 6 ...................................................................................................................................................................
H22 Beacon * 15 ....................................................................................................................................................................................................
H23 lndicator light / hydraulic oil overheat 100C 3, 4, 5 ...............................................................................................
K1 Relay / blinker 13, 14 .............................................................................................................................................................................
K2 Relay Preglow time 40 sec. 3 .......................................................................................................................................................
K2a Relay Preglow / R3 3 ............................................................................................................................................................................
K3 Relay / engine stop / Y5 2 ................................................................................................................................................................
K4 Relay, starting quantity / Y1 ** 2 ................................................................................................................................................
K5 Relay / Wipe, wash, intermittent 16 .........................................................................................................................................
K6 Relay / Oil cooler motor / M6 3 ....................................................................................................................................................
K7 Relay / Back up alarm * 10 ..............................................................................................................................................................
K8 Relay / Supply Electronic control, lnstruments 3 .......................................................................................................
08.99
Item Listing
FunctionaI diagram
L 506 / L 507
L 508 / L 509
2501 / 0101
2501 / 0101
12.05.11/1
M1 Starter motor 2 .............................................................................................................................................................................................
M2 Wiper motor front 16 ..............................................................................................................................................................................
M3 Wiper motor rear 16, 17 ......................................................................................................................................................................
M4 Winshild flushing motor 16 ...............................................................................................................................................................
M5 Heater fan motor 18 ................................................................................................................................................................................
M7 Compressor Operator's seat * 19, 20 ....................................................................................................................................
P1 Hour meter 4, 5, 6 .....................................................................................................................................................................................
P3 Fuel level indicator 4, 5, 6 .................................................................................................................................................................
P5 Engine oil temperature indicator 4, 5, 6 ..............................................................................................................................
R3 Glow plug 3 .....................................................................................................................................................................................................
S1 Keyed switch 1, 2 .....................................................................................................................................................................................
S2 Travel range switch 7, 8 .....................................................................................................................................................................
S4 Emergency blinker switch / K1 13, 14 ...................................................................................................................................
S6 Switch - travel lights 13 .......................................................................................................................................................................
S7 Switch - Working floodlight / E10 / E11 * 14, 15 .........................................................................................................
S8 Switch - Working floodlight / E12 / E13 * 15 ...................................................................................................................
S9 Switch / beacon * 15, 16 ....................................................................................................................................................................
S10 Battery master switch 1 ......................................................................................................................................................................
S12 Switch for Y11 / Y12 * 8 ......................................................................................................................................................................
S13 Switch Wiper motor / rear 16, 17 ...............................................................................................................................................
S14 Switch - Bucket return / Y9 * 17, 18 ........................................................................................................................................
S15 Neutral switch / travel direction
1)
7 .........................................................................................................................................
V1 Diode / Y9 17, 18 .......................................................................................................................................................................................
V3 Diode 4 ................................................................................................................................................................................................................
V5 Diodes solenoid valves Y2, Y3, Y6, Y11, Y12 8, 9, 10 .......................................................................................
Plug connections A, B, C, D
lndicator lights 4, 5, 6 ............................................................................................................................................................................
ST1 Plug connection / Electronic A1 2-pole 7 ...........................................................................................................................
ST6 Plug connection / Electronic A1 10-pole 9 .......................................................................................................................
ST8 Plug connection / Electronic A1 4-pole (Reserve) 9 ...............................................................................................
X1 Plug connection 70-pole 1-19 ......................................................................................................................................................
X1b Screw connection 3-pole 1, 2, 3 .................................................................................................................................................
X1c Schraubverbindung 3-pole 3 .........................................................................................................................................................
X4 Plug connection 1-pole terminal W 1 .....................................................................................................................................
X5 Plug connection 8-pole K2 3 ..........................................................................................................................................................
X5a Plug connection 4-pole M2 16 ......................................................................................................................................................
X6 Plug connection 2-pole B5 4 ..........................................................................................................................................................
X7 Plug connection 8-pole 12-15 .......................................................................................................................................................
X11 Plug connection 2-pole A3 19 .......................................................................................................................................................
X16 Plug connection 2-pole M7 19, 20 ............................................................................................................................................
X17 Plug connection 6-pole E12, E13, E14 * 13, 15 ..........................................................................................................
X21 Round plug connection 7-pole S3 12, 13 ..........................................................................................................................
X22 Round plug connection 4-pole B15 18 .................................................................................................................................
X24 Plug connection 10-pole S2, Y9 7, 8, 17 ...........................................................................................................................
X24a Plug connection 2-pole S15
1)
7 ..................................................................................................................................................
X25 Round plug connection 7-pole S3 12, 13 ..........................................................................................................................
X26 Plug connection 4-pole M5 18 ......................................................................................................................................................
X28 Plug connection 8-pole M3, M4, E12, E13 15-17 .....................................................................................................
X33 Valve plug 4-pole Y2 9 ........................................................................................................................................................................
X41 Socket 2-pole 19 ........................................................................................................................................................................................
Y1 Solenoid valve additional Starting aid ** 2 .......................................................................................................................
Y2 Solenoid valve - Travel direction / forw. 9 .........................................................................................................................
Y3 Solenoid valve - Travel direction / rev. 9 ............................................................................................................................
Y4 Solenoid - travel direction recognition Page 12.05.14 .........................................................................................
Y5 Solenoid / Motor stop 2 .......................................................................................................................................................................
Y6 Solenoid valve Travel range ll 9, 10 .......................................................................................................................................
Y8 Retaining magnet / Float position Page 12.05.15 ....................................................................................................
Y9 Solenoid / Bucket return * 17, 18 ...............................................................................................................................................
Y11 Solenoid valve Additional installation * 8 ...........................................................................................................................
* = Special installation
** = only L 509 S/N 0101 - 2924
1)
= only previous version
05.97
L 506 / L 507 3096
L 508 / L 509 3025
12.05.14
TraveI hydrauIic with variabIe dispIacement motor A6VM .. HA 1R1 (ReguIation with traveI
direction recognition)
Shifting function:
Y2 Forward
Y3 Reverse
Y4 Travel direction recognition
Y6 Travel stage l (slow)
Travel ranges Y2 Y3 Y4 Y6
Forward l
Reverse l
Forward ll
Reverse ll
08.99
FunctionaI diagram
L 506 / L 507
L 508 / L 509
4282
12.05.15
PiIot ControI unit with retaining magnet for fIoat position
2 Control valve
Lift arm up / Lift arm down
float position
3 Retaining magnet Y8
float position
The retaining magnet Y8 is
automatically actuated after
engine start by the control
electronics A1.
05.97
EIectronic ControI
L 506 / L 507
L 508 / L 509
2501 / 0101
2501 / 0101
12.05.20
1. FUNCTIONAL DESCRIPTION:
The electronic control is installed on the left hand side of the instrument panel.
1.1 Protective and support function of the eIectronic controI:
Bulb check, warning signal - buzzer, travel lock , control of travel ranges and control of additional
functions.
2. SELECTION OF TRAVEL DIRECTION:
2.1 The seIection of traveI direction is onIy possibIe:
after the Diesel engine has been started (Signal from terminal 61)
if the parking brake is released
2.2 TraveI direction preseIection is turned off, if:
the control lever is turned into direction of travel range l (N) and held for 2 seconds (valid for
electronic control, ld. No. 975796801)
the parking brake is applied
the Diesel engine is turned off
there is no power for the electronic control
the alternator is not functioning (terminal 61)
if the neutral button is actuated (valid for L 507 and L 509 with electronic control, ld. No. 975749901),
signal from terminal 61 is interrupted.
2.3 InIets:
- Signal from terminal 61 of alternator (analog)
- Signal from parking brake (active grounded)
- Button "forward" (active grounded)
- Button "reverse" (active grounded)
2.4 OutIets:
- Solenoid valve travel direction "FORWARD" (Solenoid 12V / 30W)
Solenoid valve "Travel direction recognition " (solenoid 12 V / 28 W)
valid for: L 506, L 507 from S/N 3096, L 508, L 509 from S/N 3025
- lndicator light for travel direction "forward" (Bulb 12V / 2,0W)
- Solenoid valve travel direction "REVERSE" (Solenoid 12V / 30W)
- lndicator light for travel direction "reverse" (Bulb 12V / 2,0W)
3. TRAVEL RANGE CONTROL
3.1 TraveI range I :
When the keyed switch S1 is turned on:
- the travel range I is already selected, the indicator for travel range I lights up.
- from S/N 3128, travel range II is already selected, (different electronic control A1) the indicator
for travel II lights up.
3.2 TraveI range II :
- Travel range preselection is only possible after signal from terminal 61 is available.
- Trigger the switch by turning the control lever counterclockwise to shift up from travel
range l to ll.
- Trigger the switch by turning the control lever clockwise to shift down from travel range ll to l.
- Whenever the travel range is changed, a buzzer will sound (valid for electronic control,
ld. No. 975796801).
- After releasing it, the control lever will return automatically to center position, then it is possible
again to shift up or down to the next higher or lower travel range.
- Delay time for shifting up or shifting down between the various travel ranges is 200 ms .
3.3 InIets:
- Signal "shift up" (active grounded)
- Signal "shift down" (active grounded)
3.4 OutIets:
- lndicator light for l. travel range (bulb 12V / 2W)
- Solenoid valve for l. travel range (solenoid 12V / 30W)
- lndicator light for ll. travel range (bulb 12V / 2W)
4. ADDED FUNCTIONS:
4.1 Actuated
- by switch S 12
- Actuated via 2 buttons on control lever S2 for 2 possible outlets
4.2 InIets: (grounded)
- Switch added functions
- Button 1 added function 1
- Button 2 added function 2
4.3 OutIets:
- Solenoid valve - added function 1 (solenoid 12V / 30W)
- Solenoid valve - added function 2 (solenoid 12V / 30W)
- Optical indicator - added function (bulb 12V / 2W)
05.95
EIectronic ControI
L 506 / L 507
L 508 / L 509
2501 / 0101
2501 / 0101
12.05.21
5. BuIb check:
- After turning on the starter switch S 1 to position I , the bulbs for the following indicator lights
are checked for about 4 seconds:
5.1 OutIets: (grounded)
- Engine overheat H 5 (bulb 12V / 2W)
- Hydraulic oil overheat H 23 (bulb 12V / 2W)
- Air filter contamination H 7 (bulb 12V / 2W)
6. Warning function (buzzer):
- in addition to the optical indication of certain warning messages, an acoustical warning signal is
also given.
- acoustical indication also at every shifting procedure (valid for electronic control,
ld. No. 975796801).
- Engine oil pressure
- Engine overheat
- Hydraulic oil overheat
- Spare for 5 additional warning signals
7. TechnicaI data:
- Fuse : 8,0 AT
- Voltage supply: 12V power supply
- Temperature range: -25 to +85 degrees
- Measurements: Size of circuit board, max. 160 x 160 mm
- 19 lnlets
- 14 Outlets
- 6 Finals stages control outlets 5 V - 42 V, overvoltage surpressor >18 V
- LED 1 - 6 as problem indicator (only in case of short circuit)
PIug configuration - eIectronic controI
PIug 1: (InIets)
St 1.1 Voltage supply "12V"
St 1.2 Supply voltage "ground"
PIug 2: (InIets)
St 2.1 Signal - terminal 61 of alternator
St 2.2 Signal - switch - parking brake
St 2.3 Signal - button "forward" (active grounded)
St 2.4 Signal - button "reverse" (active grounded)
St 2.5 Signal - button "shift up" (active grounded)
St 2.6 Signal - button "shift down" (active grounded)
PIug 3: (InIets)
St 3.1 Signal - switch "added functions" (active grounded)
St 3.2 Signal - button "added functions 1" (active grounded)
St 3.3 Signal -button "added functions 2" (active grounded)
(OutIets)
St 3.4 Voltage supply for solenoid valve "added function 1"
St 3.6 Signal for indicator light "added functions" (active 12V)
PIug 5: (InIets)
St 5.1 Warning function "engine overheat"
St 5.2 Warning function "hydraulic oil overheat"
St 5.3 Warning function " engine oil pressure"
St 5.4 not used
St 5.5 not used
St 5.6 not used
St 5.7 not used
St 5.8 not used
PIug 6: (OutIets)
St 6.1 Voltage supply for solenoid valve "forward"
St 6.2 lndicator light for travel direction "forward"
St 6.3 Voltage supply for solenoid valve "reverse"
St 6.4 lndicator light for travel direction "reverse"
St 6.5 Voltage supply for "bucket return"
St 6.6 Voltage supply for solenoid valve - travel range l
St 6.7 lndicator light for travel range l
St 6.8 not used
St 6.9 not used
St 6.10 lndicator light for travel range ll
PIug 7: (OutIets)
St 7.1 lndicator light "engine overheat"
St 7.2 lndicator light "hydraulic oil overheat"
St 7.3 not used
St 7.4 lndicator light "Air filter contamination"
PIug 8: (OutIets)
St 8.1 not used (for bulb check)
05.95
EIectronic ControI A1
Id. No. 975796801
L 506 / L 507
L 508 / L 509
2501 - 9226 / 0101 - 9226
2501 - 9226 / 0101 - 9226
12.05.22
1 Fuse 8,0 AT
1a Monitor - fuse
2 Control outlet - travel direction
"FORWARD"
2a Error message
"FORWARD" LED 1 .............................
"REVERSE"
3a Error message
"REVERSE" LED 2 ..............................
4 Voltage supply - bucket return
4a Error message
Bucket return LED 9 .............................
5 Control outlet - travel range l
5a Error message
Travel range l LED 3 ............................
6 Control outlet - added function 1
6a Error message
Added function 1 LED 5 .......................
7 Control outlet - Added function 2
7a Error message
10 Buzzer
11 Plug 1 "voltage supply electronic con-
trol (12V)
12 Plug 2 "signal inlets travel logic"
13 Plug 3 "inlets/outlets added function"
15 Plug 5 inlets for warning functions
(error messages)
16 Plug 6 outlets for travel function and
bucket return
17 Plug 7 Outlets for bulb check
18 Plug 8 Outlets for bulb check (free for
additional functions)
Note: Error messages 2a - 7a will be actuated in case of short circuit or overheating, but not in case of
a broken wire.
Electronic control, ld. No. 975749901 is replaced by ld. No. 975796801
ld. No. is shown on the buzzer.
MJFCIFSS
L 506 / L 507 9226 / 9226
Datum / Edition / Date L 508 / L 509 9226 / 9226
Blatt / Page Feuille
06.04
Control electronics A1
12.05.24
1 Plug 1 control electronics power supply (12 V)
2 LED 1 controller power indicator
3 Plug 7 lamp check outputs
4 Plug 6 bucket return-to-dig travel function outputs
5 LED 7 forward travel direction solenoid valve fault
indicator
6 LED 6 reverse travel direction solenoid valve fault
indicator
7 LED 5 lift kick-out power fault indicator
8 LED 4 travel range I swivel restrictor fault
indicator
9 LED 3 additional equipment 1 fault indicator
10 LED 2 additional equipment 2 fault indicator
11 Plug 3 Additional function inputs/outputs
12 ID no.
13 Buzzer
14 Plug 8 lamp check outputs
15 Plug 2 travel logic signal inputs
16 Plug 5 alarm function inputs (fault messages)
Note: Fault indicators LED2 - LED7 are activated when connections are interrupted or short-circuited.
Control electronics ID no. 975749901 and 975796801 are replaced by ID no. 10028968
The ID no. is marked on the component cover
05.95
TroubIeshooting
EIectronic ControI
Id. Nr. 975749901 and 975796801
L 506 / L 507
L 508 / L 509
2501 / 0101
2501 / 0101
12.05.26
Error Cause Remedy
- Monitor indicator 1a
(LED 8) does not light up
- no voltage supply
- Fuse FA7 is defective
- Fuse 1 is defective
- Monitor indicator 1a is
defective
- Check voltage supply
- Replace fuse FA7
- Replace fuse 1
- Turn on bulb check at ignition,
does not function, only
partially or not at all
- no voltage supply
- Wire / plug ST7 (ST8) is
defective
- lndicator lights are defective
- Electronic is defective
- Replace fuse FA7
- Replace fuse 1
- Check cable / plug
- Replace indicator lights
- Replace electronic
- Travel only possible in travel
range l
- Button / cable / plug ST2 to
shift up / down defective
- Check button / cable / plug to
shift up / down
range ll
shift up / down is defective
- Plug ST6 / cable / solenoid
travel range l defective
- Electronic defective
shift up / down
- Check plug / cable / solenoid
travel range l
- Travel direction selection for-
ward/ reverse is not possible
- no voltage supply
- Fuse FA7 defective
- Fuse 1 defective
- Parking brake applied
- Signal terminal 61 is missing
- Plug ST2 or ST6 / button /
cable / solenoid for
travel direction is defective
- Replace fuse FA7
- Replace fuse 1
- Release parking brake
- Check signal terminal 61
- Check plug / button / cable /
solenoid for travel direction
- Problem indicators 2a to 7a
light up
- Plug ST6 not connected
- Short circuit or overheating of
corresponding outlet (cable in-
dicator light or solenoid)
- Connect plug
- Check cable / solenoids
- lndi cat or l i ght s for travel
functions do not light up, travel
functions are O.K
- lndicator light is defective
- Plug ST6 / cable to indicator
light is defective
- Check indicator light
- Check plug / cable for corre-
sponding indictor light
- Travel functions are not O.K.,
indicator lights are O.K
- Plug ST6 / cable / solenoid for
corresponding travel function
are defective
f or cor r espondi ng t r avel
function
Error Cause Remedy
- Bucket return is not
functioning
- no voltage supply
- Fuse 1 defective
- Plug ST6 / cable defective
- Replace fuse FA7
- Replace fuse 1
- Check plug / cable
- Buzzer does not functi on
when reporting error message
- Steuerelectronic defective
- Replace electronic control
- Added f unct i ons do not
function
- Switch / button / plug ST3 /
cable / solenoids are defective
- Check switch / button / plug /
cable / solenoids
Checking for error when engine is not running: (no signal from alternator terminal 61)
Voltage supply from fuse FA7 must be available on plug ST1.
disconnect the pink cable or cable No. 301 from terminal 61 on the alternator and supply the cable
with battery voltage - terminal ST2.1 to obtain a control signal.
11.93
L 512 / L 522 101-151/101-233
12.10.01
1
G2 Batteries
2 x 12 V 88 Ah
2
F Main fuses:
50 A Main fuse
25 A Additional user (special installation)
3
FUSE BOX in the instrument paneI (right)
4
F1 25 A Solenoid - Engine Stop
F2 20 A Oil cooler motor
F3 15 A Working flood lights
F4 15 A lnterior lighting, beacon,
Radio, Electr. socket
F5 20 A Preglow
F6 7,5 A Emergency blinker system
F7 5 A Electronic control
F8 7,5 A Brake light, additional installations,
turn signal
F9 15 A Heater fan motor
F10 15 A Windshield wiper, horn
F11 7,5 A Reserve fuse
F12 7,5 A lnstrument lights,
lndicators, gauges
F13 7,5 A Parking, tail and profile lights, left ,
lnstrument illumination
F14 7,5 A Parking, tail and profile lights, right, license
plate illumination
F15 7,5 A Low beam, left
F16 7,5 A Low beam, right
F17 7,5 A High beam, left
F18 7,5 A High beam, right
5
6
7
M1 Starter 24 V / 4,0 KW
8
Y5 Solenoid - Engine stop
Pick up current 20 A
Holding current 0,5 A
Adjustment: see page 8.20.01
11.93
L 512 / L 522 101-151/101-233
12.10.02
9
B1 Sensor - engine oil temperature
10
B2 Thermo switch - engine overheat 150C
11
B3 Transmitter - emergency steering
(Flow indicator in valve block 20)
12
B4 Transmitter - air filter contamination
13
B5 Switch - parking brake
Function:
lndicator light
Travel lock
14
B6 Thermo switch - hydraulic oil
overheat 100C
15
B7 Transmitter - engine oil pressure
16
B8 lndicator - fuel level
11.93
L 512 / L 522 101-151/101-233
12.10.03
17
B12 Brake light switch
18
B13 Transmitter - V-belt monitor
19
B14 Proximity switch - hoist limit shut off
Type:
RP024RK 050680
20
B15 Proximity switch - bucket return
Type for Z-bar kinematics:
AP024 SEMY 029383
Type for P-kinematics:
RP024RK 050680
21
B 17 Thermo switch - oil cooler 70 / 65
22
B 21 lnductive transmitter - travel speed
23
R 3 Flame glow plug
24
Y 1 Solenoid valve - preglow
07.94
L 512 / L 522 101-151/101-233
12.10.04
25
A 1 Electronic control
26
S 2 Travel range switch
a = shift up
b = shift down
L 512 Travel range I =0- 8.0 km/h
Travel range II =0- 32.0 km/h
L 522 Travel range I =0- 8.0 km/h
Travel range II=0- 18.0 km/h
Travel range III =0- 32.0 km/h
N = Button for neutral position of
travel direction
F = Travel ditection forward
R = Travel ditection reverse
27
Y 6 Solenoid valve - travel range ll
Y 7 Solenoid valve - travel range lll (only L522)
28
Y 2 Solenoid valve - travel direction forward
Y 3 Solenoid valve - travel direction reverse
29
30
31
32
11.93
Positions
PIug connections
and Fuses
L 512 / L 522 101-151/109-233
12.10.10
F Main fuse
F1-18 Fuse
K1-8 Relay
X1 Plug connection 70-pole
X1b Screw connection 3-pole
X1c Screw connection 3-pole
X2 Round plug connection 24-pole
X5a Plug connection 4-pole
X38 Valve plug 4-pole
X41 Socket 2-pole
H1 lndicator light travel range l
H2 lndicator light preglow
H3 lndicator light forward travel
H4 lndicator light engine oil pressure
H5 lndicator light engine overheat
H6 lndicator light charge indicator
H7 lndicator light air filter contamination
H8 lndicator light flow indicator
H9 lndicator light reverse travel
H10 lndicator light Blinker
X11 lndicator light parking brake
H12 lndicator light high beam
H13 lndicator light Travel range ll
H14 lndicator light Travel range lll
(only L 522)
H23 lndicator light Hydraulic oil
temperature
P1 Hour meter
P3 Fuel level indicator
P4 Electronic tachometer
P5 Engine oil temperature indicator
S1 Keyed switch
S4 Switch emergency blinker system
S6 Switch travel lights
S7 Switch working flood lights / front
S8 Switch Working flood lights / rear
S11 Switch heater fan
S13 Switch windshield wiper / rear
S14 Switch bucket return
S15 Switch hoist limit switch
* for additional installation
11.93
Item Listing
FunctionaI diagram
L 512 / L 522 101-151/109-233
12.10.11
A1 Electronic control 6 ,7,8 ......................................................................................................................................................................
A3 Radio * 19, 20 ...............................................................................................................................................................................................
B1 Transmitter engine oil temperature 4 ....................................................................................................................................
B2 Thermo switch engine overheat 150 5 ..............................................................................................................................
B3 Contact transmitter emergency steering (flow indicator) 5 ...............................................................................
B4 Contact transmitter air filter contamination 5 .................................................................................................................
B5 Switch parking brake 5 ........................................................................................................................................................................
B6 Thermo switch Hydraulic oil overheat 100 5 ................................................................................................................
B7 Switch / engine oil pressure 4 .......................................................................................................................................................
B8 Transmitter / fuel level 4 .....................................................................................................................................................................
B10 Horn 13 ................................................................................................................................................................................................................
B11 Loudspeaker * 19, 20 ............................................................................................................................................................................
B12 Brake light switch 10 ..............................................................................................................................................................................
B13 Contact transmitter V-belt monitor 2 ......................................................................................................................................
B14 Proximity switch / hoist limit shut off / Y8 17 ..................................................................................................................
B15 Proximity switch / bucket return / Y9 18 ..............................................................................................................................
B16 Reverse travel warning device * 9 ............................................................................................................................................
B17 Thermo switch oil cooler 70 / 65 3 ......................................................................................................................................
B21 lnductive sensor - travel speed 8 ..............................................................................................................................................
E3 Head light / left 12 .....................................................................................................................................................................................
E5 Engine compartment illumination 20 ......................................................................................................................................
E6 Tail light / left 12 .........................................................................................................................................................................................
E9 Profile light / right 11, 12 ....................................................................................................................................................................
E10 Working flood light /left front 14 ...................................................................................................................................................
E11 Working flood light / right front 14 .............................................................................................................................................
E12 Working flood light /left rear 15 ....................................................................................................................................................
E13 Working flood light / right rear 14 ...............................................................................................................................................
E14 License plate illumination 13 ..........................................................................................................................................................
Fuses F, F1-19
F Fuse box 50 A, 25 A (Main fuse) 1 ..........................................................................................................................................
F1 25 A Solenoid / engine stop 2 ......................................................................................................................................................
F2 20 A Oil cooler motor 3 .......................................................................................................................................................................
F3 15 A Working floodlight 14 ...............................................................................................................................................................
F4 15 A lnterior lighting, beacon, plug, radio 15 .................................................................................................................
F5 20 A preglow 3 .............................................................................................................................................................................................
F6 7,5 A Emergency blinker system 13 .......................................................................................................................................
F7 5 A Electronic control 7 .......................................................................................................................................................................
F8 7,5 A Brake light, blinker, additional installations 9 .................................................................................................
F9 15 A Blower motor 10 ...........................................................................................................................................................................
F10 15 A Windshield wiper, horn 17 ..................................................................................................................................................
F11 7,5 A spare fuse 18 .................................................................................................................................................................................
F12 7,5 A lndicator lights 4 .........................................................................................................................................................................
F13 7,5 A Parking, tail, profile light / left lnstrument lighting 12 ..............................................................................
F14 7,5 A Parking , tail, profile lights / right
License plate illumination 13 ..........................................................................................................................................................
F15 7,5 A Low beam / left 12 ....................................................................................................................................................................
F16 7,5 A Low beam / right 13 .................................................................................................................................................................
F17 7,5 A High beam / left 12 ...................................................................................................................................................................
F18 7,5 A High beam / right 13 ................................................................................................................................................................
F19 Transformer f. Radio * 19 ..................................................................................................................................................................
G2 Batteries 1 ........................................................................................................................................................................................................
H1 lndicator light Travel range l 8 ......................................................................................................................................................
H2 lndicator light Preglow "ON" 3 ......................................................................................................................................................
H3 lndicator light forward / Y2 8 ..........................................................................................................................................................
H4 lndicator light Engine oil pressure 4 .......................................................................................................................................
H5 lndicator light Engine overheat 5 ...............................................................................................................................................
H6 lndicator light - battery charge 4 .................................................................................................................................................
H7 lndicator light Air filter contamination 5 ...............................................................................................................................
H8 lndicator light flow indicator 5 ........................................................................................................................................................
H9 lndicator light reverse / Y3 8 ..........................................................................................................................................................
H10 lndicator light Blinker 13 .....................................................................................................................................................................
H11 lndicator light - Parking brake "APPLlED" 5 ...................................................................................................................
H12 lndicator light High beam 12 ...........................................................................................................................................................
H13 lndicator light Travel range ll 8 ....................................................................................................................................................
H14 lndicator light Travel range lll (L 522) 8 .....................................................................................................................................
H15 Turn signal / left front 13 .....................................................................................................................................................................
H16 Turn signal / right front 14 .................................................................................................................................................................
H17 Turn signal/ left rear 14 .......................................................................................................................................................................
H18 Turn signal / rear right 14 ..................................................................................................................................................................
H20 Brake light / left / B12 10 ....................................................................................................................................................................
H21 Brake light / right / B12 9 ...................................................................................................................................................................
H22 Beacon * 15 ....................................................................................................................................................................................................
H23 lndicator light / hydraulic oil overheat 5 ...............................................................................................................................
K1 Relay / blinker 13 .......................................................................................................................................................................................
K2 Relay / Start repeat lock 2 ................................................................................................................................................................
K3 Relay / engine stop / Y5 2 ................................................................................................................................................................
K5 Relay / Wipe-Wash-lnterval 16 ....................................................................................................................................................
K6 Relay / Oil cooler motor / M6 3 ....................................................................................................................................................
K7 Relay / Reverse travel warning device * 9 .......................................................................................................................
K8 Relay / Supply Electronic control 3 ..........................................................................................................................................
11.93
Item Listing
FunctionaI diagram
L 512 / L 522 101-151/109-233
12.10.11/1
M1 Starter motor 1 .............................................................................................................................................................................................
M2 Wiper motor front 15, 16 ....................................................................................................................................................................
M4 Windshield flushing motor 16 ........................................................................................................................................................
M7 Compressor Operator's seat * 20 ..............................................................................................................................................
P1 Hour meter 4 ..................................................................................................................................................................................................
P3 Fuel level indicator 4 ..............................................................................................................................................................................
P4 Electronic Tachometer 9 ....................................................................................................................................................................
P5 Engine oil temperature indicator 4 ...........................................................................................................................................
R1 Preglow resistor 3 .....................................................................................................................................................................................
R3 Flame glow plug 3 ....................................................................................................................................................................................
R5 Transformer * 19 ........................................................................................................................................................................................
S1 Keyed switch 1, 2 .....................................................................................................................................................................................
S2 Travel range switch 6 ............................................................................................................................................................................
S3 Steering column combination switch 11, 12 ...................................................................................................................
S4 Emergency blinker switch / K1 13 .............................................................................................................................................
S5 Switch / lnching gear * 9 ....................................................................................................................................................................
S7 Switch - Working floodlight / E10 / E11 14 .......................................................................................................................
S8 Switch - Working floodlight / E12 / E13 15 .......................................................................................................................
S9 Switch / beacon * 15 ..............................................................................................................................................................................
S12 Switch for Y11 / Y12 * 7 ......................................................................................................................................................................
S13 Switch Wiper motor / rear 16 .........................................................................................................................................................
S14 Switch - Bucket return / Y9 18 ......................................................................................................................................................
S15 Switch Hoist limit shut off / Y8 17 ..............................................................................................................................................
S16 Switch Engine compartment illumination. E5 20 ........................................................................................................
V1 Diodes Y8 / Y9 17 .....................................................................................................................................................................................
V5 Diodes (Solenoid valves Y2, Y3, Y6, Y7, Y10, Y11, Y12) 8, 9 ....................................................................
X1 Plug connection 70-pole - ................................................................................................................................................................
X1b Screw connection 3-pole 1, 2 .......................................................................................................................................................
X1c Screw connection 3-pole 3 ..............................................................................................................................................................
X2 Round plug connection HD30 24-19 - ..................................................................................................................................
X3 Plug connection 24-pole front section - ..............................................................................................................................
X4 Plug connection 1-pole (terminal W) 1 .................................................................................................................................
X5a Round plug (M2 4st) 16 ......................................................................................................................................................................
X7 Plug connection 8-pole - ....................................................................................................................................................................
X11 Plug connection 2-pole (A3) 19 ...................................................................................................................................................
X16 Plug connection 2-pole (M7) 20 ..................................................................................................................................................
X17 Plug connection 6-pole (S16, E5, E14) - ...........................................................................................................................
X20 Round plug connection 4-pole (B14) 17 .............................................................................................................................
X21 Round plug connection 7-pole (S3) 12 ................................................................................................................................
X24 Plug connection 10-pole (S2, Y8, Y9) 7, 17 ...................................................................................................................
X24a Plug connection 2-pole (S2) 6 ......................................................................................................................................................
X28 Plug connection 8-pole (M3, M4, E12, E13) - ..............................................................................................................
X29 Plug connection AMP Junior Timer 3-pole (B21) 8 .................................................................................................
X33 Valve plug 4-pole (Y2 forw.) 8 ......................................................................................................................................................
X34 Valve plug 4-pole (Y3 rev.) 8 .........................................................................................................................................................
X35 Valve plug 4-pole (Y6 2-Step) 8 .................................................................................................................................................
X36 Valve plug 4-pole (Y7 3-Step) 9 .................................................................................................................................................
X37 Valve plug 4-pole (Y10 *) 9 .............................................................................................................................................................
X41 Socket 2-pole 19 ........................................................................................................................................................................................
X52 Plug connection 12-pole - ................................................................................................................................................................
Y1 Solenoid valve - Preglow 3 ..............................................................................................................................................................
Y2 Solenoid valve - Travel direction / forw. 8 .........................................................................................................................
Y3 Solenoid valve - Travel direction / rev. 8 ............................................................................................................................
Y4 Solenoid valve additional Starting aid 2 ..............................................................................................................................
Y5 Solenoid / Motor stop 2 .......................................................................................................................................................................
Y6 Solenoid valve Travel range ll 8 .................................................................................................................................................
Y7 Solenoid valve Travel range lll (L 522) 9 ..........................................................................................................................
Y8 Solenoid / Hoist limit shut off 17 .................................................................................................................................................
Y9 Solenoid / Bucket return 18 .............................................................................................................................................................
Y10 Solenoid valve / lnching gear * 9 ...............................................................................................................................................
11.93
CabIe Chart
L 512 / L 522 101-151/109-233
12.10.14
Current Iines / section 100
CabIe No. CabIe from - - to
100 Battery + Fuse F 50 A
101 Fuse F 50 A Plug connection X1 Pin 1
102 Plug connection X52 Pin 1 Switch S6 Pin 6, 9
103 Starter M1 Kl. 30 Alternator G1 Kl. 30
104 Switch S6 Pin 3 Round plug connection X25 Pin 3
105 Fuse F 50 A Screw connection X1b
106 Screw connection X1b Keyed switch S1 Pin 30
106 Circuit board Kl.1 Screw connection X1b
107 Circuit board Kl.1 Round plug connection X25 Pin 2
107 Circuit board Kl.1 Switch S6 Pin 2
108 Keyed switch S1 Pin 19 Preglow resistor R1
109 Keyed switch S1 Pin 17 Preglow resistor R1
109 Circuit board Kl. 2 Preglow resistor R1
110 Keyed switch S1 Pin 15 Plug connection X51 Pin 3
111 Electronic ST1 Pin 1 Plug connection X51 Pin 4
111 Plug connection X1 Pin 1 Plug connection X50 Pin 1
112 Plug connection S4 Pin 8 Switch S5 Pin 5
112 Plug connection X51 Pin 5 Switch B12
112 Plug connection X51 Pin 5 Relay K7 Pin 87
113 Switch Blower S11 Pin 3 Plug connection X50 Pin 5
114 Relay K6 Pin 86 Switch S9 Pin 5
114 Relay K6 Pin 86 Plug connection X1 Pin 26
114 Switch S9 Pin 5 Socket X41
114 Plug connection X41 Plug connection X51 Pin 1
115 Round plug connection X21 Pin 6 Plug connection X51 Pin 7
115 Plug connection X1 Pin 30 Switch S13 Pin 1
115 Switch S13 Pin 1 Plug connection X5a Pin 4
115 Relay K5 Pin 15 K8, K3, H23, H8, H7, H5, H11, H4, H6, P5, P3
117 Battery + Plug connection X50 Pin 3
118 Relay K8 Pin 87 Relay K8 Pin 30
119 Plug connection X1 Pin 64
Ground wires, Group 200
200 Ground connection / Rear section Round plug connection X2 Pin 8
203 Sensor Air filter B4 Round plug connection X24 Pin 1
204 Ground connection / lnstruments lndicator lights H2, H12, H10, H12
204 Ground connection / lnstruments lndicators P1, P3, P4, P5
204 Ground connection / lnstruments Plug connection St 1 Pin 2
205 Ground connection / lnstruments Socket X41
205 Ground connection / lnstruments Relay K5 Pin 31
205 Ground connection / lnstruments Plug connection X5a Pin 1
205 Ground connection / lnstruments Plug connection X7 Pin 6
205 Ground connection / lnstruments Plug connection X1 Pin 4,5,6,7
206 Ground connections / Rear section Oil cooler motor M6
207 Sensor Air filter B4 Thermo switch oil cooler B17
208 Ground connection / Rear section Thermo switch Oil cooler B17
209 Ground connection / Rear section Round plug connection X26 Pin 4
210 Switch Parking brake B5 Round plug connection X26 Pin 4
211 Ground connection / Rear section Plug connection X16 Pin 2
213 Plug connection X11 Pin 2 Plug connection X28 Pin 4, 6, 8
214 Plug connection X28 Pin 8 Thermo switch 100 B6
215 Thermo switch 100 B6 Tail light / left E6
216 Ground connection / Rear section Reverse travel warning device B16
217 Tail light / right E7 Reverse travel warning device B16
218 Plug connection X17 Pin 2 Tail light right E7
220 Plug connection X3 Pin 1 Round plug connection X20 Pin 3
222 Plug connection X3 Pin 3 Head light / left E3
224 Plug connection X3 Pin 4 Head light / right E4
226 Plug connection X3 Pin 5 Turn signal / left front H15
228 Plug connection X3 Pin 6 Turn signal / right front H16
229 Plug connection X2 Pin 8 Solenoid / Engine stop Y5
230 Solenoid / Engine stop Y5 V-belt switch B13
231 Plug connection X28 Pin 8 Working floodlights / right rear E13
232 Plug connection X28 Pin 8 Working floodlights / left rear E12
233 License plate illumination left. H14 Plug connection X17 Pin 4
234 Plug connection X17 Pin 4 License plate illumination , right H14
235 Plug connection X17 Pin 6 Engine compartment illumination E5
11.93
CabIe Chart
L 512 / L 522 101-151/109-233
12.10.15
Motor/ engine Iines and safety devices, group 300
300 Screw connection X1b Circuit board Kl. 8
301 Alternator Kl. 61 Round plug connection X2 Pin 1
301 Plug connection X53 Pin 7 Emergency blinker switch S4 Pin 4 / 6
302 Emergency blinker switch S4 Pin 5 Plug connection X53 Pin 8
302 Plug connection 53 Pin 8 Round plug connection X21 Pin 5
303 Plug connection X1 Pin 15 Emergency blinker switch S4 Pin 1
303 Emergency blinker switch S4 Pin 1 Round plug connection X21 Pin 2
305 Emergency blinker switch S4 Pin 3 Round plug connection X21 Pin 3
306 Plug connection X53 Pin 3 lndicator light H6
306 lndicator light H6 Hour meter P1 Pin +
307 Solenoid valve / Preglow Y1 Flame glow plug R3
308 Flame glow plug R3 Round plug connection X2 Pin 10
309 lndicator light H2 Circuit board Kl. 5
309 Circuit board Kl. 5 Screw connection X1c
310 Round plug connection X2 Pin 10 Screw connection X1c
311 Plug connection X1 Pin 9 Relay Engine stop K3 Pin 85
312 Screw connection X1b Relay Engine stop K3 Pin 30
313 Round plug connection X2 Pin 12 Screw connection X1b
314 Solenoid Engine stop Y5 Round plug connection X2 Pin 12
316 Transmitter B13 Round plug connection X2 Pin 2
317 Round plug connection X2 Pin 14 Screw connection X1b
318 Starter M1 Kl. 50 Round plug connection X2 Pin 14
319 Solenoid valve / Y4 Starter M1 Kl. 50
320 Circuit board Kl. 7 Keyed switch S1 Pin 50a
321 Relay K6 Pin 87 Circuit board Kl. 4
322 Screw connection X1C Relay K6 Pin 30
323 Oil cooler motor M6 Screw connection X1c
325 Thermo switch B17 Plug connection X1 Pin 10
328 Plug connection X1 Pin 55 Brake light switch B12
331 Round plug connection X5a Pin 3 Round plug connection X21 Pin 1
332 Relay K5 Pin 86 Round plug connection X25 Pin 6
333 Relay K5 Pin J Round plug connection X21 Pin 7
334 Relay K5 Pin 53 Round plug connection X21 Pin 4
335 Round plug connection X5a Pin 2 Relay K5 Pin 31b
339 Plug connection X1 Pin 32 Switch bucket return S14 Pin 1
Motor / engine Iines and safety devices Group 300
340 Electronic ST6 Pin 5 Switch S15 Pin 5
340 Switch S15 Pin 5 Switch S14 Pin 5
342 Blinker light H15 Plug connection X3 Pin 8
346 Circuit board Kl. 6 Switch S7 Pin 5
346 Switch S7 Pin 5 Switch S8 Pin 5
347 Relay Engine stop K3 Pin 87 Circuit board Kl. 3
348 Plug connection X1 Pin 31 Switch Hoist limit control S15 Pin 1
ControI instruments, Group 400
400 Plug connection X1 Pin 16 Fuel level indicator P3
401 lndicator / Fuel B8 Plug connection X1 Pin 16
402 lndicator light H4 Electronic ST5 Pin 3
404 Electronic ST5 Pin 1 lndicator light H5
406 Plug connection X1 Pin 19 Engine oil temperature indicator P5
409 Transmitter B4 Plug connection X1 Pin 20
411 Transmitter Emergency steering B3 Plug connection X1 Pin 21
412 Plug connection X1 Pin 22 Electronic ST2 Pin 2
412 Electronic ST2 Pin 2 Electronic ST7 Pin 3
413 Switch Parking brake B5 Plug connection X1 Pin 22
415 Thermo switch Hydr.oil B6 Plug connection X1 Pin 23
416 Transmitter engine oil pressure B7 Round plug connection X2 Pin 3
417 Thermo switch 150 B2 Round plug connection X2 Pin 4
418 lndicator light- forward H3 Electronic ST6 Pin 2
419 lndicator light-reverse H9 Electronic ST6 Pin 4
423 Tachometer P4 Pin + Electronic ST4 Pin 3
424 Tachometer P4 Pin - Electronic ST4 Pin 4
425 Plug connection X52 Pin 11 lndicator light / high beam H12
426 lndicator light H10 Plug connection X53 Pin 9
427 lndicator / motor temperature B1 Round plug connection X2 Pin 5
428 Transmitter B13 Thermo switch 150 B2
11.93
CabIe Chart
L 512 / L 522 101-151/109-233
12.10.16
EIectricaI equipment, group 500
500 Switch S12 Pin 5 Electronic ST3 Pin 1
501 Switch S12 Pin 10 Electronic ST3 Pin 6
516 Plug connection X3 Pin 13 Plug connection X22 Pin 2/4
521 Solenoid Hoist limit shut off Y8 Round plug connection X24 Pin 8
522 Solenoid Bucket return Y9 Round plug connection X24 Pin 9
SoIenoid vaIves, eIectricaI connection, group 600
607 Round plug connection X24 Pin 4 Plug connection + X1 Pin 37
613 Round plug connection X24a Pin 1 Plug connection X1 Pin 43
614 Round plug connection X24a Pin 2 Round plug connection X2 Pin 1
616 Valve plug X38 Cl. 1 Plug connection X3 Pin 14
620 Valve plug X33 Cl.1 Plug connection X1 Pin 47
11.93
CabIe Chart
L 512 / L 522 101-151/109-233
12.10.17
Lighting system, group 700
701 Plug connection X52 Pin 3 RounD plug connection X25 Pin 5
709 Reverse travel warning device B16 Plug connection X1 Pin 52
710 Emergency blinker switch S4 Pin 7 lndicators P5, P3,
P4
711 Plug connection X1 Pin 54 Plug connection + X7 Pin 3
712 Profile lighting / left E8 Plug connection X7 Pin 2
713 Profile lighting / right E9 Plug connection X7 Pin 3
714 Tail light / left E6 Plug connection X1 Pin 53
715 Plug connection X1 Pin 54 Tail light / right E7
716 Plug connection X17 Pin 3 Tail light / right E7
718 Brake lights H20 /
H21
Plug connection X1 Pin 55
720 License plate illumination E14 Plug connection X17 Pin 3
721 License plate illumination / left E14 K License plate illumination / right E14
722 Head light / left E3 Plug connection X3 Pin 16
723 Head light / right E4 Plug connection X3 Pin 17
730 Working floodlight E12 /
E13
Plug connection X28 Pin 7
731 Working floodlight E11 Plug connection X7 Pin 1
732 Working floodlight E10 Plug connection X7 Pin 1
733 lnterior light E2 Plug connection X7 Pin 4
734 Beacon H22 Plug connection X7 Pin 5
735 Plug connection X17 Pin 5 Switch S16
735 Switch S16 Engine compartment illumination E5
Test Iines, group 800
800 Round plug connection X2 Pin 6 Alternator G1
800 Alternator G1 Plug connection X4
11.93
EIectronic ControI
L 512 / L 522 101-151/101-233
12.10.20
1. DESCRIPTION OF FUNCTION:
The electronic control is installed in the left hand side of the instrument panel.
1.1 Protective and supportive functions of the eIectronic controI:
Bulb check, warning signal transmitter - buzzer, starting lock, reverse lock, control of electronic speedo-
meter, control of travel ranges and control of additional functions.
2.1 SeIection of traveI direction is onIy possibIe:
after starting the Diesel engine (terminal 61)
2.2 The preseIection of the traveI direction wiII be eIiminated:
if the parking brake is applied
if the Diesel engine is turned off
if there is no current on the electronic system
if the button for neutral gear is pushed (signal from terminal 61 is being interrupted)
if the alternator fails (terminal 61)
2.3 Incoming:
- Signal from terminal 61 of the alternator (analog)
- Button "Forward" (active grounded)
- Button "Reverse" (active grounded)
2.4 Outgoing:
- Solenoid valve - travel direction "FORWARD" (Solenoid valve , max. 1 A)
- lndicator light for travel direction "Forward" (Bulb 24 V / 1,2 W)
- Solenoid valve - travel direction "REVERSE" (Solenoid valve, max. 1 A)
- lndicator light for travel direction "Reverse" (Bulb 24 V / 1,2 W)
- When the starter switch S 1 is turned on, travel range I is always selected,
indicator light for travel range I lights up.
3.2 TraveI range II and III : (Travel range III only for L 522)
- Preselection of travel range is only possible if the signal from terminal 61 is available.
- lf the switch is changed by turning the control lever counterclockwise, the gear shifts to the next
higher travel range.
lf the lever is held in that direction for a longer period of time, the setting remains the same, it
has no further influence.
- lf the switch is changed by turning the control lever in clockwise direction, the gear shifts back to
the next lower travel range.
lf the lever is held in that direction for a longer period of time, the setting remains the same, it
has no further influence.
- The control lever returns automatically to center position as soon as it is released, only then is it
possible to change to the next higher or lower travel range (gear).
- Delay time for shifting up or down between the different gear is 200 ms .
3.3 Incoming:
- Signal " shift up"(active grounded)
- Signal from terminal 61 of the alternator (analog)
3.4 Outgoing:
- lndicator light for l. travel range (Light bulb 24 V / 1,2 W)
- Solenoid valve for ll. travel range (Solenoid 24 V / 30 W)
- lndicator light for ll. travel range (Light bulb 24 V / 1,2 W)
- Solenoid valve for lll. travel range ( Solenoid 24 V / 30 W)
- lndicator light for lll. travel range (Light bulb 24 V / 1,2 W)
4. BUCKET RETURN AND HOIST LIMIT SHUT OFF:
4.1 Activated
- via switch S 14 Bucket return or S 15 Hoist limit shut off on instrument panel
- Functions only if signal is coming from terminal 61
4.2 Incoming:
- Signal from terminal 61 of alternator
4.3 Outgoing:
- 24 V Voltage supply
5. ADDITIONAL FUNCTIONS:
5.1 Activated
- via switch S 12
- Actuated via 2 buttons on the control lever S2 for 2 possible outlets
5.2 Incoming: (active grounded)
- Switch - additional function
- Button 1 Additional function 1
- Button 2 - additional function 2
5.3 Outgoing:
- Solenoid valve - additional function 1 ( Solenoid 24 V / 30 W)
- Solenoid valve - additional function 2 (Solenoid 24 V / 30 W)
- optical indicator - additional function (Light bulb 24 V / 1,2 W)
07.94
EIectronic ControI
L 512 / L 522 101-151/101-233
12.10.21
6. Reverse traveI Iock :
- At a speed of more than 16 km/h, it is not possible to change travel direction .
6.1 Incoming:
- lncoming signal "plus" Speed sensor
- lncoming signal "minus" Speed sensor
6.2 Outgoing:
- Speedometer signal "plus"
- Speedometer signal "minus"
7. BuIb check:
- after turning the starter switch S 1 to position I , a bulb check is done for about 4 seconds for
the following indicator lights:
7.1 Incoming: (grounded)
- Engine overheat H 5 (bulb 24 V / 1,2 W)
- Hydraulic oil overheat H 23 (bulb 24 V / 1,2 W)
- Parking brake H 11 (bulb 24 V / 1,2 W)
- Air filter contamination H 7 (bulb 24 V / 1,2 W)
8. Monitor "Speed sensor":
- in case of failure of the speed sensor, the system always shifts to travel range I and the LED 7
on the circuit board blinks.
8.1 Incoming:
- lncoming signal "plus" speed sensor
- lncoming signal "minus" speed sensor
9. Warning function ( Buzzer):
- in addition to the optical indication of certain warning messages, an acoustical warning is also
triggered.
9.1 Incoming: (grounded)
- Engine overheat
- Reserve for 5 additional warning signals
10. TechnicaI Data:
- Fuse : 1,25 AT
- Voltage supply: 24 V system
- Temperature range: -25C to +85C
- Size: size of circuit board, max. 160 x 160 mm
- 21 inlets
- 19 outlets
- 6 End stages control outlets 5 V - 42 V, high voltage protections ~ 36,5 V
Connector assignment - EIectronic controI
Connector 1:
St 1.1 Voltage supply "24 V"
St 1.2 Voltage supply " ground"
Connector 2:
St 2.1 Signal terminal 61 of alternator
St 2.2 Signal switch - parking brake
St 2.3 Signal button "Forward" (active , grounded)
St 2.4 Signal button "Reverse" (active, grounded)
St 2.5 Signal button "Shift up" (active, grounded)
St 2.6 Signal button "Shift down" (active, grounded)
Connector 3:
St 3.1 Signal switch "Additional functions" (active, grounded)
St 3.2 Signal button "Additional function 1" (active, grounded)
St 3.3 Signal button "Additional function 2" (active, grounded)
St 3.4 Supply voltage for solenoid valve "Additional function 1"
St 3.5 Supply voltage for solenoid valve "Additional function 2"
St 3.6 Signal for indicator light " Additional functions" (active 24V)
Connector 4:
St 4.1 lncoming signal "plus" of speed sensor
St 4.2 lncoming signal "minus" of speed sensor
St 4.3 Speedometer signal "plus"
St 4.4 Speedometer signal "minus"
Connector 5:
St 5.1 Warning function " Engine overheat"
St 5.2 Warning function "Hydraulic oil overheat"
St 5.3 Warning function "Engine oil pressure "
St 5.4 not used
St 5.5 not used
St 5.6 not used
St 5.7 not used
St 5.8 not used
Connector 6:
St 6.1 Supply voltage for solenoid valve "Forward"
St 6.2 lndicator light for travel direction "Forward"
St 6.3 Supply voltage for solenoid valve "Reverse"
St 6.4 lndicator light for travel direction "Reverse"
St 6.5 Supply voltage for "Hoist limit shut off" and "bucket return"
St 6.6 Supply voltage for solenoid valve travel range ll
St 6.8 Supply voltage for solenoid valve travel range lll
St 6.9 lndicator light for travel range lll
Connector 7:
St 7.1 lndicator light "Engine overheat"
St 7.2 lndicator light "Hydraulic oil overheat"
St 7.3 lndicator light "Parking brake "
St 7.4 lndicator light "Air filter contamination"
07.94
BIock Wiring Diagram
L 512 / L 522 101-151/101-233
12.10.22
1 Overvoltage protection
2 Pole protection
3 Control output
4 Control output
5 Control output
6 Control output
7 Control output
8 Control output
9 Adapter
10 Monitor
11 Transformer
12 programable logic
13 Monitor
14 Bulb check
15 Opto coupler
16 Opto coupler
EIectronic controI A1
1 Fuse 1,25 AT
2 Control outlet Travel direction
"FORWARD"
2a Problem indicator
"FORWARD" LED 1 .............................
3 Control outlet Travel direction
"REVERSE"
"REVERSE" LED 2 ..............................
4 Control outlet Travel range ll
Travel range ll LED 3 ...........................
5 Control outlet Travel range lll
Travel range lll LED 4 ..........................
6 Control outlet Additional function 1
Additional function 1 LED 5 ..................
7 Control outlet Additional function 2
Additional function 2 LED 6 ..................
8 Coding switch
9 Problem indicator
"Speed sensor" LED 7 .........................
10 Buzzer
11 Plug 1 "Voltage supply - Electronic
control (24V)
12 Plug 2 "lncoming signals - Travel lo-
gic"
13 Plug 3 "lnput/Output Additional
function"
14 Plug 4 "Speed sensor, Speedometer
15 Plug 5 lnputs for warning functions
(problem notification)
16 Plug 6 Outputs for travel functions,
hoist limit shut off and bucket return
17 Plug 7 Outputs for bulb check
18 Potentiometer speedometer
19 Potentiometer reverse travel lock
Note: Problem indicators LED 1 - 6 are only actuated if there is a short circuit - not if there is a broken
line.
free pIugs for: PIug designation:
Switch - inching gear S5 8-pole
Switch illumination S5 K5 2-pole
Switch - beacon S9 8-pole
Switch - Additional equipment. S12 8-pole
05.95
Id. No. 975729001
L 512 / L 522 101-151/101-233
12.10.23
Note:
Electronic control, ld. No. 975729001 has been replaced by ld. No. 975796701 (see page
12.11.24).
L 522 to S/N 321 is only operational with electronic control, ld. No. 975729001 (Machines with
travel range lll).
Adjustment Chart - speedometer coding
Machine Coding
switch
Switch
position
Frequency
at 10 km/h
L 512 2 ON 810 Hz
L 522 1+3 ON 780 Hz
Remaining coding switches are at OFF
Note:
Code electronic control according to the adjustment chart (important for correct speed indication
and also for shifting of travel ranges - L 522 up to S/N 321 lll travel range)
Seal switch position after coding (lacquer, ld. No. 7005 588)
07.94
TroubIeshooting
EIectronic ControI
L 512 / L 522 101-151/101-233
12.10.24
ProbIem Cause Remedy
- Bulb check functions only
partially or not at all when igni-
tion is turned on
- no voltage supply
- Fuse F7 is defective
- Wire / Plug ST7 defective
- lndicator lights defective
- Replace fuse F7
- Check wire / plug
- Gear always jumps to travel
range l
- Problem indicator 9 blinks
- Speed sensor or wire / plug
ST4 to sensor are defective
- Check wire / plug
- Replace sensor
- Travel is only possible in tra-
vel range l
- No voltage supply
- Fuse F7 defective
- Button / wire / plug ST6 to
shift up is defective
- Signal from terminal 61 is mis-
sing
- Plug ST6 / wire / solenoid for
travel range ll is defective
- Replace fuse F7
- Check button / wire / plug to
shift up
- Check plug / wire or solenoid
for travel range ll
- Travel only possible in
travel range ll
- Button / wire / plug ST2 to
shift up / down
is defective
- Plug ST6 / wire / solenoid val-
ve travel range lll is defective
- Coding is incorrect
- Check button / wire / plug to
shift up / down
- Check plug / wire / solenoid
valve travel range lll
- Code correctly
- No voltage supply
- Fuse F7 defective
- Signal Terminal 61 missing
- Plug ST2 / button / wire / sole-
noid valve for travel direction
is defective
- Replace fuse F7
- Check signal Terminal 61
- Check plug / button / wire /
solenoid valve for travel direc-
tion
light up
- Plug ST6 is not
connected
- Temperature is too high in fi-
nal stage 2 to 6 due to short
circuit in corresponding wire or
solenoid valves or overheating
- Connect plug
- Check wire / solenoid valves
function do not light up; travel
function is OK
- Plug ST6 / wire to correspon-
ding indicator light is defective
- Check plug / wire to corre-
sponding indicator light
- Travel functions are not al-
right, indicator lights are OK
- Plug ST6 / wire / solenoid
valve to corresponding travel
function is defective
- Check plug / wire / solenoid
valve to corresponding travel
function
ProbIem Cause Remedy
- Hoist limit shut off and bucket
return do not function
- No voltage supply
- Fuse F7 is defective
- Plug ST6 / wire defective
- Signal Terminal 61 is missing
- Replace fuse F7
- Check plug / wire
- Check signal Terminal 61
- Speedometer indicator does
not function
- Plug ST4 / wire defective
- Speedometer is defective
- Speedometer sensor is defec-
tive
- Check plug / wire
- Replace speedometer
- Check sensor
- Speed indication
does not match the actual tra-
vel speed
- Coding 8 is incorrect
- Speedometer is incorrect or
defective
- Code correctly
- Check speedometer
- Additional functions are not
functioning properly
- Switch / button /
Plug ST3 / wire / solenoid val-
ve are defective
wire / solenoid valve
VoItage suppIy for troubIe shooting, when engine is not running:
For troubleshooting, a line can be laid from ST1 Pin 1 (+) to ST2 Pin 1.
(to avoid short circuit disconnect the line on neutral switch - button N" for neutral position of travel
direction - or keep the button depressed)
11.93
L 512 / L 522 152 / 234
12.11.01
33
G2 Batteries
2 x 12 V 88 Ah
34
F Main Fuses:
50 A Main fuse
25 A Added user (Special equipment)
35
FUSE BOX A, B in instrument paneI
36
FA1 25 A Solenoid - Engine stop
FA2 20 A Oil cooler motor
FA3 15 A Working floodlights
FA4 15 A Electr. socket, beacon,
interior lighting, radio
FA5 30 A Preglow
FA6 7,5 A Emergency blinker system
FA7 5 A Electronic control
FA8 7,5 A Brake light, additional installations, blinker
FA9 15 A Blower motor
FA10 15 A Windshield wiper, flushing motor, horn
FA11 7,5 A Reserve fuse
FB1 7,5 A lndicator instruments, indicator lights
FB2 7,5 A Parking, tail, profile light, left,
lnstrument lighting
FB3 7,5 A Parking, tail, profile light, right, License
plate illumination
FB4 7,5 A Low beam, left
FB5 7,5 A Low beam, right
FB6 7,5 A High beam, left
FB7 7,5 A High beam, right
FB8 7,5 A Reserve fuse
FB9 15 A Preglow, switch illumination
37
38
39
M1 Starter 24 V / 4,0 KW
40
Y5 Solenoid Engine stop
Pick up current 20 A
Holding current 0,5 A
Adjustment: see page 8.20.01
11.93
L 512 / L 522 152 / 234
12.11.02
41
B1 lndicator Engine oil temperature
42
B2 Thermo switch - engine overheat 150C
43
B3 Transmitter - emergency steering
(flow indicator in valve block 20)
44
B4 Transmitter - air filter contamination
45
B5 Switch - Parking brake
Function:
lndicator light
Travel lock
46
B6 Thermo switch Hydraulic oil-
overheat 100C
47
B7 Transmitter - engine oil pressure
48
B8 lndicator - fuel level
11.93
L 512 / L 522 152 / 234
12.11.03
49
B12 Pressure switch - brake lights
50
B13 Transmitter - V-belt monitor
51
B15 Proximity switch - bucket return
Type for Z-bar kinematics:
AP024 SEMY 029383
Type for P-kinematics:
RP024RK 050680
52
B 17 Thermo switch - oil cooler 70 / 65
53
B 21 lnductive transmitter - travel speed
54
R 3 Flame glow plug
55
Y 1 Solenoid valve - preglow
56
A 1 Electronic control
05.95
L 512 / L 522 152 / 234
12.11.04
57
S 2 Travel range switch
L 512 up to S/N 263
L 522 up to S/N 385
a = shift up
b = shift down
N = Button for neutral position of
travel direction
F = Travel direction - forward
R = Travel direction - reverse
L 512 Travel range I =0- 8,0 km/h
Travel range II=0- 32,0 km/h
L 522 From S/N 101 to 321
Travel range I =0- 8,0 km/h
Travel range III =0- 32,0 km/h
L 522 from S/N 322
Travel range I =0- 8,0 km/h
58
Y 6 Solenoid valve - Travel range ll
L 512 from S/N 101
L 522 from S/N 322
59
Y 6 Solenoid valve - Travel range ll
Y 7 Solenoid valve - Travel range lll
L 522 up to S/N 321
60
Y 2 Solenoid valve - travel direction forward
Y 3 Solenoid valve - travel direction reverse
L 512 up to S/N 263
L 522 up to S/N 385
61
L 512 from S/N 264
L 522 from S/N 386
F = Travel direction forward
R = Travel direction reverse
l = Travel range l 0-8 km/h
ll = Travel range ll 0-32 km/h
N = Neutral position of travel direction
Note:
At every change, a signal will sound.
62
Y 2 Solenoid valve - travel direction, forward
Y 3 Solenoid valve - travel direction, reverse
(Current consumption, approx. 1.5 A)
L 512 from S/N 264
L 522 from S/N 386
63
64
11.93
Positions
PIug Connections
L 512 / L 522 152 / 234
12.11.10
F Main fuse
X1b Screw connection 3-pole
X1c Screw connection 3-pole
X41 Socket 2-pole
P = Parking position
0 = 0 - Position / engine off
l = Contact- operating- preglow position
ll = Starting position
05.97
Item Listing
L 512 / L 522 152 / 234
12.11.11
A1 Electronic control 7, 8, 9 .....................................................................................................................................................................
A3 Radio * 19 .........................................................................................................................................................................................................
B1 lndicator - engine oil temperature 4 ........................................................................................................................................
B3 Transmitter - emergency steering (flow indicator) 5 ...............................................................................................
B4 Transmitter - air filter contamination 5 ..................................................................................................................................
B5 Switch - parking brake / travel lock 4 .....................................................................................................................................
B6 Thermo switch Hydraulic oil overheat 100 C 5 ..........................................................................................................
B7 Pressure switch - engine oil pressure 5 ..............................................................................................................................
B8 lndicator - fuel level 5, 6 .....................................................................................................................................................................
B9 Pressure switch - Quick change installation * 4 ..........................................................................................................
B10 Horn 13 ................................................................................................................................................................................................................
B11 Loudspeaker * 19 ......................................................................................................................................................................................
B12 Pressure switch - Brake light 6 ....................................................................................................................................................
B13 Transmitter - V-belt monitor 2 .......................................................................................................................................................
B15 Proximity switch - bucket return / Y9 17, 18 ...................................................................................................................
B16 Reverse travel warning device * 10 .........................................................................................................................................
B17 Thermo switch - oil cooler 70 C / 65 C 3 .......................................................................................................................
B19 Pressure switch - accumulator pressure/Brake 6 .....................................................................................................
B21 lnductive sensor - travel speed 8, 9 .......................................................................................................................................
E3 Head light / left 12, 13 ...........................................................................................................................................................................
E6 Tail light / left 12 .........................................................................................................................................................................................
E9 Profile light / right 12 ..............................................................................................................................................................................
E10 Working floodlight / left front 14 ...................................................................................................................................................
E11 Working floodlight / right front 14 ...............................................................................................................................................
E12 Working floodlight / left rear 15 ....................................................................................................................................................
E13 Working floodlight / right rear 15 ................................................................................................................................................
E14 License plate illumination 14 ..........................................................................................................................................................
Fuses F, FA1 - 11, FB1 - 9
F Fuse box 50 A, 25 A (Main fuse) 1 ..........................................................................................................................................
FA1 25 A Solenoid - engine stop 2 ......................................................................................................................................................
FA2 20 A Oil cooler motor 3 .......................................................................................................................................................................
FA3 15 A Working floodlights 14, 15 ..................................................................................................................................................
FA4 15 A lnterior lighting, beacon, 2-pol socket, Radio 15 ..........................................................................................
FA5 30 A Preglow 3 ............................................................................................................................................................................................
FA6 7,5 A Emergency blinker system 14 .......................................................................................................................................
FA7 5 A Electronic control 7 .......................................................................................................................................................................
FA8 7,5 A Brake light, blinker, additional installations 10 ..............................................................................................
FA9 15 A Fan motor 18 ...................................................................................................................................................................................
FA10 15 A Windshield wiper, horn, flushing motor 16 .........................................................................................................
FA11 7,5 A Reserve fuse 18 ..........................................................................................................................................................................
FB1 7,5 A lnstruments, indicator lights 2 .......................................................................................................................................
FB2 7,5 A Parking,- tail,- profile lights / left, instrument illumination 12 ...........................................................
FB3 7,5 A Parking,- tail,- profile lights / right,
license plate illumination 13 ............................................................................................................................................................
FB4 7,5 A Low beam left 12, 13 ..............................................................................................................................................................
FB5 7,5 A Low beam right 13 ....................................................................................................................................................................
FB6 7,5 A High beam left 12, 13 ............................................................................................................................................................
FB7 7,5 A High beam right 13 ...................................................................................................................................................................
FB9 7,5 A Switch illumination, preglow relay 17 .....................................................................................................................
F19 2 A Transformer f. Radio * 19 .......................................................................................................................................................
G2 Batteries 1 ........................................................................................................................................................................................................
H1 lndicator light - travel range l 4, 5, 6 .......................................................................................................................................
H2 lndicator light - Preglow "ON" 4, 5, 6 .....................................................................................................................................
H3 lndicator light - forward / Y2 4, 5, 6 ..........................................................................................................................................
H4 lndicator light - Engine oil pressure 4, 5, 6 .......................................................................................................................
H5 lndicator light - Engine overheat (cylinder temperature 150C)
1)
4, 5, 6 ...........................................
H6 lndicator light - - battery charge 4, 5, 6 ................................................................................................................................
H7 lndicator light - Air filter contamination 4, 5, 6 ...............................................................................................................
H8 lndicator light - Flow indicator 4, 5, 6 .....................................................................................................................................
H9 lndicator light - reverse / Y3 4, 5, 6 ..........................................................................................................................................
H10 lndicator light - Blinker 4, 5, 6 ........................................................................................................................................................
H11 lndicator light - - Parking brake "APPLlED" 4, 5, 6 ..................................................................................................
H12 lndicator light - High beam 4, 5, 6 .............................................................................................................................................
H13 lndicator light - Travel range ll 4, 5, 6 ...................................................................................................................................
H14 lndicator light - Travel range lll
3)
4, 5, 6 .............................................................................................................................
H15 Blinker, left front 14 .................................................................................................................................................................................
H16 Blinker, right front 14 ..............................................................................................................................................................................
H17 Blinker, left rear 14 ...................................................................................................................................................................................
H18 Blinker, right rear 14 ...............................................................................................................................................................................
H19 lndicator light - Quick change coupling 4 ..........................................................................................................................
H20 Brake light, left / B12 6 .........................................................................................................................................................................
H21 Brake light, right / B12 6 .....................................................................................................................................................................
H22 Beacon * 15 ....................................................................................................................................................................................................
H23 lndicator light - Hydraulic oil overheat 4, 5 ......................................................................................................................
H24 lndicator light - Accumulator pressure/Brake 4, 5, 6 ..............................................................................................
K1 Relay blinker 13, 14 ................................................................................................................................................................................
K2 Relay preglow time 20 sec. 3 ........................................................................................................................................................
K3 Relay engine stop / Y5 2 ...................................................................................................................................................................
K5 Relay Wipe-Wash-lnterval 15, 16 .............................................................................................................................................
K6 Relay Oil cooler motor / M6 3 .......................................................................................................................................................
K7 Relay Reverse travel warning device * 10 ........................................................................................................................
K8 Relay Supply - Electronic control 3 .........................................................................................................................................
1)
= L 512 from S/N 263 and L 522 from S/N 385 indicates engine oil overheat above 130 C.
05.97
Item Listing
L 512 / L 522 152 / 234
12.11.11/1
M1 Starter motor 2 .............................................................................................................................................................................................
M2 Wiper motor front 15, 16 ....................................................................................................................................................................
M4 Windshield flushing motor 16 ........................................................................................................................................................
M7 Compressor Operator's seat * 19 ..............................................................................................................................................
P1 Hour meter 4, 5 ...........................................................................................................................................................................................
P3 Fuel level indicator 4 ..............................................................................................................................................................................
P4 Electronic speedometer 4, 5 ..........................................................................................................................................................
P5 Engine oil temperature indicator
2)
5, 6 ...............................................................................................................................
R3 Flame glow plug 3 ....................................................................................................................................................................................
R5 Transformer * 19 ........................................................................................................................................................................................
S1 Keyed switch 2 ............................................................................................................................................................................................
S2 Travel range switch 7, 8 .....................................................................................................................................................................
S4 Emergency blinker switch / K1 13, 14 ...................................................................................................................................
S5 Switch - lnching gear * 17 .................................................................................................................................................................
S7 Switch - Working floodlights / E10 / E11 14, 15 ..........................................................................................................
S8 Switch - Working floodlights / E12 / E13 15 ....................................................................................................................
S9 Switch - Beacon * 15 .............................................................................................................................................................................
S11 Switch - Heater fan / M5 18 .............................................................................................................................................................
S12 Switch - for Y11 / Y12 * 8 ..................................................................................................................................................................
S13 Switch - Wiper motor rear 16 .........................................................................................................................................................
S14 Switch - Bucket return / Y9 17 ......................................................................................................................................................
S15 Neutral switch / travel direction 7 ..............................................................................................................................................
S16 Switch - Quick change coupler * 20 ........................................................................................................................................
V1 Diode / Y9 17 .................................................................................................................................................................................................
V2 Diode (Lock bulb check) 7, 8 ........................................................................................................................................................
V3 Diode
V5 Diode solenoid valves Y2, Y3, Y6, Y7, Y10, Y11, Y12 8, 9 ............................................................................
Plug connections A, B, C, D lndicator lnstruments 4, 5, 6 ...............................................................................
ST1 Plug connection Electronic A1 2-pole 7 ..............................................................................................................................
2)
= L 512 from S/N 263 and L 522 from S/N 385 indicates cylinder temperature above 150 C
X1 Plug connection 70-pole 1-19 ......................................................................................................................................................
X1b Screw connection 3-pole 1, 2 .......................................................................................................................................................
X1c Screw connection 3-pole 3 ..............................................................................................................................................................
X3 Plug connection 24-pole front section 8-17 ....................................................................................................................
X4 Plug connection 1-pole (Terminal W) 1, 2 ........................................................................................................................
X5 Plug connection 8-pole (K2) 3 ......................................................................................................................................................
X5a Plug connection 4-pole (M2) 16 ..................................................................................................................................................
X7 Plug connection 8-pole 12-15 .......................................................................................................................................................
X11 Plug connection 2-pole (A3) 19 ...................................................................................................................................................
X17 Plug connection 6-pole (E14) 13, 15 ......................................................................................................................................
X21 Round plug connection 7-pole (S3) 12, 13 ......................................................................................................................
X24 Plug connection 10-pole (S2, Y9) 7, 8, 17 .......................................................................................................................
X24a Plug connection 2-pole (S15) 7 ...................................................................................................................................................
X28 Plug connection 8-pole (M3, M4, E12, E13) 15-17 .................................................................................................
X29 Plug connection AMP Junior Timer 3-pole (B21) 9 .................................................................................................
X32 Valve plug 4-pole (Y14) * 9 .............................................................................................................................................................
X33 Valve plug 4-pole (Y2) 9 ....................................................................................................................................................................
X36 Valve plug 4-pole (Y7) 10 .................................................................................................................................................................
X37 Valve plug 4-pole (Y10) 17 ..............................................................................................................................................................
X41 Socket 2-pole 18, 19 ..............................................................................................................................................................................
Y1 Solenoid valve - Preglow 3 ..............................................................................................................................................................
Y2 Solenoid valve - Travel direction forw. 9 ............................................................................................................................
Y3 Solenoid valve - Travel direction rev. 9 ...............................................................................................................................
Y4 Solenoid valve - additional starting aid 2 ...........................................................................................................................
Y5 Solenoid - Engine stop 2, 3 ............................................................................................................................................................
Y6 Solenoid valve - Travel range ll 9, 10 ...................................................................................................................................
Y7 Solenoid valve - Travel range lll
3)
10 ...................................................................................................................................
Y9 Solenoid - Bucket return 17 ............................................................................................................................................................
Y10 Solenoid valve - lnching gear * 17 ............................................................................................................................................
Y11 Solenoid valve - additional installation * 8, 9 .................................................................................................................
Y12 Solenoid valve - additional installation * 9 ........................................................................................................................
Y14 Solenoid valve - Quick change coupler * 7 ......................................................................................................................
3)
Note: valid only up to S/N 321
05.95
EIectronic ControI
Id. No. 975729001 and Id. No. 975796701
L 512 / L 522 152 / 234
12.11.20
1. FUNCTIONAL DESCRIPTION:
The electronic control is installed on the left hand side of the instrument panel.
1.1 Protective and support function of the eIectronic controI:
Bulb check, warning signal - buzzer, travel lock, reverse travel lock, control of electronic speedometer,
travel range and control of additional functions.
2.1 The seIection of traveI direction is onIy possibIe:
after the Diesel engine has been started (Signal from terminal 61)
if the brake accumulator system is filled
2.2 TraveI direction preseIection is turned off, if:
the control lever is turned into direction of travel range l (N) and held for 2 seconds (valid for
electronic control, ld. No. 975796701)
the parking brake is applied
the brake pressure drops
the Diesel engine is turned off
there is no power for the electronic control
the alternator is not functioning (terminal 61)
the neutral button is actuated (valid for machines with electronic control, ld. No. 975729001) Signal
from terminal 61 is interrupted.
2.3 InIets:
- Signal from brake accumulator system (active grounded)
- Button "forward" (active grounded)
- Button "reverse" (active grounded)
2.4 OutIets:
- Solenoid valve - travel direction "FORWARD" (Solenoid 24V / 30W)
- lndicator light for travel direction "forward" (bulb 24V / 2W)
- Solenoid valve - travel direction "REVERSE" (Solenoid 24V / 30W)
- lndicator light for travel direction "reverse" (bulb 24 V / 2 W)
- When turning the starter switch S 1 on, travel range I is always turned on,
optical indicator for travel range I lights up.
3.2 TraveI range II : (Travel range III only for L 522 up to S/N 321)
- Travel range preselection is only possible after signal from terminal 61 is available..
- Trigger the switch by turning the control lever counterclockwise to shift up from travel range l
into the next higher travel range.
lt is not necessary to hold the lever for a longer period of time in the trigger direction.
- Trigger the switch by turning the control lever clockwise to shift town into the next lower travel
range.
- Whenever the travel range is changed, a buzzer will sound (valid for electronic control, ld. No.
975796701).
- After releasing it, the control lever will return automatically to center position, then it is possible
again to shift up or down to the next higher or lower travel range.
- Delay time for shifting up or shifting down between the various travel ranges is 200 ms .
3.3 InIets:
- Signal "shift up"(active grounded)
3.4 OutIets:
- lndicator light for l. travel range (bulb 24 V / 2 W)
- Solenoid valve for ll. travel range (solenoid 24 V / 30 W)
- lndicator light for ll. travel range (bulb 24 V / 2 W)
- Solenoid valve for lll. travel range (solenoid 24 V / 30 W)
- lndicator light for lll.travel range (bulb 24 V / 2 W)
4. BUCKET RETURN :
4.1 Actuate
- via switch S 14 on instrument panel
- Functions only if signal is available from terminal 61
4.2 InIets:
- Signal from terminal 61 of alternator
4.3 OutIets:
- 24 V Voltage supply for bucket return
5. ADDED FUNCTIONS:
5.1 Acutate
- via switch S 12
- Control via 2 buttons on control lever S2 for 2 possible outlets
- Switch - added function
- Button 1 - added function 1
- Button 2 - added function 2
5.3 OutIets:
- Solenoid valve - added function 1 (solenoid 24 V / 30 W)
- Solenoid valve - added function 2 (solenoid 24 V / 30 W)
- Optical indicator - added function (bulb 24 V / 2 W)
05.95
EIectronic ControI
Id. No. 975729001 and Id. No. 975796701
L 512 / L 522 152 / 234
12.11.21
6. Reverse traveI Iock:
- lf the travel speed is higher than 16 km/h, the travel direction cannot be changed.
6.1 InIets:
- Signal inlet "plus" speed sensor
- Signal inlet "minus" speed sensor
6.2 OutIets:
- Speedometer signal "plus"
- Speedometer signal "minus"
7. BuIb check:
- After turning on the starter switch S1 to position I , the bulbs for the following indicator lights are
checked for about 4 seconds:
7.1 OutIets: (grounded)
- Engine overheat H 5 (Bulb 24 V / 2 W)
- Hydraulic oil overheat H 23 (Bulb 24 V / 2 W)
- Accumulator brake system H 24 (Bulb 24 V / 2 W)
- Air filter contamination H 7 (Bulb 24 V / 2 W)
8. Monitor "speed sensor":
- lf the speed sensor fails, the system always shifts back to travel range I and the indicator light
LED 7 on the circuit board blinks.
8.1 InIets:
- Signal inlet "plus" speed sensor
- Signal inlet "minus" speed sensor
9. Warning function (buzzer):
- ln addition to the optical indication of certain warning messages, an acoustical warning is also
given.
- acoustical indication also at every shifting procedure (valid for electronic control, ld. No.
975796701).
- Engine overheat
- Accumulator brake system
- Quick change system - pressure switch 5 bar
- Spare for 3 additional warning signals
10. TechnicaI data:
- Fuse : 1.25 AT (4.0 AT for electronic control, ld. No. 975796701)
- Voltage supply : 24 V power supply
- Temperature range: -25 to +85 degrees
- Measurements: Size of circuit board, max. 160 x 160 mm
- 21 lnlets
- 19 Outlets
- 6 final stages control outlets (5 V - 42 V), overvoltage surpressor ~36,5 V
PIug configuration - eIectronic controI
PIug 1: (InIets)
St 1.1 Voltage supply "24 V"
St 1.2 Voltage supply "ground"
PIug 2: (InIets)
St 2.1 Signal - terminal 61 of alternator
St 2.2 Signal - switch - parking brake switch accumulator brake
St 2.3 Signal - button "forward" (active grounded)
St 2.4 Signal - button " reverse" (active grounded)
St 2.5 Signal - button "shift up" (active grounded)
St 2.6 Signal - button "shift down" (active grounded)
PIug 3: (InIets)
St 3.1 Signal - switch "added functions" (active grounded)
St 3.2 Signal - button "added function 1" (active grounded)
St 3.3 Signal - button "added function 2" (active grounded)
(OutIets)
St 3.6 Signal for indicator light "added functions" (active 24V)
PIug 4:
St 4.1 Signal inlet "plus" for speed sensor
St 4.2 Signal inlet "minus" for Speed sensor
St 4.3 Speedometer signal "plus"
St 4.4 Speedometer signal "minus"
PIug 5: (InIets)
St 5.1 Warning function "engine overheat"
St 5.2 Warning function "hydraulic oil overheat"
St 5.3 Warning function "engine oil pressure"
St 5.4 Warning function "accumulator brake system"
St 5.5 Warning function "quick change device"
St 5.6 not used
St 5.7 not used
St 5.8 not used
PIug 6: (OutIets)
St 6.1 Voltage supply for solenoid valve "forward"
St 6.2 lndicator light for travel direction "forward"
St 6.3 Voltage supply for solenoid valve "reverse"
St 6.4 lndicator light for travel direction "reverse"
St 6.5 Voltage supply for "bucket return",
quick change device
St 6.6 Voltage supply for solenoid valve travel range ll
St 6.8 Voltage supply for solenoid valve Travel range lll
(only L 522 up to S/N 321)
St 6.9 lndicator light for travel range lll (only L 522 up to S/N 321)
PIug 7: (OutIets)
St 7.1 lndicator light "engine overheat"
St 7.2 lndicator light "hydraulic oil overheat"
St 7.3 lndicator light "accumulator brake system"
St 7.4 lndicator light "air filter contamination"
05.95
Wiring Diagram
Id. No. 975729001 and Id. No. 975796701
L 512 / L 522 152 / 234
12.11.22
PIug 8: (on eIectronic controI, Id. No. 975796701)
St 8.1 not used (outlets for bulb check)
1 Overvoltage surpressor
2 Pole protector
3 Control outlet
4 Control outlet
5 Control outlet
6 Control outlet
7 Control outlet
8 Control outlet
9 Acclimation
10 Monitoring
11 Transfer
12 Programmable logic
13 Monitoring
14 Bulb check
15 Optokoppler
16 Optokoppler
EIectronic ControI A1 ld. No. 975729001
1 Fuse 1.25 AT
2 Control outlet travel direction
"FORWARD"
"FORWARD" LED 1 .............................
3 Control outlet travel direction
"REVERSE"
"REVERSE" LED 2 ..............................
4 Control outlet - travel range ll
Travel range ll LED 3 ...........................
5 Control outlet - travel range lll
Travel range lll LED 4 ..........................
added function 2 LED 6 .......................
8 Coding switch
9 Problem indicator
"speed sensor" LED 7 ..........................
10 Buzzer
11 Plug 1 "Voltage supply - Electronic
control (24V)
12 Plug 2 "Signal inlets - travel logic"
13 Plug 3 "lnlet / outlet added function"
14 Plug 4 "Speed sensor, speedometer
15 Plug 5 lnlets for warning function (er-
ror messages)
16 Plug 6 Outlets for travel function and
bucket return
18 Potentiometer - speedometer outlet
19 Potentiometer - reverse travel lock
Note:
Problem indicators 2a - 7a are actuated in case of short circuit or overheat, not broken wires.
free pIugs for : PIug
description:
Switch - inching gear S5 8-pole
Switch - beacon S9 8-pole
Switch - added attachment S12 8-pole
05.95
Id. No. 975729001
L 512 / L 522 152 / 234
12.11.23
Note:
Electronic control, ld. No. 975729001 has been replaced by ld. No. 975796701
(see page 12.11.24).
L 522 up to S/N 321 is only operational with electronic control. ld. No. 975729001 (machines with
travel range lll).
Adjustment chart - speedometer coding
Machine Coding
switch
Switch
position
Frequency
at 10 km/h
L 512 2 ON 810 Hz
L 522
(101-321)
1+3 ON 780 Hz
L 522
(from 322)
2 ON 810 Hz
Remaining coding switches are at OFF
Note:
Code electronic control according to adjustment chart (important for correct speed indication and
also for shifting of travel ranges - L 522 up to S/N 321 lll travel range)
Seal switch positions after coding (lacquer, ld. No. 7005 588)
05.95
Id. Nr. 975796701
L 512 / L 522 101 / 322
12.11.24
EIectronic controI A1 Id. No. 975796701 (Id. No. is shown on the buzzer)
1 Fuse 4.0 AT
1a Monitor
Fuse LED 8 ..........................................
"FORWARD"
"VORWRTS" LED 1 ............................
"REVERSE"
"REVERSE" LED 2 ..............................
4 Control outlet - bucket return
bucket return LED 9 .............................
5 Control outlet - travel range ll
travel range ll LED 3 ............................
6 Control outlet added function 1
8 Coding switch
9 Problem indicator
"speed sensor" LED 7 ..........................
10 Buzzer
11 Plug 1 "voltage supply electronic con-
trol (24V)
12 Plug 2 "signal inlets travel logic"
13 Plug 3 "inlets / outlets Added function"
14 Plug 4 "speed sensor, speedometer
15 Plug 5 lnlets for warning function (er-
ror messages)
16 Plug 6 Outlets for travel function and
Bucket return
18 Plug 8 Outlets for bulb check (not
used)
19 Potentiometer - reverse travel lock
20 Potentiometer - speedometer outlet
Note: Problem indicators 2a - 7a will be actuated in case of short circuit or overheating - not in case of a
broken line or wire.
05.95
TroubIeshooting
EIectronic ControI
Id. Nr. 975729001 and Id. Nr. 975796701
L 512 / L 522 152 / 234
12.11.25
Error Cause Remedy
- Monitor indicator 1a
(LED 8) does not light up
- no voltage supply
- Monitor indicator 1a is
defective
- Replace fuse FA7
- Replace fuse 1
- Bulb check at ignition on does
not function, only
partially or not at all
- no voltage supply
- Wire / plug ST7 (ST8) is
defective
- lndicator lights are defective
- Replace fuse FA7
- Replace fuse 1
- Gear always jumps into travel
range l
- Monitor indictor 9
(LED7) blinks
- Speed sensor or cable / plug
ST4 to sensor is defective
- Replace sensor
range l
shift up / down defective
travel range ll is defective
shift up / down
- Check plug / cable or solenoid
for travel range ll
range ll
shift up / down is defective
- Plug ST6 / cable / solenoid
travel range lll defective
1)
- Coding wrong
shift up / down
travel range lll
1)
- Recode correctly
- no voltage supply
- Fuse 1 defective
- Pressure too low in
accumulator brake system
- Plug ST2 or ST6 / button /
cable / solenoid for
travel direction is defective
- Replace fuse FA7
- Replace fuse 1
- Check brake system
- Check plug / button / cable /
solenoid for travel direction
light up
- Plug ST6 not connected
- Short circuit or overheating of
corresponding outlet (cable in-
dicator light or solenoid)
- Connect plug
- Check cable / solenoids
Error Cause Remedy
functions do not light up, travel
functions are O.K
- Plug ST6 / cable to indicator
light is defective
- Check plug / cable for corre-
sponding indictor light
- Travel functions are not O.K.,
indicator lights are O.K
corresponding travel function
are defective
f or cor r espondi ng t r avel
function
- Bucket return is not
functioning
- no voltage supply
- Fuse 1 defective
- Replace fuse FA7
- Replace fuse 1
- Buzzer does not functi on
when reporting error message
- Steuerelectronic defective
- Replace electronic control
- Speedometer indicator does
not function
- Plug ST4 / Cable defective
- Speedometer defective
- Speed sensor defective
- Replace speedometer
- Check sensor
- Speed indicator
does not match travel speed
- Coding 8 is incorrect
- lncorrect speedometer or it is
defective
- Recode correctly
- Check speedometer
- Added f unct i ons do not
function
- Switch / button / plug ST3 /
cable / solenoids are defective
cable / solenoids
Checking for error when engine is not running: (no signal from alternator terminal 61)
Voltage supply from fuse FA7 must be available on plug ST1.
disconnect the pink cable or cable No. 301 from terminal 61 on the alternator and supply the cable
with battery voltage - terminal ST2.1 to obtain a control signal.
1)
Note: = only valid for L 522 to S/N 321
Sub Group lndex
11.93
TraveI Gear
14.
14. 06. Travel Gear L 512 / L 522 ......................................................................................
14. 20. lnductive transmitter - Travel speed
11.93
TraveI Gear
L 512 / L 522 101
14.06.01
Machine L 512 L 522
SeriaI No. 101 - 101 -
Planetary gear axle Type see Section 15 see Section 15
Transmission Hurth Type 310 310
Gear ratio i:
Variable motor 1 i 1,829 1,829
Variable motor 2 i 1,829 1,641
Oil quantity l 2,4 2,4
Oil viscosity SAE 90 LS SAE 90 LS
11.93
GeneraI
L 512 / L 522 101
14.06.02
L 512 L 522
Pos.1 VariabIe motor 1 A6VM 107 DA A6VM 107 DA
Pos. 2 VariabIe motor 2 A6VMN 107 HD1D A6VMN 160 HD1D
Pos. 3 VariabIe pump A4VG 90 DA Series 3 A4VG 90 DA Series 3
Pos. 4 TraveI gear L 512 L 522
Spur gear / output shaft Z1 64 teeth 64 teeth
Motor 1 Spur gear / drive shaft Z2 35 teeth 35 teeth
Motor 2 Spur gear / drive shaft Z3 35 teeth 39 teeth
Identification of gears:
35 teeth : 310 14 003 01
39 teeth : 310 14 004 01
11.93
Components of TraveI Gear
L 512 / L 522 101
14.06.03
2 Allen head screw (240 Nm)
3 Cover
4 Shim
5 Vent
6 Gear
7 Ball bearing
8 Flange
12 Allen head screw
13 Gear
14 Flange
15 Allen head screw (50 Nm)
16 Stud screw
17 Spacer ring
18 Hex nut (210 Nm)
20 O-Ring
21 Hex head screw (50 Nm)
23 Nut (300-350 Nm)
24 O-Ring
25 Flange
26 Protective plate
27 Shaft seal ring
28 Cover
29 Ball bearing
30 Plug
31 Magnetic plug
32 Housing
33 Drive shaft
34 O-Ring
Note for repair :
1. To repIace the oiI motor
1.1 To puII off the gear, use a 3- arm gear puIIer
1.2 To instaII the gear onto the motor shaft
- Warm the gear to about 180
- Pull the gear onto the motor shaft (do not hit)
(Use aid, such as screw M16x80 with nut and washer)
- Adjust play of 0.2 mm with shims, Pos. 4 (see illustration)
- Cover Pos. 3 must touch on the motor shaft and not on the gear (play 0.2 mm)
- Tighten screw, Pos. 2 with retaining fluid, such as Loctite 601 and torque to 240 Nm
Variable motor
K = ldentification
W = Motor shaft
4 = Shim(s)
13 = Gear
InstaIIation aid :
NOTE:
Pay attention to the gear type(see 14.06.02)
Shim Pos. 4 0,2 mm ld. No. 7618 488
Shim Pos. 4 0,3 mm ld. No. 7618 491
11.93
Inductive Transmitter
TraveI Speed
L 512 / L 522 101
14.20.01
Test:
Note installation depth for new installation
Gap is about 1.5 mm
Test value 516 Ohm (between Pin 2 and 1)
B 21 lnductive transmitter, ld. No. 635867001
Sub Group lndex
05.97
AxIes
15.
15. 01. General
15. 02. List of Axles
15. 03. Axle lnstallation
15. 04. Screw Tightening Torques L 512 / L 522 ...............................................................
15. 20. Differential
15. 30. Wheel Hub
15. 50. Gear Shaft
11.93
Fixed AxIe
15.01.01
Design of the fixed axIe
The differential is installed in the axle casing of the fixed axle, which transfers the axle load of the
vehicle to the wheels.
The differential transferes half of the power from the travel gear to the planetary drive of the wheel hubs.
lnstalled in the housing is the hydraulically respectively mechanically actuated wet disk brake 22. lt is
actuated with brake oil when the brake pedal (service brake) is pushed down, or via a Bowden cable
(parking brake) and it closes.
For description of brake system, see section 17.
Power fIow in the fixed axIe
The output torque of the travel gear is transferred via the universal drive shaft onto the drive flange 14 of
the differential. The tapered gear 13 and the ring gear 10 forward the power via the differential housing
onto the equalizer pins in the differential housing via the equalizer and axle tapered gears 5 .
The shaft 6 drives the planetary gears 20. They roll off on the stationary gear 26. This results in a large
speed reduction and therefore a large power transfer onto the rotating wheel hub 8. lt drives the wheels
via the wheel pin 7 with corresponding power and speed.
AxIe maintenance
The axle must be inspected in preset intervals, see maintenance guidelines in section 7, check the oil
level and for leaks as well as mounting tightness. ln addition, the wheel lugs 9 must be checked
regularly to see if they are tightened to the correct tightening torque.
The lube oil must be replaced in certain intervals, see maintenance guidelines.
ln addition, when performing these maintenance tasks, the disk brake must be checked if it is functioning
properly, see description in section 17. Brakes.
08.99
AxIe Listing
15.02.01
L 504
Front axIe
PIanetary steering axIe
Rear axIe
Machine S/N Axle type ld. No. Axle type ld. No.
101 - APL - 2010 5716 119 APL - 2010 5716 120
1 AVG 95
L 506
Front axIe
PIanetary drive axIe
Rear axIe
2501 - 3385 171 / 202 5716 132
1)
3386 - 171 / 292 5716 621
2)
2501 - 2720 302 / 271 / 167 5716 133
3)
2721 - 302 / 271 / 167 5716 441
4)
L 507
Front axIe
Rear axIe
0101 - 3387 171 / 202 5716 132
1)
3388 - 171 / 292 5716 621
2)
0101 - 2704 302 / 271 / 167 5716 133
3)
2705 - 302 / 271 / 167 5716 441
4)
L 508
Front axIe
Rear axIe
2501 - 3459 171 / 223 5716 169
1)
3460 - 4084 171 / 295 5716 622
2)
2501 - 3480 302 / 271 / 230 5716 170
3489 - 4084 313 / 271 / 51 5716 684
4085 - 4329 AP - R725 5716 775
2)
APL - R725 5716 837
4330 - AP - R725 5716 926
2)
APL - R725 5716 837
L 509
Front axIe
Rear axIe
0101 - 3461 171 / 223 5716 169
1)
3462 - 4088 171 / 295 5716 622
2)
0101 - 3488 302 / 271 / 230 5716 170
3494 - 4088 313 / 271 / 51 5716 684
4089 - 4321 AP - R725 5716 775
2)
APL - R725 5716 837
4322 - AP - R725 5716 926
2)
APL - R725 5716 837
L 512
Front axIe Rear axIe
101 - 151 176 / 114 5715 773 310 / 176 / 50 5715 774
152 - 177 / 95
5)
5716 091 310 / 177 / 56 5716 092
L 522
Front axIe Rear axIe
101 - 257 176 / 114 5715 773 310 / 176 / 50 5715 774
258 - 297 176 / 164 5716 096 310 / 176 / 55 5716 098
298 - 176 / 179
5)
5716 183 310 / 176 / 57 5716 184
1)
Hydraulically and mechanically actuated drum brake (180 x 40) on axle input (service and parking
brake)
2)
Hydraulically and mechanically actuated drum brake (203 x 60) on axle input (service and parking
brake)
3)
Gear ratio i = 2.27
4)
Gear ratio i = 2.54
5)
Mechanically actuated drum brake on axle input (parking brake)
05.97
AxIe InstaIIation
L 504
15.03.01
Front axIe
Mounting with screws 5 ( 22) 280 Nm
Self locking differential 45 %
Drum brake in axle input
(Service and parking brake)
with axle pivot steering
with steering cylinder
Rear axIe
oscillating - central lube point
Mounting with pin 5
Tightening torque of screws 6 (120 Nm)
Tightening torque of screws 15 (280 Nm)
Self locking differential 45 %
with installed travel gear
with axle pivot steering
with steering cylinder
11.93
Screw Tightening Torques
WheeI Hub
L 512 / L 522 101
15.04.01
A Tightening torque 460 Nm / inserted with Loctite 270
B Tightening torque 650 Nm
11.93
Screw Tightening Torques
DifferentiaI
L 512 / L 522 101
15.04.02
A Tightening torque 135 Nm / inserted with Loctite 270
B Tightening torque 135 Nm / inserted with Loctite 270
C Tightening torque 600-800 Nm / inserted with Loctite 270
D Tightening torque 135 Nm / inserted with Loctite 270
E inserted with Loctite 270
F Tightening torque 135 Nm / inserted with Loctite 242
11.93
DifferentiaI
15.20.01
Design and function of the differentiaI
The differential is installed in the fixed axle's axle casing. lt transfers the power from the travel gear onto
the planetary drive of the wheel hubs and at the same time it transfers the speed and power (torque) of
the gear via the tapered and ring gear.
The self locking differential takes advantage of the expanding forces, which occur in the equalizer axles
6 and the inclined surfaces. The locking effect is created, in proportion to the torque, on the two
symmetrically installed disk packets in the housing.
With increased driving torque, the expanding forces, which press on the disks, are changing. As a result,
the locking value changes due to the internal friction of the disks. The outer disks are connected with the
housing and the inner disks with the equalizer shaft gears, so that they are not able to slip. The locking
effect causes a corresponding torque and speed dependent locking action of the transfer of force onto
the axle shafts.
When operating on restrictive ground surfaces, when traveling in curves or if one wheel slips due to low
friction, the other wheel still retains sufficient drive torque, due the action of the clutch (up to 80% higher
torque on the wheel with better grip).
1 Ring gear
2 Tapered gear shaft
3 Differential housing
4 Axle tapered gear
5 Equalizer tapered gear
6 Equalizer axle
7 Thrust washer
8 Pressure disk
9 Outer disk
10 lnner disk
Torque flow (schematic) at equally good wheel grip of
both wheels or when driving straight ahead.
Torque flow (schematic) at unequal wheel grip or when
driving into a left hand curve.
Gear mesh in the differential
11.93
DifferentiaI
15.20.02
1 Adjustment screw (play of brake
disks)
2 Shaft nut
4 Differential housing
5 Equalizer pin
6 Equalizer tapered gear
7 Breather vent
8 Housing
9 lntermediate cover
10 Ring gear
11 Spacer ring
12 Cover
13 Tapered gear shaft
14 Flange (Drive- front axle)
15 Retaining nut
16 Shaft nut
17 Seal ring
19 Equalizer shaft gear
20 Brake piston
21 Brake lever
22 Brake disks
11.93
WheeI Hub
15.30.01
1 Axle casing
6 Shaft
7 Stud
8 Wheel hub
9 Wheel lug
20 Planetary gear
23 Pin
24 Hollow gear carrier
26 Gear rim
29 O-Ring
30 Ring
31 Seal ring
11.93
Gear Shaft
L 512 / L 522 101
15.50.01
InstaIIation:
Gear shaft, Pos. 1 with longitudinal equalizing section (sliding section), mounted on the travel gear
side.
The marking arrows on both half shafts must be exactly opposite from each other.
The balancing plates may not be removed.
The half shafts may not be interchanged nor mixed up.
All given tightening torques for screw connections must be adhered to, this also applies to the
inspection intervals, to assure that they are still mounted tightly.
Maintenance:
For lubrication intervals, see section 7.
Repairs:
When replacing and reinstalling the gear shafts, make sure to follow installation guidelines.
The screw connections (nuts) must be placed with new ones.
Sub Group lndex
04.95
Steering
16.
16. 01. General Data
16. 04. Hydraulic Steering System L 504 ........................................................................
16. 05. Hydraulic Steering System L 506 / L 507 ..............................................................
L 508 / L 509
16. 06. Hydraulic Steering System L 512 / L 522 ..............................................................
16. 20. Valve block
16. 30. Servostat Eaton
16. 32. Servostat ZF
16. 50. Steering Cylinder
03.95
GeneraI Data
16.01.01
GeneraI Data Machine L 504
S/N 0101
Fixed dispI. pump with priority
fIow divider
Type Ultra 1 PX 140
Flow max. l/min 35
Primary pressure relief valve
(steering)
bar 180
Servostat Typ Eaton 263-4062
Pilot flow l/min 3
Steering cyIinder
Diameter, cylinder / rod mm 60/32
GeneraI Data Machine L 507 L 509
S/N 0101 - 0340 0101 - 0172
Fixed dispI. pump with priority fIow divider Type Ultra 1 PX 250 Ultra 2 PX 330
Flow max. l/min 62,5 82,5
Displacement volume cmt/U 25 33
Primary pressure relief valve (steering) bar 180 180
Servostat Typ Eaton 263-4183 Eaton 263-4183
Pilot flow l/min 3 3
Secondary pressure relief bar 240 240
Steering cyIinder
Diameter, cylinder / rod mm 70/30 70/30
Stroke, max. mm 260 260
lnstallation length mm 500 500
GeneraI Data Machine L 506 / L 507 L 508 / L 509
S/N from 2501 / 2501 2501 / 2501
Fixed dispI. pump with priority fIow divider Type Ultra 1 SX 250 Ultra 2 SR 033
Flow max. l/min 62,5 82,5
Primary pressure relief (steering) bar 180 180
Servostat Type Eaton 263-4183 Eaton 263-4183
Pilot flow l/min 3 3
Secondary pressure relief bar 240 240
Steering cyIinder
Diameter, cylinder / rod mm 70/30 70/30
Stroke, max. mm 260 260
lnstallation length mm 500 500
GeneraI Data Machine L 512 / L 522
S/N from 101
Fixed dispIacement pump Type G25-58-BF6F1
Flow max. l/min 133
VaIve bIock Type ZF - 7760
Pilot flow l/min 5
Primary pressure relief
(steering)
bar 180
Emergency steering pump Type ZF - 8605
Servostat Type ZF - 8476
Steering cyIinder
Diameter cylinder / rod mm 90/40
Stroke, max. mm 515
lnstallation length mm 730
04.95
HydrauIic Steering System
L 504 0101
16.04.05
1
15 Gear pump with
2
33 Servostat
3
45 Steering cylinder - front axle
4
46 Steering cylinder - rear axle
1 Hydraulic tank
6 Bleeder filter
7 Drain valve
10 Diesel engine
15 Gear pump with
18 Orifice
19 Orifice
20 Orifice
21 Filter
25 Orifice 0,8 mm
29 Return flow oil cooler
30 Suction connection - replenishing
pump
32 Return flow - var. displ. pump
33 Servostat
34 Hand pump
35 Valve spool
36 Check valve
(suction - emergency steering)
37 Check valve
38 Secondary pressure relief
valve 240 bar
39 Check valve
40 Change over valve
45 Steering cylinder - front axle
46 Steering cylinder - rear axle
50 Control valve block /
working hydraulic
04.95
HydrauIische LenkanIage
HydrauIic steering system
Direction hydrauIique
L 504 0101
16.04.06
Hose routing pIan:
11.94
L 507
L 509
0101 - 0340
0101 - 0172
16.05.05
1
Gear pump with priority flow divider
2
Servostat
3
Steering cylinder
4
Parts Listing for hydrauIic schematic 16.05.06
1 Hydraulic tank
(Combi filter) 10 m
4 Collector tube
5 Pretension valve, 0.6 bar
6 Bleeder filter
7 Collector point, return lines
9 Drain valve
10 Diesel engine
18 Orifice
19 Orifice
20 Orifice
21 Filter
32 Orifice 0,8 mm
33 Servostat
34 Hand pump
35 Valve spool
36 Check valve
(Suction, emergency steering)
37 Check valve
38 Sec. pressure relief valve 240 bar
39 Check valve
45 Steering cylinder
50 Control valve block / Working hydrau-
lic
Return Iines from:
22 Oil cooler
24 lnching valve
11.94
L 507
L 509
0101 - 0340
0101 - 0172
16.05.06
Hose routing pIan:
04.95
L 506 / L 507
L 508 / L 509
2501
16.05.07
1
1 Hydraulic tank
2
15 Gear pump with
3
33 Servostat
4
1 Hydraulic tank
(combi filter) 10 m
6 Bleeder filter
9 Drain valve
10 Diesel engine
18 Orifice
19 Orifice
20 Orifice
21 Filter
32 Orifice 0,8 mm
33 Servostat
34 Hand pump
35 Valve spool
36 Check valve
(Suction emergency steering)
37 Check valve
38 Secondary pressure relief
valve 240 bar
39 Check valve
50 Control valve block /
working hydraulic
Return Iines from:
22 Oil cooler (Hydraulic var. displ. motor)
23 Servo control valve
24 lnching valve
04.95
L 506 / L 507
L 508 / L 509
2501
16.05.08
Hose routing pIan:
Parts Listing for hydrauIic schematic 16.06.10
1 Hydraulic tank
(Combi filter) 10 m
4 Collector tube
7 Bleeder filter
8 Hydraulic oil cooler
10 Diesel engine
12 Emergency steering pump
13 Travel gear
15 Gear pump
20 Valve block
23 Shifting valve
26 Flow indicator
27 Check valve
28 Check valve
29 Restrictor and check valve
30 Check valve
31 Test connection
33 Servostat
34 Hand pump
35 Valve spool
38 Sec. pressure relief valve
50 Control valve block / Working hydrau-
lic
11.93
L 512 / L 522 101
16.06.10
05.97
VaIve BIock
L 512 / L 522 0101
16.20.01
Use:
The valve block is installed in the steering circuit and is actuated by the hydraulic flow from the gear
pump / working hydraulic.
Function
The load dependent flow divider control connects the steering circuit with the working hydraulic. Due to
this control, the steering only takes as much oil from the pump flow as it requires for the turning speed
on the steering wheel. The remaining oil flow is therefore available for the working hydraulic. The
steering system is supplied with pump oil flow on a priority basis.
5 Valve block - housing
6 Seal ring
7 Valve piston / cut-in valve
8 Spring
9 O-ring
10 Plug
11 Valve insert / flow indicator
19 Plug
20 Plug
24 Data tag
25 Rivet
29 Valve insert / pressure relief valve -
180 bar
30 O-ring
33 Plug
60 Valve element / check valve, complete
60.2 O-ring
60.4 O-ring
60.5 Valve insert
60.6 O-ring
61 Plug
62 Ball
63 Plug
70 Valve piston / flow divider valve
71 Spring
Connections
1 Gear pump
2 Working hydraulic
3 ZF - Servostat - PU - connection
4 ZF - Servostat - P - connection
T Hydraulic tank
Parts Iisting for steering cyIinder 16.50.04
1 Hydraulic cylinder, complete
2 Cylinder
3 Piston rod
4 Piston nut (tightening torque 640 Nm)
5 Fitting
6 Bearing
7 Lock ring
10 Piston
11 Piston guide ring
12 O-ring
13 Turcon-Glyd ring
20 Piston rod bearing
21 O-ring
22 Support ring
23 O-ring
24 Dual scraper ring
25 O-ring
26 PU-Stepseal
27 Guide ring
03.95
Steering cyIinder
L 506 / L 507
L 508 / L 509
2501 / 0101
2501 / 0101
16.50.04
Sub Group lndex
05.97
Brakes
17.
17. 01. General
17. 04. Brake System L 504 ............................................................................................
17. 05. Brake System L 506 / L 507 ..................................................................................
L 508 / L 509
17. 06. Brake System L 512 / L 522 ..................................................................................
17. 15. Adjustment Brake Disk Play
Brake Disks - Wear Check
17. 16. Bleeding the Brake System
17. 20. Accumulator Charge Valve
17. 30. Service Brake Valve
17. 40. Main brake cylinder L 504 ...................................................................................
L 506 / L 507
L 508 / L 509
17. 42. Main brake cylinder (2 - stages) L 512 / 101 - 151 .................................................
L 522 / 101 - 233
17. 50. Drum Brake L 504 - L 522 ....................................................................................
11.93
GeneraI
Brake System
101
17.01.02
1 Wet disk brake
2 Parking brake, mech. control
3 Service brake, hydr. control
4 Adjustment screw, 3 each per brake side
5 Bleeder valve
37 lnching valve
105 Brake light switch
110 Reservoir
115 Main brake cylinder
120 Drum brake, front axle
122 Bleeder valve
130 Front axle
Test connections:
(forward)
04.95
HydrauIische BremsanIage
HydrauIic brake system
Frein hydrauIique
L 504 0101
17.04.10
Hose routing pIan:
37 lnching valve
110 Reservoir
115 Main brake cylinder
120 Drum brake, front axle
122 Bleeder valve
130 Front axle
Test connections:
(forward)
03.95
Frein hydrauIique
L 506 / L 507
L 508 / L 509
2501 / 0101
2501 / 0101
17.05.10
Hose routing pIan: :
11.93
Brake System
L 512 / L 522 101-151/101-233
17.06.01
Machine ModeI L 512 / L 522
S /N 101-151 / 101-233
Stage main brake cylinder ld. No. 5715 934
Type FAG 3.2326-0216.3
Change over pressure bar 15
Brake pressure max. bar 45
Brake fluid (only mineral oil ) SAE 10
Parking brake
mechanically acting on disk brake
Rear axle
lnching valve ld. No. 5715 911
11.93
Brake System
L 512 / L 522 101-151/101-233
17.06.03
ln order to assure proper function of the inching brake system, the linkage and the pedal height must be
adjusted correctly. For new adjustment, proceed as follows:
1. Adjustment of pedaI height in resting position
Use stop screw 7 to adjust the upper pedal height to 145 mm, measured from the cab floor (see
drawing on reverse page).
2. Adjust the threaded rod 5 to a Iength of 405 mm,
measured from the center of the pins on the fork linkages 6
3. Adjust threaded rod 14 to the correct Iength.
from a pedal height of 115 mm on, the threaded rod 14 must take along the brake piston in the stage
main brake cylinder (stronger resistance can be felt on the brake pedal)
4. Adjust the Iength of the spring 17 by turning the spring washer 15 .
in resting position of the pedal, the length of the spring must be 50 mm
The spring washer 15 is attached on the threaded rod 14 with 2 threaded pins Pos. 31.
5. Adjust the Iever on the inching vaIve
Turn the inching valve in such a way that a gap A of about 1 mm remains between pin and stop
pin.
Then retain the lever 20 with stop screw 21 in such a way that the lever is even with the edge of the
housing B.
6. Hang the threaded rod 18 on the Iever 10 and the inching Iever 20
Adjust the length of the threaded rod 18 in such a way that the inching lever 20 retains the position as
described above.
ln resting position of the pedal, the pin may not touch the stop pin (keep gap of about 1 mm ).
7. Adjustment of the brake Iight switch 25
The brake lights should not turn on until the main brake cylinder is actuated, that corresponds to a
pedal height of less than
115 mm.
37 lnching valve
110 Reservoir
115 Stage main brake cylinder
120 Disk brake rear axle
121 Disk brake front axle
122 Bleeder valve
Test connections:
(forward)
11.93
HydrauIic Brake System
Frein hydrauIique
L 512 / L 522 101-151/101-233
17.06.10
Pipe routing:
11.93
HydrauIic Brake System
L 512 / L 522 152 / 234
17.06.15
Model L 512 L 522 L 522
S / N from 152 234-297 from 298
Gear pump 14 Type
Displacement cm
3
/ rev. 4 4 4
Flow max. l / min 10 10 10
AccumuIator charge vaIve 100 Type LT 06 LT 06 LT 06
Cut in pressure bar 120
+10
120
+10
120
+10
Cut off pressure bar 150
-10
150
-10
150
-10
Pressure switch 105 bar 90
5
90
5
90
5
Foot brake vaIve 115 Type LT 05 LT 05 LT 05
Brake pressure max. bar 60
5
60
5
60
5
Pressure switch 116 bar 19
2
19
2
19
2
Cut in vaIve 125
Opening pressure bar - 9 -
Brake accumuIator 110
Nominal volume cm
3
750 750 750
Fill pressure bar 50 50 50
Parking brake
mechanically acting on drum brake -
front axle
disk brake -
rear axle
drum brake -
front axle
1 Hydraulic tank
2 Return and suction filter 10 m
4 Collector tube
7 Bleeder filter
10 Diesel engine
14 Gear pump - Brake system
22 Control valve
37 lnching valve
38 Bleeder valve
100 Accumulator charge valve
102 Main spool
103 Control spool
104 Check valve
105 Pressure switch - Accumulator pres-
sure 90 bar
106 Test point - Accumulator pressure
115 Foot brake valve
116 Pressure switch - Brake lights 19 bar
118 Test point / Brake pressure
120 Disk brake - Rear axle
121 Disk brake - Front axle
122 Bleeder valve
125 Cut in valve 9 bar
(only L 522 234-298)
04.95
Frein hydrauIique
L 512 / L 522 152 / 234
17.06.20
Hose routing pIan:
11.93
Brake Disk PIay
Wear Check
L 512 / L 522 101
17.15.01
1. Check and adjust the brake disk pIay :
(should be checked every 1000 hrs.)
Play0,75 mm L 512 / L 522 Front and rear axle
Actuate brake with pressure
- Apply brake
Loosen lock nut 2
- 3 each per brake side (see fig. 1)
Turn out adjustment screws 1 to the stop (counterclockwise)
Turn in screws Pos. 1 (clockwise)
- 3/4 turn corresponds to a gap of 0,75mm
Tighten lock nut
1
2. Brake pad wear check:
(every 2000 hrs.)
Actuate brake with pressure
- Apply brake
Turn out oil filler screw
with feeler gauge (tool 128), measure the gap "S"
between the brake disks (though the oil filler port)
minimum permissible gap (thickness of disk) is 4.5
mm
lf brake disk thickness is less than 4.5 mm, replace
the disks (new brake disk thickness is 4.9 mm).
2
Note:
The wet disk brakes are running in oil (SAE 90 LS)
from the differential gear.
lf loud noise develops when braking, the brake pads
are worn and must be replaced immediately.
To repair the axle, refer to the separately issued "Re-
pair Manual for Planetary Axles".
11.93
BIeeding the Brake System
L 512 / L 522 101-151/101-233
17.16.01
3
1. BIeeding the brake system:
Note:
Make sure there is always sufficient, air free oil (SAE
10 W)in the reservoir.
1.1 Stage main cyIinder :
Slowly actuate the brake pedal, the air in the piston
ring area will slowly rise over the feeder hose to the
reservoir.
Continue to slowly press down the pedal several times
and release it again.
Set the bleeder bottle with transparent hose onto the
bleeder valve.
Actuate the pedal and open the bleeder valve.
Close the bleeder valve, slowly loosen the pedal.
Repeat the procedure several times until there are no
more air bubbles in the fluid.
1.2 Rear and front axIe:
Set the bleeder bottle with transparent hose onto the
bleeder valve.
Actuate the pedal and open the bleeder valve .
Close the bleeder valve, slowly loosen the pedal .
Repeat the procedure several times until there are no
more air bubbles in the fluid.
Important:
After the bleeding procedure has been completed,
check the fluid level in the reservoir, it should be
between the MlN and MAX mark.
Check the breather hole in the cover of the reservoir
(it equalizes the pressure when the fluid level chan-
ges).
2. BIeeding the system with a fiIIer- and bIeeder
unit: (fig 5)
A bleeder unit (Tool No. 119 and 120) assures a quick
and safe bleeding procedure (and is recommended,
especially when working alone).
Set on the main brake cylinder with pedal support (hold the pedal down).
Connect a filler and bleeder unit onto the reservoir
- A working pressure of maximum 2 bar is permissible
Open the shut off valve .
Bleed the bleeder valves in the order described in paragraph 1 until there are no more bubbles in
the fluid.
4
5
11.93
AccumuIator Charging
VaIve LT 06
17.20.01
The accumulator charging valve or pressure shut - 0ff valve is used to maintain the pressure in
accumulator circuit between certain limits.
The valve consists mainly of a spool with pressure adjustment element 103, main spool 102 and check
valve 104.
To change the pump fIow from P to Sp to P to N
During the charging procedure, the pump supplies oil via the check valve 104 into the accumulator circuit
. Pressure is available at the main spool 102 via the control line and the servo spool . The main spool
restricts the flow until the pressure, which is building up in the accumulator circuit exceeds the spring
force in the pressure adjustment element via the surface of the control spool 103. The control spool 103
now shuts off the supply from the control line from P and relieves the rear area of the main spool 102 to
the tank T.
The path from P to N is free due to the change over of the main spool 102 and the check valve 104
closes. The charging procedure is over and the pump flow can now flow with low through the charge
valve.
To change the pump fIow from P to N to P to Sp. (from neutraI circuIation to accumuIator
charging)
lf the pressure in the accumulator circuit drops to the lower shifting point (cut in pressure), then P is
connected with the rear area of the spool 103, and the pump again supply into the accumulator circuit .
Shifting pressure difference
The shifting pressure difference is realized by the surface difference in the control part. The upper
shifting point (cut off pressure) is reached when the T-edge opens, however, the lower shifting point (cut
in pressure) only when the P-edge opens.
100 Accumulator charging valve
102 Main spool
103 Spool with adjustment element
104 Check valve
105 Pressure switch
A Adjustment screw
11.93
Service Brake VaIve LT 05
17.30.01
Description of function:
The foot brake valve is a direct controlled, 3- way pressure reducing valve with stepless, mechanical
control. lt contains maximum pressure relief for the secondary circuit (brake circuit), adjusted at
adjustment screw 9, as well as stepless build up of pressure in the secondary circuit, proportionally to
the stroke of the control element 4 .
The valve is actuated via pedal and the control element 4. lt pushes the main control spring 3 against
the control piston 2. At first, the control edge on channel T closes, then the path from P to B is open.
The pressure, which is now build up in the brake line, acts at the same time onto the main control spring
3 via the servo oil bore 6 behind the piston , so that the brake pressure (secondary pressure) increases
in proportion to the deflection of the control element 4. When the deflection of the control element
remains constant, the control piston 2 goes to regulating position and keeps the adjusted pressure in
channel P constant. The control force of the control element is in proportion to its deflection. lf the main
control spring 3 is released, the return spring 5 moves the control piston 2 in such a way, that it closes
path P to B and B to T opens and relieves the secondary circuit (brake circuit).
1 Housing
2 Control piston
3 Main control spring
4 Control element
5 Return spring
6 Servo oil bore
7 Dust cover
8 Foot pedal
9 Adjustment screw (P max)
10 Adjustment screw (Pedal in resting
position)
115 Foot brake valve, complete
116 Pressure switch, 19 bar
Sub Group lndex
10.94
Main Frame / Cab
18.
18. 06. Cab lnstallations / Control console L 512 / L 522 ..................................................
18. 25. Articulation / Osciallation L 506 / L 507 .................................................................
L 508 / L 509
18. 26. Articulation / Osciallation L 512 / L 522 .................................................................
11.93
Cab InstaIIations
ControI ConsoIe
L 512 / L 522 101-151/101-233
18.06.05
To remove the consoIe cover, Pos. 1
Remove the arm rest 2 (via the knurled screw 3)
Remove the lever retainer 5 by turning out the screw 4 (push the operator's seat all the way to the
rear).
Remove the shut off lever 6 (pull it out, the lever is held only by a spring loaded pin. To reinstall, keep
the same lever position).
Remove the dust cover 11 on the control lever 7 on top and push it down.
Loosen the 3 screws 8 on the retainer plate 9 (accessible with a socket driver in the dust cover) .
Push the dust cover 11 up and remove the retainer plate 9 (watch the spacer sleeves 10).
Lift the console cover 1 up ( the control lever with dust cover for additional functions remains in
place).
03.95
ArticuIation / OsciIIation
L 506 / L 507
L 508 / L 509
2501 / 0101
2501 / 0101
18.25.01
1 Rear section
2 Bearing fork
3 Damper element
4 Girder
5 Screw M20 Tightening torque 550 Nm
6 Washer
7 Tension sleeve
RepIacement of damper eIements:
Park and secure the machine on firm and level ground. (place the bucket with float position on the
ground). Place wheel chocks under the front wheels, do not lock the articulation linkage.
Attach a suitable lifting device under the articulation point - secure it to prevent it from slipping. (the
gear shaft and steering cylinder can remain in place).
Remove the screws, pos. 5, girder pos. 4 and the front damper element, pos. 3.
To replace the rear damper element, pos. 3, lift the machine with a suitable lifting device until the
bearing fork, pos. 2, can be moved to the side (watch the cables, hoses, and steering cylinder).
Grease the pins and surface on the damper elements before installation.
Tightening torque for screws M20 = 550 Nm
03.95
L 506 / L 507
L 506 / L 507
2501 / 0101
2501 / 0101
18.25.02
1 Front section
2 Rear section
3 Bearing fork
4 Pin
5 Pressure flange
6 Screws M10 x 25
Tightening torque 75 Nm
7 Support plate
8 Bearing
9 Support plate with lock ring
10 Bearing cover
11 Screws M10 x 45
12 Seal ring
13 Spacer bushing
14 Spacer bushing
11.94
L 512 / L 522 101
18.26.01
1 Rear section
2 Bearing fork
3 Damper element
4 Girder
5 Screw M27
6 Washer
7 Tension sleeve
RepIacement of damper eIements:
Park and secure the machine on firm and level ground (place the bucket with float position on the
ground). Place wheel chocks under the front wheels, do not lock the articulation linkage
Attach a suitable lifting device under the articulation point - secure it to prevent it from slipping (the
gear shaft and steering cylinder can remain in place..
Remove the screws, pos. 5, girder, pos. 4 and the front damper element, pos. 3.
To replace the rear damper element, pos. 3, lift the machine with a suitable lifting device until the
bearing fork, pos. 2, can be moved to the side (watch the cables, hoses, and steering cylinder).
Grease the pins and surface on the damper elements before installation.
Tightening torque for screws M27 = 1400 Nm
11.94
L 512 / L 522 101
18.26.02
1 Front section
2 Rear section
3 Bearing fork
4 Pin
5 Pressure flange
6 Screws M10 x 25
7 Spacer bushing
8 Bearing
9 Support plate with lock ring
10 Bearing cover
11 Screws M10 x 65
12 Seal ring
Sub Group lndex
05.97
Hoist Frame / Accessories
19.
19. 01. Hoist Frame / Tilt angle stops
19. 02. Hydraulic Quick Change Cylinder / Z - Kinematics
05.97
Hoist Frame/
TiIt angIe stops
Z - Kinematics
L 506 - L 509
19.01.01
To check the tiIt angIe stops:
Raise the hoist frame with fully tilted out bucket until the stop "a" becomes effective.
Check measurement "Z" and "D" .
lf the measurement "D" on stop "b" is smaller than 2 mm (measured from the center of the stop)
or if the measurement "Z" is larger than 330 mm, weld on stop "a" to correct measurements.
Adjustment vaIue for L 506 - L 509 from S/N 0101 to 3433
To check tiIt angIe stops:
Raise the hoist frame with fully tilted out bucket until stop "a" becomes effective.
lf measurement "D" on stop "b" is smaller than 2 mm (measured from the center of the stop) or if
measurement "Z" is larger than 330 mm, weld on stop "a" to correct measurements.
Adjustment vaIues for L 506 - L 509 from S/N 3434
05.97
Hoist Frame /
TiIt angIe stops
ParaIIeI - Kinematics
L 506 - L 509
19.01.02
To check the tiIt angIe stops:
Raise the hoist frame until it is in horizontal position and tilt the bucket out all the way.
Make sure to check that the stop sequence at the left and right stops is the same, and the stop
surfaces "a" are parellel (also important if buckets made by other manufacturers are installed).
There must be a gap of 6 mm on stop "b" (stop "b" is intended for hoist frame movements
without mounted attachment).
lf the measurement "b" is smaller than 3 mm, weld on stop "a" to correct measurement.
VaIid for:
L 506 from S/N 2501
L 507 from S/N 0101
L 509 from S/N 0101 - 0172
To check tiIt angIe stop :
Make sure to check that the stop sequence at the left and right stops is the same and the stop
surfaces "a" are parallel (also important if buckets made by other manufacturers are installed).
VaIid for:
L 508 from S/N 2501
L 509 from S/N 2501
05.97
Hoist Frame /
TiIt angIe stops
L 512 / L 522 0101
19.01.03
To check the tiIt angIe stops for Z- Kinematics:
Raise the hoist frame with fully tilted out bucket until stop "a" becomes effective.
lf the measurement "D" on stop "b" is smaller than 4 mm (measured from the center of the stop)
or if the measurement "Z" is larger than 474 mm, weld on stop "a" to correct measurement.
Adjustment vaIues / Z-bar kinematics
To check the tiIt angIe stop for ParaIIeI Kinematics:
Make sure to check that the stop sequence at the left and right stops is the same and the stop
surfaces "a" are parallel (also important if buckets made by other manufacturers are installed).
05.97
HydrauIic Quick
Change CyIinder
Z - Kinematics
L 507
L 509
0101 - 0340
0101 - 0172
19.02.01
HydrauIic quick change cyIinder (ld. No. 5716 202 - cannot be replaced)
1 Plug
2 Cylinder tube
3 Piston rod 40
4 Piston 70
5 Piston rod bearing
6 Nut
7 Side section
8 Lock screw
05.97
HydrauIic Quick
Change CyIinder
Z - Kinematics
L 506 - L 509 2501 - 3433
19.02.02
HydrauIic quick change cyIinder (ld. No. 5716 530 - replaces ld. No. 5716 331)
15 Guide bushing
32 Piston rod
39 Retracing retainer
41 Piston
55 Guide flange
71 Allan head screw
72 Threaded pin
73 Hex nut
75 Allan head screw
88 Scraper
94 O - ring
96 Pin
97 Pin
99 Seal kit, complete
05.97
HydrauIic Quick
Change CyIinder
Z - Kinematics
L 506 - L 509 3434
19.02.03
InstaIIation notes for hydrauIic quick change cyIinder on hoist frame
When turning the flange 2 in or out, loosen the lock screw 26
- remove the grease nipple 4
- Before passing the O-ring 3 on the lube bore (4) , protect the O-ring 3 from damage in the bore
hole (close the bore hole by pushing a 5 mm rod in (for example a drill bit).
After attaching the quick change cylinder on the hoist frame (turn in and tighten the flange 2),
loosen the flange 2 again by 1/4 turn.
HydrauIic quick change cyIinder (ld. No. 5716 599)
1 Shaft (install without grease)
2 Mounting flange
3 O-ring
4 Grease nipple (lube bore)
5 Shim 70 x 90 x 1
8 Piston (locking pin)
26 Lock screw
34 Shut off valve
38 Coupling
40 Dust cap
41 Storage for dust cap
Sub Group lndex
11.93
SpeciaI InstaIIations
20.
20. 30. Hydraulic Quick Change Coupler L 512, L 522 ....................................................
20. 32. Hydraulic lnstallations L 512 / from 152 .................................................................
L 522 / from 234
20. 36. Speed limitation 20 km/h L 512, L 522 .................................................................
06.94
HydrauIic
Quick Change CoupIer
L 512 / L 522 152 / 234
20.30.05
Function:
- The hydraulic quick change coupler is controlled via switch S16 and via the control lever (tilt in). For
the control, oil pressure is directed from the working hydraulic pump, via the solenoid valve Y14 to the
hydraulic cylinder 2.
- To reIease: Switch S16 "On" (see also page 20.30.06)
Solenoid valve Y14 shifts, connects P - B, A - T, hydraulic cylinder 2 are actuated on the piston
rod side with pressure.
- To Iock: Switch S16 "Off"
Solenoid valve Y14 in neutral position, connects P - A, B - T. hydraulic cylinder 2 are actuated on
the piston side constantly with system pressure from the working hydraulic.
1 Locking pin
2 Hydraulic cylinder
L 512 from S/N 176
L 522 from S/N 290
4 Orifice 1 mm
B9 Pressure switch 5 bar
Y14 Soelnoid valve
H19 lndicator light
S16 Switch
06.94
HydrauIic
L 512 / L 522 152 / 234
20.30.06
1
1. To reIease the hydrauIic quick change coupIer
To disconnect the attachment:
2
1.1 Turn on switch S16 (warning sound)
The solenoid valve Y14 shifts (P - B, A - T)
The buzzer is actuated (triggered via switch S16)
3
1.2 Move control lever to position C (tilt in) and drive to block.
Note:
To release or lock the quick change coupler, the system
pressure in the working hydraulic must be built up by moving
the control lever to "tilt in" function.
4
2. To Iock the hydrauIic quick change coupIer
To attach the attachment:
2.1 Turn off switch S16 (the warning sound turns off)
Solenoid valve Y14 is not actuated
Neutral position connects P - A, B - T
5
2.2 Bring control lever to position C (tilt in ) and drive to
block .
The hydraulic cylinders 2 are constantly actuated with
system pressure from the working hydraulic and there-
fore held in locking position.
The function is also monitored via the switch B9
(shifting point 5 bar), which actuates the indicator light
H19 in case a hose brakes or in case the pressure
drops to below 5 bar.
Note:
Before operating the machine with attached attach-
ment, check the locking position, to assure it is secu-
re.
Note:
Even if the working or steering function is not actuated, the pressure is about 8 bar (dynamic
pressure).
To check the indicator light:
The indicator light lights up when the engine is not running and the key is in position l.
ln L 512 up to S/N 176 and L 522 up to S/N. 290, the indicator light H19 also lights up when the
switch S16 is turned on.
Y14 Solenoid valve / Quick change coupler
1 Hydraulic tank
4 Orifice 1 mm
10 Diesel engine
15 Gear pump (working and steering hy-
draulic)
50 Control valve block
80 Lift cylinder
81 Tilt cylinder
06.94
HydrauIic -
L 512 / L 522 152 / 234
20.30.07
06.94
HydrauIic
L 512 / L 522 152 / 234
20.30.08
EI. FunctionaI schematic
A1 Electronic control
FB9 Fuse
H19 lndicator light
S14 Switch / bucket return
S16 Switch / quick change coupler
V5 Diode
Y14 Solenoid valve
X1 Plug connection, 70-pole
X32 Plug, 4-pole
ST5 Plug connection, buzzer function
ST6 Plug connection
(Control of solenoid valves)
11.93
3. ControI Circuit with
Servo ControI
L 512 / L 522 152 / 234
20.32.01
20 from valve block
30 from replenishing pump
33 Check valve / Servo Control
34 Accumulator
35 Two way valve (shut off valve)
41 Servo control / Additional installations
51 3. Control circuit / Additional installa-
tions
54 Spool / Lift cylinder
55 Spool / Additional installations
64 Sec. pressure relief and suction valve
A2
B2
B1
A3
B3
80 Lift cylinder
81 Tilt cylinder (P-Cinematic)
85 Connector possibility for
11.93
3.ControI Circuit with
Servo ControI
L 512 / L 522 152 / 234
20.32.02
05.97
EIectricaI ControI
L 512 / L 522 152 / 234
20.32.05
Function:
The electrical control is actuated by switching on the switch S12. The solenoid valves Y11 and Y12 are
actuated via the switches S2.3 and the electronic A1. As soon as the actuated switch S2.3 is released,
the spool in the control block returns to the center position (see page 20.32.06 and 20.32.07).
To control the spool, servo oil from the travel pump (connection G) is directed via the check valve 33,
accumulator 34, 2 way directional valve 35 and via end element 52 to the 3rd control circuit 51. Due to
restriction of the servo oil (orifice 58), the spool 55 is controlled smoothly (see schematic, page
20.32.06).
To connect or separate the quick change coupIings to the added instaIIations,
the pressure in the Iines must be reIieved:
Turn the Diesel engine off
Switch the keyed switch to pos. l
Open the 2-way directional valve 35 (shut off valve)
Turn on switch S 12
Actuate both switches S 2.3 several times
10 Diesel engine
15 to oil motors / lubrication oil
20 from valve block and gear pump
29 Travel pump
33 Check valve / Servo control
34 Accumulator
35 Two way valve (shut off valve)
41 Orifice 1,5 mm
42 Orifice 1,5 mm
51 3. Control circuit / electr. control
52 End element
53 Spool / Tilt cylinder
54 Spool / Lift cylinder
55 Spool / 3. Control circuit
56 Solenoid valve Y11
57 Solenoid valve Y12
58 Orifice 0,7 mm
60 Primary-pressure relief valve
A2
B2
B1
A3
B3
80 Lift cylinder
81 Tilt cylinder
85 Connector possibility for
05.97
EIectricaI ControI
L 512 / L 522 152 / 234
20.32.06
11.94
EIectricaI ControI
L 512 / L 522 152 / 234
20.32.07
FunctionaI schematic:
A1 Electronic
S12 Switch
S2.3 Switch
Y11 Solenoid valve
Y12 Solenoid valve
V5 Diodes
X38 Valve plug, 4-pole
X39 Valve plug, 4-pole
05.97
Speed Limiter
20 km/h
L 512 101
20.36.01
Description Pos. Id. No.
Speed tag 20 1 9226 777
Safety cap 2 7009 316
for modification kit, complete 9518 919
Adjustment procedure 20 km/h :
Set threaded pin 1 (same threaded pin as for 32 km/h) to given measurement
(X = 8.2 mm).
Raise the machine or drive on level ground. Accelerate in 2nd travel range, to maximum speed.
lf this speed cannot be obtained or gets above 20 km/h , correct on threaded pin 1 (Q-min stop).
Secure the pin 1 with the safety cap 2 .
05.97
Speed Limiter
20 km/h
L 522 101
20.36.02
Description Pos. Id. No.
Threaded pin M12 x 90 1 4635 247
Safety cap 2 7009 316
Speed tag 20 3 9226 777
for modification kit, complete 9518 454
Adjustment procedure 20 km/h :
Replace threaded pin 1 (only by retrofit)
Set threaded pin 1 to given measurement (X = 16 mm).
Raise the machine or drive on level ground. Accelerate in 2nd travel range (in 3rd travel range until
S/N 321) to maximum speed.
lf this speed cannot be obtained or gets above 20 km/h, correct on threaded pin 1 (Q-min stop).
Secure the pin 1 with the safety cap 2 .
further instructions, see reverse page
Readjustment of 2nd traveI range: (valid for S/N 101 - 321)
vaIues
Test point
Pressure reducing vaIve 43
(Travel 2. Travel range, full throttle)
Adjustment screw D
Control pressure bar 8 - 12 M3
Speed km/h 15

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