Wheel Loader Liebherr L 512-L 514 Stereo - Service Manual

Service Manual
(20
Wheel loader
(10 points)
L512 - L514 Stereo
(10
en
L512-466/from 0501
L514-467/from 0501
0-)&,)66
Address
Address: LEBHERR-WERK BSCHOFSHOFEN GMBH
Dr. Hans Liebherr Strae 4
A 5500 BSCHOFSHOFEN, AUSTRA
Product identification
Manufacturer: LEBHERR-WERK BSCHOFSHOFEN GMBH
Product group: Wheel loader
Type: L512 L514
Construction number: 466 467
SeriaI number: from 0501 from 0501
Document identification
Order number: 8450816
Author: LBH/Dept. - TP
Document version: 01
ManuaI number:
Owner:
Service Manual
(20
Wheel loader
(10 points)
L512 - L514 Stereo
(10
en
L512-466/from 0501
L514-467/from 0501
0-)&,)66
Foreword
Target group This Service Manual has been written for those whose job it is to make
sure that the machines remain operational on a daily basis. This specifi-
cally includes the mechanics and workshop specialists at Liebherr dealers
and Liebherr branch offices.
Contents n the first chapter you will find information about safety regulations as well
as specifications of the special tools needed for maintenance and repair.
Chapter 2 provides an overview of all important technical data for the
entire machine and the individual assemblies.
The following chapter, entitled Maintenance, contains the maintenance and
inspection schedule, inspection and setting logs, lubrication schedules and
filling quantity tables, a description of maintenance procedures and speci-
fications for prescribed lubricants and fuels.
The technical description of the machine in the following chapters is
divided into 15 functional groups. The design, function, and technical data
for each group, components and parts will be explained.
This manual does not contain repair instructions. Repair manuals for
individual components are available upon request.
How to use this manuaI This manual describes a variety of types and finished forms. n general,
this information applies to the types and serial number groups specified in
the footnotes. One exception is that specific type and serial number data
are indicated at the beginning of each section (e.g. the technical specifica-
tions of the components).
Whenever possible, parts and components are supplemented by indication
of the identification number in the heading.
This manual is available in German, English and French.
Working instructions t is imperative that safety regulations be observed with all tasks done on
the machine. You will find information on this in the "GeneraI
Information" chapter.
A complete set of tools in perfect condition is required for work on the
machine, along with any special tools that might be needed. Absolute
cleanliness must be observed with all tasks!
Sealing material such as O-rings and surface seals should be replaced
whenever repairs are carried out.
CD edition We would particularly like to draw your attention to the fact that this book
is available not only in printed form, but also as an electronic document on
CD.
Service manual
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A
Accessories 18.0 - 1
Air filter 16.2 - 4
Function description 16.2 - 5
Layout 16.2 - 5
Technical data 16.2 - 5
Air filter system 4.3 - 1
Layout 4.3 - 1
Air-conditioning system 2.1 - 20
16.3 - 1
Basic refrigeration function 16.3 - 2
Layout 16.3 - 1
Re-heat mode 16.3 - 3
Temperature control 16.3 - 3
Articulation lock 13.3 - 1
Basic function 13.3 - 1
Layout 13.3 - 1
Attachments 18.0 - 1
B
Ballast weight 2.1 - 20
13.4 - 1
Layout 13.4 - 1
Technical data (ID 9654274) 13.4 - 1
Batteries 10.4 - 1
Layout 10.4 - 1
Battery 2.1 - 18
10.4 - 1
Bleeder filter 7.5 - 12
Function 7.5 - 13
Layout 7.5 - 12
Blower 2.1 - 20
16.2 - 2
Layout 16.2 - 2
Brake light pressure switch 9.1 - 4
Layout 9.1 - 4
Switching on the brake lights 9.1 - 5
Brake system 9.0 - 1
Layout 9.0 - 3
Bucket bearing 17.1 - 5
Bearing sealing 17.1 - 5
Layout 17.1 - 5
4-in-1 bucket 18.3 - 1
Layout 18.3 - 1
4-in-1 bucket (optional)
(ID 9607757)
2.1 - 23
18.3 - 2
4-in-1 bucket (optional)
(ID 9607758)
2.1 - 23
18.3 - 3
C
Cab 16.0 - 1
Cab windows 16.0 - 4
Layout 16.0 - 1
Cab access 15.2 - 1
Layout 15.2 - 1
Cab roof wiring harness 10.1 - 5
Layout 10.1 - 5
Cab wiring harness 10.1 - 3
Layout 10.1 - 3
Cardan shafts 12.3 - 1
Central lubrication 14.1 - 1
Layout 14.1 - 1
Central lubrication system 14.0 - 1
Central wiring harness 10.1 - 6
Layout 10.1 - 6
Cold start solenoid valve
(ID 5716155)
8.1 - 6
Cold start solenoid valve 8.1 - 6
Layout 8.1 - 6
(ID 5716694)
8.1 - 8
Index
Index Service manual
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Cold start solenoid valve 8.1 - 8

Layout 8.1 - 8
Collector pipe 7.5 - 13
Function 7.5 - 14
Layout 7.5 - 13
Complete machine 2.1 - 1
Wheel loader with P-lift arms (L512-
466/0501)
2.1 - 3
467/0501-0786)
2.1 - 9
467/0787-)
2.1 - 11
Wheel loader with Z-bar lift arm
(L512-466/0501)
2.1 - 1
(L514-467/0501-0786)
2.1 - 5
(L514-467/0787-)
2.1 - 7
Control board A2 10.2 - 1
Layout 10.2 - 1
Control electronics A1 10.3 - 1
Emergency steering check 10.3 - 4
Emergency steering pump 10.3 - 5
Emergency steering pump control 10.3 - 4
Fan control 10.3 - 3
Layout 10.3 - 1
LED display 10.3 - 5
Plug assignment 10.3 - 2
Control panel 16.1 - 1
Adjustable steering column with
steering wheel and steering column
switch
16.1 - 1
Layout 16.1 - 1
Rear part of the control panel 16.1 - 2
Right side cover (control panel) 16.1 - 1
Control valve block 7.2 - 1
Layout 7.2 - 1
Primary pressure relief valve 7.2 - 5
Secondary pressure relief valves 7.2 - 5
Working hydraulics in active condition 7.2 - 3
Working hydraulics in inactive
condition
7.2 - 3
Working hydraulics in the float
position
7.2 - 4
Cooling system 5.0 - 1
Electric control of the fan speed 5.0 - 4
Hydraulic control of the fan speed 5.0 - 4
Layout 5.0 - 3
Coupling 2.1 - 13
4.4 - 1
Layout 4.4 - 1
Covering 15.1 - 1
Layout 15.1 - 1
D
Dashboard wiring harness 10.1 - 2
Layout 10.1 - 2
Diesel engine 2.1 - 12
4.1 - 1
Layout 4.1 - 1
Differential 12.1 - 3
12.2 - 3
Differential speed locking function 12.1 - 4
12.2 - 4
12.2 - 4
Layout 12.1 - 3
12.2 - 3
Speed balance of the right and left
wheels
12.1 - 4
12.2 - 4
Disc brake 2.1 - 18
9.3 - 1
Layout 9.3 - 1
Display unit 16.1 - 2
Air filter contamination display 16.1-11
Coolant temperature display function 16.1 - 6
Direction indicator display 16.1-11
Service manual
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Displaying / reporting emergency
steering
16.1-10
Displaying / reporting the braking
system accumulator pressure
16.1-11
Displaying and reporting the engine oil
pressure
16.1 - 7
Displaying forward / reverse travel
direction
16.1 - 7
Displaying or reporting engine
overheating
16.1 - 9
Displaying parking brake activation 16.1 - 8
Displaying speed, operating hours or
time
16.1 - 6
Displaying the battery charge control 16.1 - 7
Displaying working hydraulics lockout
activation
16.1 - 9
Displaying/reporting hydraulic oil
overheating
16.1 - 8
Fuel supply indicator 16.1 - 5
High beam display 16.1-11
Instruction to use the safety belt 16.1 - 9
Lamp check during the starting
procedure
16.1 - 5
Layout 16.1 - 2
Preglow monitoring 16.1-10
Special function 16.1 - 9
Travel range display 16.1 - 8
E
Electrical system 10.0 - 1
Circuit diagrams 10.0 - 1
Electric switching of the travel
hydraulics
10.0 - 5
Electric switching of the working
hydraulics
10.0-10
How the parking brake switch S17
works
10.0 - 7
Layout 10.0 - 1
Emergency steering 8.4 - 1
Activated emergency steering system 8.4 - 2
Emergency steering function check 8.4 - 2
Layout 8.4 - 1
Emergency steering check pressure
switch
2.1 - 17
8.4 - 6
Checking the emergency steering
system
8.4 - 7
Layout 8.4 - 6
Emergency steering pressure switch 2.1 - 17
8.4 - 5
Layout 8.4 - 5
Switching on the emergency steering
function
8.4 - 6
8.4 - 3
Gear pump with pressure relief valve 8.4 - 4
Layout 8.4 - 3
Relay and overheating protection 8.4 - 4
Equalising reservoir 9.1 - 3
Layout 9.1 - 3
Pressure balance in the equalising
reservoir
9.1 - 4
F
Fine fuel filter 2.1 - 13
4.2 - 6
Layout 4.2 - 6
Forklift 18.2 - 1
Layout 18.2 - 1
Forklift (optional) 2.1 - 22
18.2 - 2
Front axle 2.1 - 19
12.1 - 1
Axle lubrication 12.1 - 2
Layout 12.1 - 1
Service brake and parking brake 12.1 - 2
Wheel attachment 12.1 - 2
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Front drive shaft 2.1 - 19

12.3 - 1
Function 12.3 - 1
Layout 12.3 - 1
Uniformity of torque transmission 12.3 - 1
Fuel level sensor 4.2 - 3
Layout 4.2 - 3
Fuel pre-filter 2.1 - 13
4.2 - 5
Layout 4.2 - 5
Fuel system 4.2 - 1
Layout 4.2 - 1
Fuel tank 2.1 - 13
4.2 - 2
Layout 4.2 - 2
G
Gear motor 2.1 -14
5.2 - 1
Fail-safe function (breakdown safety) 5.2 - 3
Fan speed control 5.2 - 3
Layout 5.2 - 1
Pressure control with the proportional
pressure relief valve
5.2 - 3
Proportional pressure relief valve 5.2 - 2
Gearwheel pump 2.1 -14
5.1 - 1
Layout 5.1 - 1
Pressure relief 5.1 - 2
H
Heat exchanger 16.2 - 3
Basic function of the heat exchanger 16.2 - 3
Layout 16.2 - 3
Heating 2.1 - 20
16.2 - 1
Heater/ventilation basic function 16.2 - 2
Layout 16.2 - 1
Heating wiring harness 10.1 - 4
Layout 10.1 - 4
High dump bucket 18.5 - 1
Layout 18.5 - 1
High dump bucket (optional)
(ID 9608916)
2.1 - 23
18.5 - 3
Hydraulic oil temperature switch 7.5 - 14
Hydraulic oil overheat warning
function
7.5 - 15
Layout 7.5 - 14
Hydraulic quick-change device 7.6 - 1
Layout 7.6 - 1
Releasing the quick-change device 7.6 - 2
The quick-change device when locked 7.6 - 2
Hydraulic quick-change device for P-
lift arm
2.1 - 21
17.3 - 3
Hydraulic quick-change device for Z-
lift arm
2.1 - 21
17.3 - 2
Hydraulic tank 7.5 - 1
Bleeder filter 7.5 - 2
Collector pipe 7.5 - 2
Layout 7.5 - 1
Return strainer 7.5 - 2
Return suction filter 7.5 - 1
Hydro accumulator pilot control
(ID 5719063)
2.1 - 15
7.3 - 13
Layout 7.3 - 13
Storing pressure for the pilot control 7.3 - 14
Inching function 6.3 - 1
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Layout 6.3 - 1
Inching valve 6.3 - 2
Function 6.3 - 3
Layout 6.3 - 2
Injection pump 4.1 - 5
Layout 4.1 - 5
L
LH control lever 16.1-15
Function description 16.1-17
Layout 16.1-15
Lift arm 17.0 - 1
Lift cylinder and tilt cylinder 7.4 - 1
Lift cylinder / P-bar kinematics 2.1 - 16
7.4 - 3
Extending and retracting 7.4 - 3
Layout 7.4 - 3
Piston rod guide 7.4 - 3
Sealing 7.4 - 3
Lift cylinder / Z-bar kinematics 2.1 - 16
7.4 - 1
Layout 7.4 - 1
Sealing 7.4 - 2
Loading bucket 18.1 - 1
Layout 18.1 - 1
Loading bucket (ID 9657896) 2.1 - 22
18.1 - 2
18.1 - 3
18.1 - 4
18.1 - 5
Lubricants and fuels 3.7 - 1
Conversion from mineral oils to
environmentally compatible hydraulic
fluids
3.7 - 1
Disposing of used materials 3.7 - 1
Environmental protection measures 3.7 - 1
Handling lubricants and fuels 3.7 - 1
Lubricant and fuel specifications 3.7 - 2
Anti-seize agent for bolt fitting 3.7 - 9
Bl * standard lubricants 3.7 - 9
Brake oil 3.7 - 7
Coolants for diesel engines 3.7 - 5
Corrosion protection grease 3.7 - 9
Diesel fuels 3.7 - 4
Grease for general lubrication points 3.7 - 8
Hydraulic oils 3.7 - 6
Lubricant grease for the automatic
central lubrication system
3.7 - 8
Lubricating oils for the diesel engine 3.7 - 2
Lubricating oils for the transmission 3.7 - 8
Lubrication chart 3.4 - 4
M
Main brake cylinder 2.1 - 18
9.1 - 3
Layout 9.1 - 3
Maintenance and inspection schedule 3.1 - 1
Maintenance tasks 3.5 - 1
O
Oscillating axle mount 13.2 - 1
Layout 13.2 - 1
P
Parking brake 9.2 - 1
How the parking brake switch works 9.2 - 3
Layout 9.2 - 1
Parking brake solenoid valve and
hydro accumulator
9.2 - 4
Valve block 9.2 - 3
Working hydraulics pump 9.2 - 3
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Parking brake hydro accumulator 9.2 - 5

Layout 9.2 - 5
Storing pressure for the parking brake 9.2 - 5
Parking brake pressure switch 2.1 - 18
9.2 - 11
Layout 9.2 - 11
Parking brake monitoring function 9.2 - 11
Parking brake solenoid valve
(ID 5716155)
9.2 - 7
Layout 9.2 - 7
Parking brake solenoid valve 9.2 - 7
(ID 5716694)
9.2 - 9
Layout 9.2 - 9
Parking brake solenoid valve 9.2 - 9
P-bar lift arm 2.1 - 21
17.2 - 1
Layout 17.2 - 1
Movements of the bucket arm 17.2 - 2
Movements of the working attachment 17.2 - 2
Pilot control 7.3 - 1
Hydro accumulator with check valve 7.3 - 4
Layout 7.3 - 1
Pilot control solenoid valve 7.3 - 4
Pilot control solenoid valve and hydro
accumulator
7.3 - 4
Pilot control unit 7.3 - 3
Variable displacement pump with
replenishing pump
7.3 - 3
Pilot control unit 2.1 - 15
7.3 - 5
Electromagnetic lock 7.3 - 8
Layout 7.3 - 5
Regulating phase 7.3 - 8
Resting condition 7.3 - 7
Pilot control solenoid valve
(ID 5716155)
7.3 - 9
Layout 7.3 - 9
(ID 5716694)
7.3 - 11
Layout 7.3 - 11
Q
Quick-change device 17.3 - 1
Layout 17.3 - 1
Quick-change device cylinder 7.6 - 5
Layout 7.6 - 5
Sealing 7.6 - 6
Quick-change device pressure switch 7.6 - 4
Layout 7.6 - 4
Quick-change device monitoring
function
7.6 - 4
Quick-change device solenoid valve 7.6 - 2
Hydraulic quick-change device
solenoid valve
7.6 - 3
Layout 7.6 - 2
R
Rear axle 2.1 - 19
12.2 - 1
Axle lubrication 12.2 - 2
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Layout 12.2 - 1
Return strainer 2.1 - 16
7.5 - 11
Layout 7.5 - 11
Return suction filter (ID 7621815) 2.1 - 16
7.5 - 3
Layout 7.5 - 3
Pressure preloading on the suction
side
7.5 - 5
Pressure relief by the bypass valve 7.5 - 5
Return suction filter (ID 7623206) 7.5 - 7
Layout 7.5 - 7
Pressure preloading on the suction
side and replenishing function
7.5 - 9
Pressure relief by the bypass valve 7.5 - 10
RPM sensor 2.1 - 19
11.1 - 2
Layout 11.1 - 2
S
Safety regulations 1.1 - 1
Introduction 1.1 - 1
Overview of safety regulations 1.1 - 2
Service brake 9.1 - 1
Disc brake 9.1 - 2
Equalising reservoir 9.1 - 2
Layout 9.1 - 1
Main brake cylinder 9.1 - 2
Servostat 2.1 - 17
8.2 - 1
Flow demand control (load sensing) 8.2 - 2
Layout 8.2 - 1
Pressure relief 8.2 - 3
Replenishing function 8.2 - 4
Steering in active condition 8.2 - 3
Steering in inactive condition 8.2 - 2
Side cover switch wiring harness 10.1 - 1
Layout 10.1 - 1
Side dump bucket 18.4 - 1
Layout 18.4 - 1
Side dump bucket (optional)
(ID 9608605)
2.1 - 23
18.4 - 2
Side dump bucket (optional)
(ID 9608985)
2.1 - 23
18.4 - 3
Special tools for maintenance and
repair work
1.2 - 1
Special electrical tools 1.2 - 1
Special tools for Liebherr diesel
engines
1.2 - 2
Special tools for the hydraulic
cylinders
1.2 - 2
Special tools for ZF axles 1.2 - 3
Special tools, general 1.2 - 1
Steering axle wheel hub 12.2 - 5
Layout 12.2 - 5
Wheel attachment 12.2 - 5
Steering cylinder 2.1 - 17
8.3 - 1
Layout 8.3 - 1
Sealing 8.3 - 1
Steering pump 8.1 - 1
Steering system oil supply 8.1 - 1
Steering system 8.0 - 1
Emergency steering function 8.0 - 7
Layout 8.0 - 3
Servostat 8.0 - 7
Steering cylinder 8.0 - 7
Valve block 8.0 - 6
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Switches on the instrument panel 16.1-12
Engaging and releasing the parking
brake
16.1-13
Function description 16.1-13
Layout 16.1-12
Switches on the side cover 16.1-14
Layout 16.1-14
T
Table of filling quantities (L512-
466/0501)
3.4 - 1
Table of filling quantities (L514-
467/0501)
3.4 - 2
Temperature sensor 5.3 - 1
Layout 5.3 - 1
Temperature measurement 5.3 - 1
Tests, adjustments 3.6 - 1
Testing and adjustment checklists 3.3 - 1
Testing and adjustment plan 3.2 - 1
Tilt cylinder / P-bar kinematics 2.1 - 16
7.4 - 6
Layout 7.4 - 6
Sealing 7.4 - 6
Tilt cylinder / Z-bar kinematics 2.1 - 16
7.4 - 4
Layout 7.4 - 4
Sealing 7.4 - 5
Transfer gear 2.1 - 18
11.1 - 1
Layout 11.1 - 1
Travel hydraulics 6.0 - 1
Inching valve 6.0 - 6
Layout 6.0 - 3
Variable displacement motor 6.0 - 6
Variable displacement pump 6.0 - 5
V
Valve block 2.1 - 17
7.1 - 2
8.1 - 1
9.2 - 4
8.1 - 2
9.2 - 4
Charging the accumulator for the
parking brake
9.2 - 4
Diesel engine starting procedure 8.1 - 3
Distribution of the oil flow in the
working hydraulics pump
7.1 - 2
8.1 - 2
Filling the parking brake hydro
accumulator
8.1 - 4
Layout 8.1 - 1
Pressure relief for the steering 8.1 - 4
Variable displacement motor 2.1 - 15
6.2 - 1
Cooling by the discharge valve 6.2 - 6
Layout 6.2 - 1
Machine in travel range 1 6.2 - 5
Speed-dependent control (DA control) 6.2 - 5
Variable displacement pump 2.1 - 14
6.1 - 1
Control by the operating pressure 6.1 - 8
Control of the pump 6.1 - 7
Layout 6.1 - 1
Pressure cut-off 6.1 - 10
Pressure relief and replenishing valve 6.1 - 11
Replenishing pressure relief valve 6.1 - 10
Replenishing pump 6.1 - 9
Servo piston and swash plate 6.1 - 6
Speed-dependent control (DA control) 6.1 - 7
Travel direction valve 6.1 - 9
Service manual
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Vehicle frame 13.1 - 1
Layout 13.1 - 1
Ventilation 2.1 - 20
16.2 - 1
Heater/ventilation basic function 16.2 - 2
Layout 16.2 - 1
W
Water valve 16.2 - 4
Layout 16.2 - 4
Wheel hub 12.1 - 5
12.1 - 6
Windscreen wiper and washer system 16.4 - 1
Front and rear windshield washer
system
16.4 - 1
Layout 16.4 - 1
Wiring harnesses 10.1 - 1
Working hydraulics 7.0 - 1
Hydraulic quick-change device 7.0 - 7
Layout 7.0 - 3
Oil cooler 7.0 - 6
Pilot control 7.0 - 7
Valve block 7.0 - 6
Working hydraulics pump 2.1 -15
7.1 - 1
Layout 7.1 - 1
Oil supply for the working hydraulics,
steering system and brake system
7.1 - 1
Z
Z-bar lift arm 2.1 - 21
17.1 - 1
Layout 17.1 - 1
Movements of the bucket arm 17.1 - 2
Movements of the working attachment 17.1 - 2
GeneraI information 1
Product description 2
Maintenance 3
DieseI engine, pump distributor gear 4
CooIing system 5
TraveI hydrauIics 6
Working hydrauIics 7
Steering system 8
Brake system 9
EIectricaI system 10
Transfer gear 11
AxIes, tyres 12
VehicIe frame, baIIast weight 13
CentraI Iubrication system 14
Covering, cab access 15
Cab, heating, air-conditioning system 16
Lift arm, quick-change device 17
Attachments, accessories 18
L512-466/from 0501
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1 GeneraI information
Chapter contents
1 General information 1.0 - 1
1.1 Safety regulations 1.1 - 1
1.1.1 ntroduction 1.1 - 1
1.1.2 Overview of safety regulations 1.1 - 2
1.2 Special tools for maintenance and repair work 1.2 - 1
1.2.1 Special tools, general 1.2 - 1
1.2.2 Special electrical tools 1.2 - 1
1.2.3 Special tools for Liebherr diesel engines 1.2 - 2
1.2.4 Special tools for the hydraulic cylinders 1.2 - 2
1.2.5 Special tools for ZF axles 1.2 - 3
1.0 - 1 of 2
General information Service manual
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1.1 Safety reguIations
Working on the machine poses safety risks to the operator, driver or
maintenance technicians. You can considerably reduce the risk of ac-
cidents by always reading and observing the various safety instructions
carefully.
This is especially important for personnel who only occasionally work on
the machine, for example, carrying out rigging or maintenance work.
The safety regulations listed below, if conscientiously followed, will ensure
your own safety and that of others, and will prevent the machine from
being damaged.
Whenever tasks which could cause danger to personnel or damage to the
machine are described in this manual, the necessary safety precautions
are explained.
These are indicated by the headings Danger, Warning or Caution.
1.1.1 Introduction
1. The symbols below have the following meaning:
"Danger"
Warning that without appropriate precautions, certain operational proce-
dures could result in fatal accidents.
"Warning"
Warning that without appropriate precautions, certain operational proce-
dures could result in severe physical injuries.
"Caution"
Warning that without appropriate precautions, certain operational
procedures could result in minor physical injuries or damage to the ma-
chine.
2. Observance of these instructions does not exempt you of the respon-
sibiIity of foIIowing any additionaI ruIes and guideIines that may
appIy!
The following should also be observed:
The safety rules in force at the operating site
Legally enforceable road traffic regulations
Guidelines issued by trade associations
Safety regulations
1.1 - 1 of 2
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1.1.2 Overview of safety reguIations
1. A detailed description of these is included in the relevant section of the
"Operator's manuaI" in the "Safety reguIations" section.
The following sections are described in the "Operator's manual:
1 ntroduction
2 General safety regulations
3 Proper use
4 Decals on the machine
5 nstructions for avoiding crushing injuries and burns
6 nstructions for avoiding fires and explosions
7 Safety instructions for start-up
8 Safety precautions during start-up
9 nstructions for safe working
10 Safety instructions for driving on slopes
11 Parking safely
12 Transporting the machine safely
13 Towing the machine safely
14 Measures for ensuring safe maintenance
15 Safety instructions for welding work on the machine
16 nstructions for working safely on machine attachments
17 Safety regulations when transporting the machine by crane
18 Safe maintenance of hydraulic hoses and hose lines
19 Attachments and accessories
Safety regulations
1.1 - 2 of 2
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1.2 SpeciaI tooIs for maintenance and
repair work
1.2.1 SpeciaI tooIs, generaI
Name ID no. Use Notes
Digital second thermometer 7020372 All wheel loaders
For taking temperature measurements
during adjustment work
ONO Sokki tachometer 7009538 All wheel loaders
For checking the speed of the diesel
engine
Optical density tester 7408922 All wheel loaders
For testing the density of the anti-
freeze and battery acid
24 Volt vacuum pump 7408148 All wheel loaders For preventing oil loss
12V to 25V voltage converter 6905469 L512 - L514 For the vacuum pump
0-40 bar pressure gauge 7361288 All wheel loaders For testing hydraulic pressures
Pressure gauge connection 7002436 All wheel loaders Connection for pressure gauge
1500 mm high-pressure tube 7002475 All wheel loaders High-pressure tube for pressure gauge
4000 mm high-pressure tube 7009134 All wheel loaders High-pressure tube for pressure gauge
Oil drain hose 7005660 All wheel loaders For draining oil via an outlet valve
Outlet piece 7402657 All wheel loaders For the oil drain hose
Safety cap SW 10 7009315 All wheel loaders
For securing the valves on the variable
displacement motor
Safety cap SW 13 7615515 All wheel loaders For securing the valves on the pumps
Safety cap SW 17 7622068 All wheel loaders
For securing the valves on the control
valve block
1.2.2 SpeciaI eIectricaI tooIs
Digital multimeter 8502956 All wheel loaders
For measuring electrical voltage, cur-
rent, resistance and frequency
Solenoid tester 8145743 All wheel loaders For checking solenoid valves
Manual crimping tool 8145434 All wheel loaders For MATE-N-LOK connectors
nsertion tool 8145432 All wheel loaders For MATE-N-LOK connectors
Extraction tool 8145433 All wheel loaders For MATE-N-LOK connectors
Manual crimping tool 7367086 All wheel loaders For DEUTSCH connectors
Size 12 extraction tool for pin
and bushing
8145674 All wheel loaders For DEUTSCH connectors
Size 16 extraction tool for pin
and bushing
8145673 All wheel loaders For DEUTSCH connectors
Special tools for maintenance and repair work
1.2 - 1 of 4
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1.2.3 SpeciaI tooIs for Liebherr dieseI engines
Strap wrench 8145593 L512 - L514 diesel engine For removing the lubricating oil filter
Cranking device 7090361 L512 - L514 diesel engine
For turning the flywheel on the diesel
engine
Adjusting pin 7090360 L512 - L514 diesel engine For setting the diesel engine at TDC
Time-Trac measuring device 7090384 L512 - L514 diesel engine
For checking and adjusting the distribu-
tor injection pump
Extraction tool 7090364 L512 - L514 diesel engine For removing the injection nozzles
nsertion tool 7090382 L512 - L514 diesel engine
For inserting the carbon seal in the
groove of the injection nozzle
Extractor 7090374 L512 - L514 diesel engine
For removing the drive gearwheel from
the injection pump
Mounting device 7090373 L512 - L514 diesel engine For mounting the front crankshaft seal
Extraction device 7090377 L512 - L514 diesel engine For removing the front wear ring
Seal extractor 7090372 L512 - L514 diesel engine For removing the front crankshaft seal
Compression tester 8008782 L512 - L514 diesel engine For testing compression levels
njection nozzle tester 7361236 L512 - L514 diesel engine For testing injection nozzles
1.2.4 SpeciaI tooIs for the hydrauIic cyIinders
80 mm installation sleeve 9227165 Tilt cylinder L512, L514 For fitting the seals
90 mm installation sleeve 9227161
Steering cylinder L512,
L514
For fitting the seals
100 mm installation sleeve 9998626 Lift cylinder L512, L514 For fitting the seals
110 mm installation sleeve 9170509
Tilt cylinder L512, L514 lift
cylinder L514
80 mm expansion tube 9227166 Tilt cylinder L512, L514 For fitting the seals
90 mm expansion tube 9227162
L514
100 mm expansion tube 9110405 Lift cylinder L512, L514 For fitting the seals
110 mm expansion tube 9170511
Tilt cylinder L512, L514 lift
cylinder L514
Assembly wrench - bearing
head 88/10 mm
9904497 Lift cylinder L512, L514 For fitting the bearing head
Assembly wrench - bearing
head 92/12 mm
9241799 Tilt cylinder-Z L512, L514 For fitting the bearing head
Assembly wrench - piston
70/8 mm
9210219 Tilt cylinder-P L512, L514 For fitting the piston
Assembly wrench - piston
75/12 mm
9239572
L514
For fitting the piston
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1.2.5 SpeciaI tooIs for ZF axIes
Grooved nut wrench 7021789
Front axle L514, rear axle
L514
For grooved nuts on the hub carrier
Centring disc 7623793
Front axle L514, rear axle
L514
Use with grooved nut wrench D No.
7021789
Measuring shaft 7011521
Front axle L512, L514, rear
axle L514
Differential measurement and adjust-
ment work
Measuring lid 7013956
axle L514
For differential measurement and ad-
justment work
Tensioner 7623794
axle L514
justment work
Spacer 7623798
axle L514
justment work
Handle 7011518
axle L512, L514
Use with various mounting tools
Mounting tool 7623795
axle L512, L514
For mounting the shaft seal ring
Mounting tool 7623797
axle L512, L514
For mounting the bearings in the wheel
hub
Handle 7017566
axle L512, L514
Use with various installation tools
nstallation tool 7623796
axle L512, L514
For fitting the support disc
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2 Product description
Chapter contents
2 Product description 2.0 - 1
2.1 Technical data 2.1 - 1
2.1.1 Complete machine 2.1 - 1
2.1.2 Diesel engine, pump distributor gear 2.1 - 12
2.1.3 Cooling system 2.1 - 14
2.1.4 Travel hydraulics 2.1 - 14
2.1.5 Working hydraulics 2.1 - 15
2.1.6 Steering system 2.1 - 17
2.1.7 Brake system 2.1 - 18
2.1.8 Electrical system 2.1 - 18
2.1.9 Transfer gear 2.1 - 18
2.1.10 Axles, tyres 2.1 - 19
2.1.11 Vehicle frame, ballast weight 2.1 - 20
2.1.12 Cab, heating, air-conditioning system 2.1 - 20
2.1.13 Lift arm, quick-change device 2.1 - 21
2.1.14 Attachments, accessories 2.1 - 22
2.0 - 1 of 2
Technical data Service manual
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2.1 TechnicaI data
2.1.1 CompIete machine
WheeI Ioader with Z-bar Iift arm Valid for: L512-466/0501-
The values stated refer to the standard version of the machine:
With Z-bar lift arm (2250 mm) without hydraulic quick-change device
With 15.5-25 EM Dunlop E91-2 tyres.
The specified tipping loads and weight include all lubricants, full fuel
tank, ROPS/FOPS cab and driver.
Dimensions of machine with Z-bar lift arms
Name VaIue Units
Bucket capacity as per DN 7546 1.3 m
Bucket width 2200 mm
Specific material weight 1.8 t/m
A - Dump height at max. lifting height
and 45 tilt-out angle
2750 mm
B - Max. dumping height 3080 mm
C - Max. height of bucket base 3295 mm
D - Max. height of bucket pivot point 3525 mm
E - Max. height of bucket upper edge 4455 mm
Technical data
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Name VaIue Units
F - Reach at max. lifting height and
45 tilt-out angle
830 mm
G - Digging depth 65 mm
H - Height above cab 3025 mm
- Height above exhaust 2690 mm
J - Ground clearance 385 mm
K - Wheel base 2500 mm
L -Overall length 6040 mm
Turning radius over bucket outer edge 4375 mm
Lifting force (SAE) 59 kN
Breakout force (SAE) 73 kN
Tipping load when straight 4970 kg
Tipping load, articulated 28 4635 kg
Angle of articulation (to each side) 28
Angle of swing (to each side) 6
Operating weight 6900 kg
Tractive force 48.8 kN
Travel speed travel range 1 (forward
and reverse)
08.0 km/h
and reverse)
030.0 km/h
Technical data
2.1 - 2 of 24
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WheeI Ioader with P-Iift arms Valid for: L512-466/0501-
With P-bar lift arm (2300 mm) and with hydraulic quick-change device
With 15.5-25 EM Dunlop E91-2 tyres.
Dimensions of machine with P-bar lift arms
Name VaIue Units
2850 mm
45 tilt-out angle
820 mm
Technical data
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Name VaIue Units
Tractive force 49 kN
and reverse)
08.0 km/h
and reverse)
030.0 km/h
Technical data
2.1 - 4 of 24
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WheeI Ioader with Z-bar Iift arm Valid for: L514-467/0501-0786
with 15.5R25 EM Dunlop E91-2 tyres.
Travel speeds with 17.5R25 tyres
The stated tipping loads and weights:
nclude all lubricants, full fuel tank, ROPS/FOPS cab and driver.
With 280 kg additional ballast.
Name VaIue Units
2825 mm
45 tilt-out angle
840 mm
Technical data
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Name VaIue Units
and reverse)
08.0 km/h
and reverse)
030.0 km/h
Technical data
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WheeI Ioader with Z-bar Iift arm Valid for: L514-467/0787-
With 17.5R25 GoodYear GP-2B tyres.
Name VaIue Units
2825 mm
45 tilt-out angle
835 mm
Technical data
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Name VaIue Units
and reverse)
08.0 km/h
and reverse)
030.0 km/h
Technical data
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WheeI Ioader with P-Iift arms Valid for: L514-467/0501-0786
With 15.5R25 EM Dunlop E91-2 tyres.
Travel speeds with 17.5R25 tyres
The stated tipping loads and weights:
nclude all lubricants, full fuel tank, ROPS/FOPS cab and driver.
With 280 kg additional ballast.
Name VaIue Units
2965 mm
45 tilt-out angle
850 mm
Technical data
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Name VaIue Units
and reverse)
08.0 km/h
and reverse)
030.0 km/h
Technical data
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WheeI Ioader with P-Iift arms Valid for: L514-467/0787-
With 17.5R25 GoodYear GP-2B tyres.
Name VaIue Units
3010 mm
45 tilt-out angle
800 mm
Technical data
2.1 - 11 of 24
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Name VaIue Units
and reverse)
08.0 km/h
and reverse)
030.0 km/h
2.1.2 DieseI engine, pump distributor gear
DieseI engine Valid for: L512-466/0501-
Name VaIue Units
Engine type D 504 NA
Number of cylinders 4
Cylinder volume 4500 cm
Rated power according to SO 9249 59 / 80 kW / hp
Rated speed 2400 min
-1
Max. torque at 1200 min
-1
302 Nm
Lower idling speed 830
50
min
-1
Upper idling speed 2550
+50
min
-1
nlet valve play (cold) 0.35 mm
Outlet valve play (cold) 0.45 mm
Coolant thermostat opening tempera-
ture
82 C
nclinability longitudinal / traverse 30 / 30
Operating voltage of the starter 12 V
Power consumption of the starter 4.8 kW
Output voltage of alternator 14 V
Current output from alternator 65 A
Emission limit values in accordance
with
SO /EPA
Technical data
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DieseI engine Valid for: L514-467/0501-
Name VaIue Units
Engine type D 504 T
-1
-1
395 Nm
50
min
-1
+50
min
-1
Coolant thermostat opening tempera-
ture
82 C
Operating voltage of the starter 12 V
Power consumption of the starter 4.8 kW
Emission limit values in accordance
with
SO /EPA
FueI tank Name VaIue Units
Tank level FULL 140 l
Tank RESERVE 10 l
FueI pre-fiIter Valid for: L512-466/0785-; L514-467/0785-
Name VaIue Units
Filter type n-line filter
Filter name AL 67 975
Fine fueI fiIter Name VaIue Units
Type Fine fuel filter with
water separator
CoupIing Name VaIue Units
Type CF-K 125-10-A
Technical data
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2.1.3 CooIing system
GearwheeI pump Name VaIue Units
Displacement 11 cm
Gear motor Name VaIue Units
Displacement of the gear motor 8 cm
Pressure relief valve 175
5
bar
2.1.4 TraveI hydrauIics
VariabIe dispIacement pump Valid for: L512-466/0501-; L514-467/0501-0786
Name VaIue Units
Type A4VG 90 DA
Max. displacement 90 cm
Flow at rated engine speed 216 l/min
Power output 65 kW
Displacement of the replenishing
pump
19 cm
Mass 60 kg
Pressure cut-off 430
5
bar
VariabIe dispIacement pump Valid for: L514-467/0787-
Name VaIue Units
Type A4VG 90 DA
Power output 65 kW
pump
19 cm
Mass 60 kg
5
bar
VariabIe dispIacement motor Valid for: L512-466/0501-
Name VaIue Units
Type A6VM 160 DA
Min. displacement 44.3 cm
Max.speed 4980 min
-1
Technical data
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Name VaIue Units
Torque (Dp 400 bar) 1016 Nm
Mass 64 kg
Control range when travelling 180
10
bar
VariabIe dispIacement motor Valid for: L514-467/0501-
Name VaIue Units
Type A6VM 200 DA
Max.speed 4005 min
-1
Mass 80 kg
10
bar
2.1.5 Working hydrauIics
Working hydrauIics pump Name VaIue Units
Type P 330
Displacement 48.4 cm
Power output 40.6 kW
ControI vaIve bIock Name VaIue Units
Type SM 18
Control piston diameter 18 mm
Primary pressure relief valve / L512 210
5
bar
5
bar
PiIot controI unit Name VaIue Units
Type 4 THF 5
Hydro accumuIator - piIot
controI
Name VaIue Units
Hydro accumulator volume 320 cm
Preload pressure (nitrogen filling) 15 bar
Technical data
2.1 - 15 of 24
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Lift cyIinder / Z-bar kinematics Valid for: L512-466/0501-; L514-467/0501-0786
Name VaIue Units
Piston diameter 100 mm
Rod diameter 60 mm
Stroke length 585 mm
Lift cyIinder / Z-bar kinematics Valid for: L514-467/0787-
Name VaIue Units
Rod diameter 60 mm
Lift cyIinder / P-bar kinematics Name VaIue Units
Rod diameter 60 mm
TiIt cyIinder / Z-bar kinematics Valid for: L512-466/0501-
Name VaIue Units
Rod diameter 60 mm
TiIt cyIinder / Z-bar kinematics Valid for: L514-467/0501-
Name VaIue Units
Rod diameter 60 mm
TiIt cyIinder / P-kinematics Name VaIue Units
Rod diameter 45 mm
Return suction fiIter Name VaIue Units
Type SR 200 L-01
Filtration grade 10 m
Return strainer Name VaIue Units
Type SK 3774/2
Technical data
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2.1.6 Steering system
VaIve bIock Name VaIue Units
Type STAC
Accumulator charge valve switch-on
point
130
10
bar
Accumulator charge valve switch-off
point
160
10
bar
Steering pressure relief valve 180
10
bar
Servostat Name VaIue Units
Type Eaton 263 -4392
Displacement 370 cm
Secondary pressure relief 240
10
bar
Steering cyIinder Name VaIue Units
Rod diameter 40 mm
Emergency steering pump Name VaIue Units
Type Bosch A541 020
319
Displacement 4 cm
5
bar
Emergency steering pressure
switch
Name VaIue Units
Type Suco
Switch type N/O switch
Switching point 5
1
bar
Emergency steering check
pressure switch
Name VaIue Units
Type Suco
Switching point 5
1
bar
Technical data
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2.1.7 Brake system
Main brake cyIinder Name VaIue Units
Type Safim
Brake pressure (at 60 kg pedal force) 120 bar
Parking brake pressure switch Name VaIue Units
Type Suco
Switching point 100
5
bar
Disk brake Name VaIue Units
Parking brake / brake pad gap 1.0
0.5
mm
Service brake lining thickness NEW 9.0 mm
Service brake lining thickness MN 2.0 mm
Parking brake lining thickness NEW 4.5 mm
Parking brake lining thickness MN 1.0 mm
2.1.8 EIectricaI system
EIectricaI system Name VaIue Units
Power supply voltage 12 V
Battery Name VaIue Units
Battery voltage 12 V
Battery capacity 88 Ah
Number of batteries Two
2.1.9 Transfer gear
Transfer gear Name VaIue Units
Type 1AVG185
Ratio 1.82
Technical data
2.1 - 18 of 24
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RPM sensor Name VaIue Units
Type nductive encoder
Distance to gearwheel ,A min.0.5 mm
max.0.75 mm
Tapped bore M 18x1.5 mm
Counternut tightening torque 50 Nm
2.1.10 AxIes, tyres
Front axIe Valid for: L512-466/0501-
Name VaIue Units
Type AP-R 735/P4
Locking value of the self-locking dif-
ferential
45 %
Wheel lug tightening torque 650 Nm
Front axIe Valid for: L514-467/0501-
Name VaIue Units
Type AP-R 745
ferential
45 %
Rear axIe Valid for: L512-466/0501-
Name VaIue Units
Type APL-R 735 /
1AVG185
ferential
25 %
Rear axIe Valid for: L514-467/0501-
Name VaIue Units
Type APL-R 745 /
1AVG185
ferential
25 %
Front drive shaft Name VaIue Units
Type GKN
Flange bolt tightening torque 76 Nm
Technical data
2.1 - 19 of 24
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2.1.11 VehicIe frame, baIIast weight
BaIIast weight Valid for: L512-466/0501-
Name VaIue Units
Mass 510 kg
Tightening torque for M20 10.9
screws
560 Nm
BaIIast weight Valid for: L514-467/0501-
Name VaIue Units
Mass 710 kg
screws
560 Nm
2.1.12 Cab, heating, air-conditioning system
Heating, ventiIation Name VaIue Units
Heating output 4800 Watts
BIower Name VaIue Units
Air throughput 630 m/h
Air fiIter Name VaIue Units
Filter type P 5209
Filter class EU3
Filtration 10
Filter surface (effective) 1.8 m
Air-conditioning system Name VaIue Units
Cooling output 4.8 kW
Compressor oil (type) ZXL 100 PG
Compressor oil filling quantity 180 cm
Operating voltage 12 V
Current input (max.) 20 A
Low pressure switch OFF 2.0
0.5
bar
Low pressure switch ON 3.5
0.5
bar
High pressure switch OFF 25.0
2.0
bar
High pressure switch ON 18.0
1.5
bar
Technical data
2.1 - 20 of 24
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Driver's seat with gas spring
suspension
Name VaIue Units
Type SR 6000/575
Type of suspension Gas spring
suspension
2.1.13 Lift arm, quick-change device
Z-bar Iift arm Valid for: L512-466/0501-
Name VaIue Units
L Length 2250 mm
Z-bar Iift arm Valid for: L514-467/0501-
Name VaIue Units
L Length 2350 mm
P-bar Iift arm Valid for: L512-466/0501-
Name VaIue Units
L Length 2300 mm
P-bar Iift arm Valid for: L514-467/0501-
Name VaIue Units
L Length 2400 mm
HydrauIic quick-change device
for Z-Iift arm
Valid for: L512-466/0501-; L514-467/0501-
This equipment is optional.
Name VaIue Units
A System connected dimensions 1000 mm
Mass 200 kg
for P-Iift arm
Valid for: L512-466/0501-; L514-467/0501-
Name VaIue Units
Mass 170 kg
Technical data
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2.1.14 Attachments, accessories
Loading bucket Valid for: L512-466/0501-
Name VaIue Units
B - Bucket width 2200 mm
Heaped bucket capacity (SO 7546) 1.1 m
Name VaIue Units
Name VaIue Units
Name VaIue Units
ForkIift (optionaI) Valid for: L512-466/0501-; L514-467/0501-
Name VaIue Units
Prong length 1200 mm
4-in-1 bucket (optionaI) Valid for: L512-466/0501-; L514-467/0501-
Name VaIue Units
Max. permissible operating pressure
of attachment hydraulics
280 bar
Technical data
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4-in-1 bucket (optionaI) Valid for: L512-466/0501-; L514-467/0501-
Name VaIue Units
280 bar
Side dump bucket (optionaI) Valid for: L512-466/0501-
Name VaIue Units
280 bar
Side dump bucket (optionaI) Valid for: L512-466/0501-; L514-467/0501-
Name VaIue Units
280 bar
High dump bucket (optionaI) Valid for: L514-467/0501-
Name VaIue Units
B Bucket width 2490 mm
Bucket capacity as per SO 7546 2.5 m
250 bar
Technical data
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3 Maintenance
Chapter contents
3 Maintenance 3.0 - 1
3.1 Maintenance and inspection schedule 3.1 - 1
3.2 Testing and adjustment plan 3.2 - 1
3.3 Testing and adjustment checklists 3.3 - 1
3.4 Lubricant chart, Filling quantities 3.4 - 1
3.4.1 Table of filling quantities 3.4 - 1
3.4.2 Table of filling quantities 3.4 - 2
3.4.3 Lubricant chart 3.4 - 4
3.5 Maintenance tasks 3.5 - 1
3.5.1 Preparatory tasks for maintenance 3.5 - 1
3.5.2 Checking the machine for external damage 3.5 - 5
3.5.3 Checking that all screwed connections are tight 3.5 - 6
3.5.4 Sealing any external leaks 3.5 - 6
3.5.5 Checking the oil level in the diesel engine 3.5 - 6
3.5.6 Changing the engine oil 3.5 - 7
3.5.7 Replacing the oil filters 3.5 - 8
3.5.8 Checking and replacing the V-ribbed belt 3.5 - 9
3.5.9 Making sure that the air inlet and exhaust lines are
securely attached 3.5 - 10
3.5.10 Checking the valve play 3.5 - 11
3.5.11 Draining off water and sediment from the fuel tank 3.5 - 14
3.5.12 Draining condensate from the fuel filter 3.5 - 14
3.5.13 Changing the fuel pre-filter 3.5 - 15
3.5.14 Replacing the fuel filter 3.5 - 16
3.5.15 Cleaning the air filter dust extraction valve 3.5 - 17
3.5.16 Cleaning or replacing the air filter main element 3.5 - 18
3.5.17 Checking the air suction hoses 3.5 - 19
3.5.18 Checking the coolant level 3.5 - 20
3.0 - 1 of 4
Maintenance Service manual
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3.5.19 Checking the antifreeze 3.5 - 21
3.5.20 Cleaning the cooling system 3.5 - 21
3.5.21 Replacing the coolant 3.5 - 22
3.5.22 Checking the oil level in the hydraulic tank 3.5 - 23
3.5.23 Checking the oil level in the hydraulic tank 3.5 - 24
3.5.24 Checking and cleaning the magnetic rod on the
hydraulic tank 3.5 - 25
3.5.25 Draining water and sediment from the hydraulic tank 3.5 - 25
3.5.26 Replacing the return suction filter 3.5 - 26
3.5.27 Cleaning the return strainer in the hydraulic tank 3.5 - 27
3.5.28 Replacing the bleeder filter on the hydraulic tank 3.5 - 28
3.5.29 Lubricating the pilot control unit, cleaning the
magnets and lubricating the universal joints 3.5 - 28
3.5.30 Replacing the hydraulic oil 3.5 - 29
3.5.31 Checking the steering 3.5 - 29
3.5.32 Lubricating the bearing points on the steering
cylinder 3.5 - 30
3.5.33 Checking the service brake and parking brake 3.5 - 30
3.5.34 Checking the oil level in the brake system
equalizing reservoir 3.5 - 31
3.5.35 Checking the wear and gap on the brake pads 3.5 - 31
3.5.36 Checking the indicator lamps and lighting 3.5 - 34
3.5.37 Checking the batteries, fluid level and terminals 3.5 - 37
3.5.38 Checking the tightness of the wheel lugs 3.5 - 38
3.5.39 Greasing the axle pivot bearing and the universal
joints on the rear axle 3.5 - 39
3.5.40 Lubricating the front drive shaft 3.5 - 39
3.5.41 Checking the oil levels on the front axle 3.5 - 39
3.5.42 Checking the oil levels on the rear axle 3.5 - 40
3.5.43 Changing the front axle gear oil 3.5 - 41
3.5.44 Changing the rear axle gear oil 3.5 - 42
3.5.45 Setting the correct tyre pressure for the machine's
use and attachments 3.5 - 43
3.5.46 Greasing the articulation and rear axle oscillating
bearings 3.5 - 43
3.5.47 Lubricating the hinges on the rear hatch and engine
compartment hood 3.5 - 45
3.0 - 2 of 4
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3.5.48 Cleaning or replacing the fresh air filter 3.5 - 45
3.5.49 Lubricating the door hinges 3.5 - 46
3.5.50 Checking and lubricating the lift arm bearings 3.5 - 46
3.5.51 Checking and lubricating the bucket bearing 3.5 - 50
3.5.52 Checking the lift arms and bucket stops 3.5 - 51
3.6 Tests, adjustment 3.6 - 1
3.6.1 Preparatory tasks before checking and adjusting 3.6 - 1
3.6.2 Checking the speed of the diesel engine 3.6 - 1
3.6.3 Checking the pressure relief valve of the fan motor
and the fan control 3.6 - 3
3.6.4 Checking the travel hydraulics in the block condition 3.6 - 5
3.6.5 Checking the replenishing pressure of the travel
pump 3.6 - 6
3.6.6 Checking the regulation begin of the travel pump 3.6 - 6
3.6.7 Checking the output of the travel pump 3.6 - 7
3.6.8 Checking the pressure relief and replenishing
valves of the travel pump 3.6 - 8
3.6.9 Checking the pressure cut-off of the travel pump 3.6 - 9
3.6.10 Checking the variable displacement motor within the
control range 3.6 - 10
3.6.11 Checking the secondary pressure relief valves on
the control valve block 3.6 - 10
3.6.12 Checking the primary pressure relief valve on the
control valve block 3.6 - 11
3.6.13 Checking the pressure relief valve of the steering
system 3.6 - 12
3.6.14 Checking the cut-off pressure of the accumulator
charge valve 3.6 - 12
3.7 Lubricants and fuels 3.7 - 1
3.7.1 Handling lubricants and fuels 3.7 - 1
3.7.2 Lubricant and fuel specifications 3.7 - 2
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3.1 Maintenance and inspection scheduIe
The following abbreviations are used in this section:
h = Service hours
OM = Operating manual
SM = Service manual
Various symbols (solid or empty circles, boxes and stars) are used to
indicate the maintenance tasks, which fall into two main types.
Reference sample
The symbols have the following meanings:
Example 1 Paper documentation
Table with solid circle, box or star
Example 2 Online documentation
Table with smbol on a dark grey background
Here, the machine operator or his maintenance personnel are respon-
sible for carring out maintenance tasks.
This affects the maintenance intervals every 10 and 50 service hours (h)
and non-scheduled intervals.
Reference sample
The symbols have the following meanings:
Example 1 Paper documentation
Table with empty circle, box or star, or service hours (h)
Example 2 Online documentation
Table with symbol or service hours (h) on a yellow background
Here, authorised specialist technicians from LEBHERR or its authoris-
ed dealers must perform or direct maintenance and inspection work.
This affects the maintenance intervals on delivery, every 500, 1000,
2000 service hours (h), and at unscheduled times.
You will find a list of the spare parts needed for maintenance and
inspection work in the "SERVCE PACKAGE of the spare parts list.
Maintenance and inspection schedule
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Customer: Machine type: ............................................... Serial No.: .................... Oper. hours: ..................... Date : ....................... ................
Maintenance/inspection
according to operating
hours
TASKS TO BE PERFORMED
By maintenance personneI By authorised quaIified personneI
R One-off activity S One-off activity
P Repetition interval Q Repetition interval
f necessary f necessary
8 Annually at the start of the cold season
CompIete machine
S Have the driver lubricate the machine in accordance with the lubrication chart and
instruct him on proper maintenance
S nstruct the driver in the operation of all functions
S P P Q Q Q Check the machine for external damage
Check that all screwed connections are tight
S Seal any external leaks
S Q Q Check the hydraulic pressure according to the testing and setting plan.
DieseI engine
S P P Q Q Q Check the oil level in the diesel engine
R Q Q Q 250H Change the engine oil (every 250 h or 500 h depending on oil specification)
R Q Q Q Change the oil filter
Q Q Q Check and, if necessary replace the V-ribbed belt
Q Q Make sure that the air inlet and exhaust lines are securely attached
Q Q Check the valve play
S P Q Q Q Drain off water and sediment from the fuel tank
P Q Q Q Drain condensation from the fuel filter
Q Q Change the fuel pre-filter
Q Q Change the fuel filter
P Q Q Q Clean the dust extraction valve of the air filter
Q Q Clean or replace the air filter main element. (Replace the safety element after the main
element has been replaced 3 times)
Q Q Q Check the air suction hoses
CooIing system
S P P Q Q Q Check the coolant level
Q Q Q 8 Check the antifreeze
Clean the cooling system
3000H Replace the coolant (or no later than every 2 years)
Working hydrauIics
S P P Q Q Q Check the oil level in the hydraulic tank
S R Q Q Q 250H Check and clean the magnetic rod on the hydraulic tank
Q Q Q Drain water and sediment from the hydraulic tank
S Q Q Replace the return suction filter
S Q Q Clean the return strainer in the hydraulic tank
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hours
Q Q Replace the bleeder filter on the hydraulic tank
Q Q Lubricate the pilot control unit, clean the solenoids and lubricate the universal joints
Q Replace the hydraulic oil
Steering system
S P P Q Q Q Check that the steering is working properly
S P Q Q Q Lubricate the bearing points on the steering cylinder
Brake system
S P P Q Q Q Check that the service and parking brakes are working properly
S P P Q Q Q Check the oil level in the brake system equalizing reservoir
Q Q Check the play and wear of the brake pads
EIectricaI system
S P P Q Q Q Check the indicator lamps and lighting
Q Q Q Check the batteries, fluid level and terminals
AxIes, tyres
S P Q Q Q Check the tightness of the wheel lugs (once after 50, 100 and 250 h)
S P Q Q Q Grease the lubrication points on the axle pivot steering and the universal joints on the
rear axle
S P Q Q Q Lubricate the front drive shaft
S Q Q Q Check the oil levels on the front axle
S Q Q Q Check the oil levels on the rear axle
S Q Q Replace the front axle gear oil
S Q Q Replace the rear axle gear oil
S Check and adjust the tyre pressure on the attachments and accessories
VehicIe frame, baIIast weight
P Q Q Q Grease the lubrication points on the rear axle, oscillating axle casing and articulated
pendulum bearing
Covering, cab access
Lubricate the hinges on the rear hatch and engine compartment hood
Cab, heating, air-conditioning system
Q Q Clean the fresh air filter and replace if necessary
Lubricate the door hinges
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hours
Lift arms, quick-change device
S P Q Q Q Check and lubricate the lift arm bearings and lubrication points
S P Q Q Q Check and lubricate the bucket bearings (the lower bucket bearings daily, if necessary)
Q Q Q Check the lift arm and bucket stops
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3.2 Testing and adjustment pIan
The tasks listed in the inspection and setting schedule may only be
performed by authorised LEBHERR engineers or contractors.
For a short description of how to perform the inspection and setting tasks,
see the "nspection and setting logs section.
For a detailed description of how to perform these tasks, see the "nspec-
tion and setting tasks section.
Testing and adjustment plan
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hours
DieseI engine, pump distributor gear
S Q Q Check the speed of the diesel engine
CooIing system
Q Q Check the pressure relief valve of the fan motor and the fan control
TraveI hydrauIics
S Q Q Check the replenishing pressure of the travel pump
S Q Q Check the regulation begin of the travel pump
S Q Q Check the output of the travel pump
S Q Q Check the pressure relief and replenishing valves of the travel pump
S Q Q Check the pressure cut-off of the travel pump
S Q Q Check the variable displacement motor within the control range
Working hydrauIics
Q Check the secondary pressure relief valves on the control valve block
Q Check the primary pressure relief valve on the control valve block
Steering system
Q Q Check the pressure relief valve of the steering system
Brake system
Q Q Check the cut-off pressure of the accumulator charge valve
Testing and adjustment plan
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3.3 Testing and adjustment checkIists
Valid for: L512-466/0501-
Testing and adjustment checklists
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3.3 - 2 of 6
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Valid for: L514-467/0501-0786
3.3 - 3 of 6
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3.3 - 4 of 6
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Valid for: L514-467/0787-
3.3 - 5 of 6
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3.3 - 6 of 6
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3.4 Lubricant chart, FiIIing quantities
3.4.1 TabIe of fiIIing quantities
Valid for: L512-466/0501-
Specifications in the "Medium" column:
The standard lubricants and fuels required for central European climate
conditions are stated here.
Before before you change or top up the oiI in the hydrauIic
system (hydrauIic tank), aIways check if it is fiIIed with petroIeum
or bio oiI.
For more detailed information about the required lubricants and service
fuels, see the "Lubricants and fuels section.
Specifications in the "Dosage" column:
The values stated for the filling quantities in the table are only guide-
lines.
The dipstick or level markings are mandatory.
Each time the oil is replaced or topped up, the level in the unit in
question must be checked.
Name Medium Dosage Units
Cooling system die-
sel engine total con-
tent
Coolant 18.4 l
Diesel engine (with
filter change)
Engine oil SAE
10W - 40
11.0 l
Front axle differential Gear oil
SAE 90LS
8 l
Front axle wheel hub
(each)
Gear oil
SAE 90LS
0.7 l
Rear axle differential /
AVG
Gear oil
SAE 90LS
7.0 l
Rear axle wheel hub
(each)
Gear oil
SAE 90LS
0.7 l
Hydraulic tank Engine oil
SAE 20W - 20
65 l
Lubricant chart, Filling quantities
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Hydraulic tank total
content
Engine oil
SAE 20W - 20
105 l
Brake system total
content
Engine oil SAE
10W
1.0 l
Air-conditioning sys-
tem
Refrigerant R
134a
1800 g
3.4.2 TabIe of fiIIing quantities
Valid for: L514-467/0501-
Specifications in the "Medium" column:
The standard lubricants and fuels required for central European climate
conditions are stated here.
Before before you change or top up the oiI in the hydrauIic
system (hydrauIic tank), aIways check if it is fiIIed with petroIeum
or bio oiI.
Specifications in the "Dosage" column:
The values stated for the filling quantities in the table are only guide-
lines.
The dipstick or level markings are mandatory.
Each time the oil is replaced or topped up, the level in the unit in
question must be checked.
Cooling system die-
sel engine total con-
tent
Coolant 21 l
Diesel engine (with
filter change)
Engine oil SAE
10W - 40
13.3 l
Front axle differential Gear oil
SAE 90LS
11 l
Front axle wheel hub
(each)
Gear oil
SAE 90LS
0.8 l
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Rear axle differential /
AVG
Gear oil
SAE 90LS
11.0 l
Rear axle wheel hub
(each)
Gear oil
SAE 90LS
0.8 l
Hydraulic tank Engine oil
SAE 20W - 20
65 l
Hydraulic tank total
content
Engine oil
SAE 20W - 20
105 l
Brake system total
content
Engine oil SAE
10W
1.0 l
Air-conditioning sys-
tem
Refrigerant R
134a
1800 g
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3.4.3 Lubricant chart
Valid for: L512-466/0501-; L514-467/0501-
The lubrication chart provides an overview of the location of the main-
tenance points on the machine and of their maintenance intervals.
You will find detailed information in the section "Maintenance and inspec-
tion schedule, as well as in the individual descriptions of the maintenance
tasks. Please see the section "Maintenance tasks.
For information about the required filling quantities, see the "Filling
quantities table.
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SymboI Name SymboI Name
General lubrication points Lubrication
Check the oil level Check the coolant level
Oil change First oil change
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3.5 Maintenance tasks
3.5.1 Preparatory tasks for maintenance
Before the various maintenance tasks are performed, the machine must be
moved into the maintenance position unless otherwise explicitly specified
in the description.
The various maintenance tasks include:
Lubricating the lift arm
Checking the oil level or changing the oil in the engine, transfer gear,
axles, hydraulic tank, etc.
Replacing the filter as well as inspecting and adjusting the hydraulic
system
Safety precautions for maintenance
It is essentiaI that the accident prevention reguIations are observed
during maintenance work.
See the "Measures to ensure safe maintenance in the "Safety regulations
section.
Visual contact
Make sure that visual contact between the operator in the cab and
maintenance personnel is always maintained.
Danger Risk of accidents for maintenance personnel!
Manipulation of the machine by unauthorised persons can place the main-
tenance personnel in extreme danger!
! Never enter one of the machine's danger areas without making your
presence known.
Make other people aware that you are about to enter one of the
machine's danger areas.
Wheel wedges
Secure the machine against accidently rolling away by using wheel
wedges.
Maintenance tasks
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Maintenance positions
The maintenance position depends on the maintenance task to be per-
formed.
The two basic maintenance positions 1 and 2 are described below.
They enable you to access the individual maintenance points.
Maintenance position 1 To move the machine into maintenance position 1 proceed as follows.
For a detailed description of the individual procedures, see the "Operation,
Handling section in the operator's manual.
Maintenance position 1
Park the machine on level ground.
Lower the lift arm.
Set the bucket down flat onto the ground.
Shut down the diesel engine.
Remove the starting key.
Maintenance position 2 To move the machine into maintenance position 2 proceed as follows.
For a detailed description of the individual procedures, see the "Operation,
Handling section in the operator's manual.
Maintenance position 2
Park the machine on level ground.
Engage the articulation lock.
Lower the lift arm.
Tilt the bucket out and set it down on the ground on its teeth or cutting
edge.
Shut down the diesel engine.
Remove the starting key.
Opening the service doors, hatches and hoods
Opening the engine
compartment rear hatch
Open the rear hatch if you need to access the following units or components:
Diesel engine
Battery main switch
Maintenance tasks
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Engine compartment rear hatch
1 Engine compartment rear
hatch
2 Handle with lock
3 Gas-filled spring
Caution Risk of injuries due to rear hatch falling closed!
! Check that the rear hatch is secured in the fully open position by the
pneumatic ram.
Open the lock of the rear hatch 1 with the starting key.
Completely open the rear hatch 1 with the handle 2.
The rear hatch is kept in this position by the pneumatic ram.
Opening the engine
compartment hood
When the hood is open, you can access the following units:
Diesel engine
Variable displacement pump
Cooling system
Hydraulic tank
Air filter
Make sure that the rear hatch is compIeteIy open.
Clamping lever for engine compartment hood
Open the clamping levers 1 on the left and right of the engine compart-
ment hood.
Maintenance tasks
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Engine compartment hood
hatch
2 Engine compartment hood
3 Gas-filled spring
4 Retaining cable
5 Handles
Warning Risk of accidents due to moving engine parts!
The rotating or moving engine parts such as the fan blades or V-belts are
potential sources of injury.
! Only open the engine compartment hood when the engine is shut down.
Completely open the hood 2 with both handles 5.
The hood is held in this position by two gas-filled springs 3.
Warning Risk of injuries! Hood can fall down.
! Check that the fully-open position can be secured by the gas-filled
springs.
f this does not function properly, the cause of the problem must be
corrected immediately.
Turning off the battery main switch
The battery main switch is located at the rear left of the engine compart-
ment.
For certain service tasks, the main battery must be switched to OFF.
Establish from the descriptions of the relevant maintenance tasks whether
the battery main switch must be turned ON or OFF. See the "Maintenance
tasks section.
Switch on the main battery switch after completing these maintenance
tasks.
Maintenance tasks
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Battery main switch
1 Battery main switch 2 Key
Caution Risk of damage to the electrical system!
! Do not turn off the main battery switch when the engine is running.
Shut down the engine first and only then turn off the main battery
switch.
Danger Unforeseen handling of the machine by an unauthorised person can place
the maintenance personnel in extreme danger!
! For safety reasons, it is essential that the battery main switch is turned
off.
! For security reasons, take the key out.
To switch off the main battery switch 1 turn the key 2 to the - 0 -
position.
3.5.2 Checking the machine for externaI damage
Make sure that the machine is in maintenance position 1.
Procedure
Before starting up the machine, check for external damage which could
impair operational safety.
Repair any damage that could impair safety.
Maintenance tasks
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3.5.3 Checking that aII screwed connections are tight
Ensure that:
The machine is in maintenance position 2
The appropriate service doors or hoods are open
Procedure
Tighten any loose screws or bolts with the required tightening torque.
3.5.4 SeaIing any externaI Ieaks
A detailed description of the safe maintenance of the hydraulic hoses and
hose lines can be found in the "Safety regulations section.
Ensure that:
The appropriate service doors or hoods are open
Procedure
Check the whole hydraulic system for leakage.
Replace any damaged hydraulic seals.
Tighten any loose hydraulic couplings.
3.5.5 Checking the oiI IeveI in the dieseI engine
The oil filler neck is located on top of the engine on the valve cover.
Ensure that:
The diesel engine is level and has not been running for 2 - 3 minutes.
Procedure
Diesel engine dipstick
Pull out the dipstick 1, wipe it clean, and re-insert it.
Pull out the dipstick 1 once again and read off the oil level.
The oil level must be within the cross hatching 2.
f the oil level is at this level 3 or below:
Top up with engine oil.
Maintenance tasks
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3.5.6 Changing the engine oiI
Ensure that:
The diesel engine is level
The diesel engine is warm
A suitable container is in place with approx. 20 l capacity, and the oil
draining hose and engine oil in accordance with the oil specifications
are ready.
Procedure
Diesel engine oil change
Unscrew the sealing cover on the oil drain valve 1 on the bottom of the
oil pan.
Screw the oil drain hose 2 onto the oil drain valve 1.
Let the oil drain off into the receptacle.
Unscrew the oil drain hose 2 and screw the sealing cover onto the oil
drain valve 1.
When changing the engine oiI and the oiI fiIter:
Change the oil filter according to the separate description.
Fill with oil via the oil filler neck 4 to the top mark 5 on the cross-
hatching on the dipstick 6 (for information on the oil quality, refer to the
"Lubricants and operating materials section).
Clean the filling cover 3, put it back on the oil filler neck 4 and tighten
it.
Maintenance tasks
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Start the diesel engine and check the oil pressure.
Shut down the diesel engine and check the oil level with the dipstick
after 1-2 minutes.
Diesel engine dipstick
f the oil level is at this level 3 or below:
Correct the oil level.
3.5.7 RepIacing the oiI fiIters
Make sure that:
The engine oil has been drained off
A LEBHERR oil filter cartridge is ready
Procedure
Unscrewing the oil filter
Release the oil filter cartridge 2 with a strap wrench 3 and unscrew the
filter.
Clean the sealing surfaces of the filter bracket 1 and remove the old
filter seal or any remnants of it if necessary.
Brush the rubber seal ring on the new oil filter cartridge 2 lightly with
engine oil.
Maintenance tasks
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Screw new the oil filter cartridge onto the filter bracket 1 until the seal
touches the filter bracket 1. Tighten by another half to three-quarter
turn.
Top up with oil via the oil filler neck 4 to the top mark 5 on the
cross-hatching on the dipstick 6 (for the oil quality, see "Lubricants and
operating materials).
Clean the oil filling cap 3, put it back on the oil filler neck 4 and tighten
it.
Start the diesel engine and check the oil pressure.
Shut down the diesel engine and check the oil level with the dipstick
after 1-2 minutes.
Diesel engine oil dipstick
f the oil level is at level 3 or below:
Correct the oil level.
3.5.8 Checking and repIacing the V-ribbed beIt
Access for inspection is available from the right-hand side of the engine.
The V-ribbed belt drive is equipped with an automatic tensioner.
The automatic tensioner cannot be repaired.
The tensioner is designed to keep the lever movement within the ten-
sioning stops 3 and the fixed stops 4.
Checking the V-ribbed beIt
Make sure that:
The engine compartment hood is open
Maintenance tasks
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Procedure
V-ribbed-belt tensioner
Check if there is play between the tensioning stops 3 and the fixed
stops 4.
Check the V-ribbed belt for damage or wear.
f there is no play between the tensioning stops 3 and the fixed stops
4:
Check the V-ribbed belt for stretching and the tension pulley bearings.
RepIacing the beIt
Make sure that:
A new V-ribbed belt is ready
Procedure
Take off the V-belt guard by loosening the three screws 2.
Slacken the tensioner and replace the V-ribbed belt.
Check the play between the tensioning stops 3 and the fixed stops 4.
f there is no play between the tensioning stops 3 and the fixed stops
4:
Check the length of the V-ribbed belt and the bearings of the tensioner.
Put the V-belt guard back on.
3.5.9 Making sure that the air inIet and exhaust Iines are secureIy
attached
Make sure that:
Maintenance tasks
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Procedure
Check that the hose 1 and hose clips 2 on the intake line between the
turbocharger 3* and the diesel engine are firmly attached and that
there are no leaks.
Check that the pipe clips 4 on the exhaust line between the
turbocharger 3*, muffler 5 and exhaust pipe 6 do not leak and are tight
7.
* The diesel engine is only equipped with a turbocharger on the L514
machine.
3.5.10 Checking the vaIve pIay
Cylinder layout, direction of rotation of the engine and valve positions:
Cylinder 4 is on the flywheel side
Anti-clockwise rotation looking towards the flywheel
Outlet valves on the flywheel side
Make sure that:
The special "cranking device D No. 0541887, a feeler gauge and new
valve cover seals are all ready.
The diesel engine is cold or has had at least 2 hours to cool down.
Maintenance tasks
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Procedure
Remove the intake line 1 from the turbocharger to the intake manifold.
Cover the opening on the intake manifold to keep out foreign particles.
Take off the plug 2 from the valve cover, loosen and remove the hex
nuts below.
Carefully take off the valve cover, making sure not to lose the sealing
rings of the cover fixing screws.
Take off the belt guard.
Turn the diesel engine at the V-belt pulley 2 using the cranking device
3. (For the cranking device 3, use a ratchet 1 with a SW 16 socket
spanner).
Valve layout
S Flywheel side
A Outlet valve
E nlet valve
1 Cylinder 1
2 Cylinder 2
3 Cylinder 3
4 Cylinder 4
Maintenance tasks
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VaIve pIay D 504 NA/T
nlet valve 0.35 mm
Outlet valve 0.45 mm
Valve play settings
Engine D 504 NA/T
Cylinder
Overlap Adjust
4 1
2 3
1 4
3 2
Valve adjustment sequence
Turn the crankshaft in the direction of rotation until the valves of the
fourth cylinder overlap.
Adjust the valves of the first cylinder.
Push the feeler gauge 6 between the valve 5 and the rocker arm 4 and
check the valve play.
f the valve play does is not the same as the required value:
Loosen the counter nut 3 of the adjusting screw of the rocker arm 4
using a ring spanner 1 (SW 17) and correct the setting using a
screwdriver 2. Tighten the counter nut 3 again.
After re-tightening the counter nut 3, check the valve play again.
Check the other cylinders by turning the crankshaft until the valves
overlap or are set according to the table, and adjust if necessary.
After testing and adjustment have been completed, put new seals on
the valve covers.
Put on the V-belt guard and inlet line again.
Maintenance tasks
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3.5.11 Draining off water and sediment from the fueI tank
Procedure
Unscrew the sealing cap A on the drain valve on the underside of the
fuel tank.
Place a suitable receptacle under the tank.
Screw the drain hose B on to the drain valve.
Drain the condensation and sediment into the receptacle until clean
fuel begins to flow.
Unscrew the drain hose B and screw the sealing cap A on to the drain
valve.
3.5.12 Draining condensate from the fueI fiIter
Make sure that:
The engine compartment rear hatch is open
Maintenance tasks
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Procedure
Place a receptacle under the fuel filter.
Open the drain plug 1 and let the condensate drain off into the
receptacle until clean fuel starts to flow.
Close the drain plug 1 again.
3.5.13 Changing the fueI pre-fiIter
Valid for: L512-466/0785-; L514-467/0785-
Make sure that:
Procedure
Release the hose clips and remove the fuel pre-filter 1.
Attach the new fuel pre-filter 1 and open the bleeder screw 4 on the
fine filter housing.
Keep pushing the pump lever on the fuel pump 5 until bubble-free fuel
flows out at the bleeder screw 4.
Close the bleeder screw 4.
Maintenance tasks
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3.5.14 RepIacing the fueI fiIter
Make sure that:
Procedure for repIacing the fueI fiIter
Carefully clean the fuel filter and the surrounding area.
Place a receptacle below the fuel filter (you may need to plug a
suitable piece of hose into the drain valve 4).
Open the drain valve 4 and let out the fuel.
Push up the snap ring 1 and turn it a quarter turn anticlockwise.
Pull down the filter element 2 with the snap ring 1.
Unscrew the water separator 3 from the filter element.
Dispose of the old filter element.
Pre-mounting the new fuel filter
Wash the water separator 3 and blow it dry. Unscrew the (old) drain
valve and dispose of it.
Unscrew the drain valve from the new filter element and screw it on to
the cleaned water separator.
Screw the water separator 3 on to the new the filter element and
tighten it.
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Check the filter base and the sealing ring, and replace if necesary.
Mount the new filter element 2 on the filter base. Make sure that the
slot in the filter base and the cams on the filter element fit.
Put on the snap ring 1 and turn it a third of a turn clockwise. The snap
ring snaps into the edge.
BIeeding air from the fueI system
Loosen the bleeder screw 1 by two turns.
Keep pushing the hand pump lever 2 until bubble-free fuel comes out
of the bleeder screw 1.
Tighten the bleeder screw 1.
Keep pushing the hand pump lever 2 until you can feel resistance.
Continue pumping and loosen the bleeder screw 1 (the remaining air
escapes under pressure).
Close the bleeder screw 1 and keep pushing the hand pump lever 2
until you can feel resistance again.
3.5.15 CIeaning the air fiIter dust extraction vaIve
Note that the valve must be closed when the diesel engine is running. f
the valve is damaged the dust will not be properly extracted and the filters
will get dirty more quickly.
Make sure that:
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Procedure
Press the rubber seal on the dust extraction valve A several times to
remove the dust from the service cap.
Empty the dust extraction valve A more often when working in dusty
conditions.
f the dust extraction valve A is damaged or will not stay shut:
Replace the dust extraction valve A.
3.5.16 CIeaning or repIacing the air fiIter main eIement
Clean or replace the main element when the air filter contamination
symbol field on the indicator unit lights up or every 1000 operating hours.
f the air filter contamination symbol field continues to light after the main
element has been serviced then the safety element must also be replaced.
Make sure that:
Procedure
Open the fixing clips on the air cleaner cover and take off the cover.
Clean or change the main filter element B.
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Blow out the main filter element from the inside out with dry air. Avoid
tapping the filter to clean it, as this could cause damage.
Replace the safety element C every third time you change the main
filter element.
Make sure all dirt has been removed from the housing before inserting
a new or cleaned filter element.
Lightly oil the seal surfaces before installing the filter elements (for the
main element this is on the inside, for the safety element C on the
outside). Put the filter elements back in and make sure that they are
correctly fitted.
Clean the air cleaner cover and put it back on the filter housing.
Only when the lid completely covers the filter housing can you close the
fixing clips without excess force.
Close the fixing clips.
3.5.17 Checking the air suction hoses
Make sure that:
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Procedure
Checking the air suction hose
Check the hose 5 between the filter housing and the turbocharger and
the hose 2 between the filter housing and the suction shaft for cracks
and damage.
Check that the hose clips 1, 3, 4, 6 are tight.
3.5.18 Checking the cooIant IeveI
Make sure that:
Procedure
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Check the coolant level in the sight glass 1 in the equalizing reservoir.
The coolant must be visible in the sight glass 1.
f the coolant level is not visible in the sight glass 1:
Top up coolant via the filler neck 2 to the top of the sight glass.
3.5.19 Checking the antifreeze
The coolant must contain at least 50% vol. but no more than 60% vol. of
concentrated anti-freeze all year round. This protects against freezing
down to around -37 C.
Make sure that:
The "optical density tester or strip test kit is ready.
Procedure
Caution There is a danger of scalding due to coolant escaping under pressure!
Only open the sealing cap when the engine has cooled down. Only one or
two bars of the coolant temperature display unit should be visible.
! Carefully open the sealing cap on the filler neck and let the pressure out
of the cooling system.
Take a sample of the coolant and check the antifreeze concentration
using the testing tool or the strip test kit.
f the antifreeze concentration is too low:
Correct the mixture ratio of anti-freeze in the coolant.
3.5.20 CIeaning the cooIing system
Clean the cooler whenever necessary in order to ensure proper cooling.
When operating in dusty conditions, the coolers should be checked daily
and cleaned if required.
Dust and other contaminants can be removed from the cooling fins with
water jets, steam or compressed air. Compressed air is preferable.
Make sure that:
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Procedure
Caution The cooler fins may be damaged if they are not treated with due care.
! Do not use any hard objects or water jets under excessive pressure
when cleaning
Clean the cooler units A with compressed air, steam or water.
3.5.21 RepIacing the cooIant
Use clean, fresh water with a Ph value between 6.5 and 8.8 and a low
sulphate / chlorine content for preparing the coolant.
The coolant must be prepared outside the cooling system. Do not mix
anti-freeze with the fresh water via the cooling system.
Always dispose of any coolant which you have drained off but no longer
need according to the applicable regulations.
Make sure that:
A suitable receptacle and drain hose (contained in the tool kit) are
available.
Procedure
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Caution There is a danger of scalding due to coolant escaping under pressure!
! Only open the sealing cap (B) on the filler neck of the equalizing
reservoir once the engine has cooled down. Slowly open the sealing cap
to the full extent to let off any excess pressure before removing it.
Unscrew the plug 2 on the drain valve, screw on the drain hose and
collect the coolant in the receptacle. To completely drain and flush the
diesel engine, remove the plug 1.
f the coolant is very dirty or corrosive, flush out the cooling system
several times.
Close the drain screw 2 and plug 1. Dispose of the coolant which you
drained off.
Caution There is a risk of damage to the diesel engine!
Never top up the cooling system while the engine is still hot.
An excessive proportion of anti-freeze and corrosion protection agent will
impair cooling, thus causing damage to the diesel engine.
! The coolant must contain at least 50% vol. but no more than 60% vol.
concentrated anti-freeze.
Top up with prepared coolant via the filler neck B on the equalizing
reservoir to the top of the sight glass.
Place the sealing cap on the filler neck and tighten it up.
Start the diesel engine, warm it up to operating temperature, switch on
the heating and check the coolant level again.
3.5.22 Checking the oiI IeveI in the hydrauIic tank
Valid for: L512-466/0501-0738; L514-467/0501-0738
Make sure that:
The machine is cold
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Procedure
The red marking OL LEVEL - max. 2 indicates the required oil level.
Check the oil level in the sight glass.
f the oil level is too low:
Top up with hydraulic oil.
Release the tank pre-pressure by unscrewing the bleeder filter 1 on the
hydraulic tank.
The hydraulic oil may only be poured in through the return strainer.
Open the cover of the return strainer 2.
Top up with hydraulic oil up to the oil level marking 3.
Put the cover with the O-ring on the housing and tighten it up.
Tighten the bleeder filter.
3.5.23 Checking the oiI IeveI in the hydrauIic tank
Valid for: L512-466/0739-; L514-467/0739-
Make sure that:
The machine is cold
Procedure
The MIN - MAX marking indicates the required oil level.
Check the oil level in the sight glass 3.
Top up with hydraulic oil.
hydraulic tank.
The hydraulic oil may only be poured in through the return strainer 2.
Open the cover of the return strainer 2.
Fill with hydraulic oil up to the MIN - MAX marking.
Tighten the bleeder filter 1.
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3.5.24 Checking and cIeaning the magnetic rod on the hydrauIic
tank
Make sure that:
Procedure
hydraulic tank by two turns.
Release the screws on the lid and slowly lift the lid with the magnetic
rod 2.
TroubIeshooting
Heavy soiling or larger metal shavings on the magnetic rod could indicate
damage in the hydraulic system.
f this is the case, locate the cause of the problem in the hydraulic
system, then correct it.
Carefully clean the magnetic rod.
Place the O-ring and cover with magnetic rod on the housing.
Tighten the screws on the cover.
3.5.25 Draining water and sediment from the hydrauIic tank
Make sure that:
The machine has not been in use for at least 3 hours
A receptacle for collecting the water and oil is ready
Procedure
The drain valve of the hydraulic tank is accessible from below the machine
near the rear axle.
Unscrew the plug from the drain valve 1.
Connect the drain hose 2 and let the water and sediment drain off into
the container.
Remove the drain hose 2 and screw on the plug on the drain valve 1.
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3.5.26 RepIacing the return suction fiIter
Make sure that:
Procedure
hydraulic tank by two turns.
Release the screws on the lid 2 and slowly lift the lid with the magnetic
rod.
Take out the filter element 3.
TroubIeshooting
Heavy soiling or larger metal shavings in the filter element or on the
magnetic rod could indicate damage in the hydraulic system.
nsert the new filter element.
Carefully clean the magnetic rod.
Place the O-ring and cover with the magentic rod on the housing and
tighten the cover screws.
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3.5.27 CIeaning the return strainer in the hydrauIic tank
Make sure that:
Clean, grease-dissolving cleaning fluid is ready
A vessel in which the return strainer can be cleaned with cleaning fluid
is ready.
Procedure
Release the tank pre-pressure by Unscrewing the bleeder filter 1 on
the hydraulic tank by two turns.
Unscrew the cover 2 from the filter housing.
Unlatch the snap ring 3 in the filter casing and take out the return
strainer 4.
TroubIeshooting
Heavy contamination or larger metal fragments in the return strainer could
indicate damage to the hydraulic system.
Dip the dirty return strainer 2 in the cleaning fluD
Collect dirt particles by pushing cardboard or corrugated card 1 into the
return strainer.
Blow pressurised air from the outside inwards.
Check the return strainer for damage.
f the return strainer is damaged:
nstall a new return strainer.
nstall the return strainer 4 and latch in the snap ring 3.
Put the cover 2 with the O-ring on the filter housing and tighten it up.
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3.5.28 RepIacing the bIeeder fiIter on the hydrauIic tank
Make sure that:
Procedure
t is not possible to clean the bleeder filter. The bleeder filter 1, along with
its plastic housing, must be replaced at the specified service intervals.
Unscrew the used bleeder filter.
Screw on the new bleeder filter.
3.5.29 Lubricating the piIot controI unit, cIeaning the magnets and
Iubricating the universaI joints
Procedure
Remove the rubber sleeve 5 of the control lever from the retaining
plate 4.
Move the control lever in the appropriate direction to improve access.
Clean the 3 retaining magnets 1 with a brush or similar utensil.
Lubricate the universal joints 2 and washers 3 with a brush.
Start the machine and test the holding function of the magnets.
Put the rubber sleeve of the control lever back on the retaining plate.
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3.5.30 RepIacing the hydrauIic oiI
Make sure that:
The machine is warm
A receptacle with a capacity of roughly 100 litres is available for the
used oil.
Procedure
Release the tank pre-pressure by unscrewing the bleeder filter 1.
Unscrew the plug from the drain valve 3.
Connect the drain hose and drain the oil into the receptacle.
Remove the drain hose and screw the plug onto the drain valve.
The hydraulic oil may only be poured in through the return strainer.
Open the cover of the return strainer.
Top up with hydraulic oil up to the oil level marking 2.
3.5.31 Checking the steering
Procedure
Start the diesel engine.
Turn the steering in both directions with the vehicle stationary and
check that it is functioning properly.
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3.5.32 Lubricating the bearing points on the steering cyIinder
Procedure
Turn the machine to the right to improve access to the articulated joint
zone.
Lubricate the bearing points on the steering cylinder.
3.5.33 Checking the service brake and parking brake
Procedure for checking the service brake
Make sure that there is enough room to check the parking brake.
Warning There is a danger of driving into bystanders or obstacles.
! Do not allow anyone into the danger area while the test is being
conducted.
! Carry out the testing on a level area without any obstacles.
Start the diesel engine and drive forwards in travel range 1 at approxi-
mately 8 km/h.
Push the inch/brake pedal 1 all the way down. The machine must
come to an abrupt stop.
TroubIeshooting
f the braking effect is too slight or entirely absent:
Have LEBHERR SERVCE identify the problem and rectify it.
Procedure for checking the parking brake
Make sure that there is enough room to check the parking brake.
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Warning There is a danger of driving into bystanders or obstacles.
conducted.
! Carry out the testing on a level area without any obstacles.
Start the machine, select travel range 1 and forward travel direction.
Move the machine forward at approx. 3 km/h and activate the parking
brake with the parking brake switch 2.
The symbol field 1 for the parking brake lights up.
The machine must come to an abrupt stop.
TroubIeshooting
f the braking effect is too slight or entirely absent:
Have LEBHERR SERVCE identify the problem and rectify it.
3.5.34 Checking the oiI IeveI in the brake system equaIizing
reservoir
Make sure that:
Procedure
The "MN - MAX markings show the required height of the oil level. The
oil level must lie between the markings.
Check the oil level in the equalizing reservoir 3.
To avoid damaging the brake system, only top up with SAE 10W petro-
leum (see the section on lubricants and fuels).
Open the cover 1 and top up with oil.
Unscrew the cover 1 on the equalizing reservoir 3.
3.5.35 Checking the wear and gap on the brake pads
Frequent braking can wear down the brake pads. The brake pads must be
renewed if they become worn down below the minimum thickness.
On the parking brake, wear to the brake pads can also alter the gap
between the brake disc and the brake pad. f the gap exceeds a certain
value it must be adjusted.
The gap is automatically adjusted on the service brake. This means that
manual adjustment is not required.
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1 Service brake caliper
2 Front brake disc
3 Parking brake caliper
4 Rear brake disc
6 Disc brake guard
Make sure that:
Put wedges under the wheels to stop the machine rolling away.
Stopping the machine from roIIing away
Put the machine in maintenance position 2.
Put wedges under the wheels to stop the machine rolling away.
Procedure for checking the wear on the brake pads
Name VaIue Unit
Check the thickness of the linings on the service brake and parking
brake (by sight, using a mirror).
f the brake lining is too thin:
Replace the brake lining on the service brake or parking brake.
Take off the disc brake guard.
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Service brake caliper
Take off the retaining splints 1 and bolts 2 on both sides.
Push in the brake piston using a suitable tool.
Take out both brake pads 3.
Put in new brake pads and assemble the brake caliper in the reverse
order.
Parking brake caliper
Unscrew the sealing cap 6 and loosen the lock nut 7 using a SW 24
box spanner.
Unscrew the adjusting screw 8 to release the brake calipers.
Remove the retaining splint 1 and nut 2 from the top screw 3.
Pull out the screw 3 and slightly pull the brake caliper 5 outwards.
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Lift out the brake pad 4.
Put in new brake pads and assemble the parking brake in the reverse
order.
Adjust the gap of the parking brake as described below.
Procedure for checking the parking brake gap
Start the diesel engine and release the parking brake by pressing the
parking brake switch.
Unscrew the sealing cap 1 and loosen the lock nut 2 using a SW 24
box spanner.
Tighten the adjusting screw 3 until the brake calipers touch the brake
disc.
Unscrew the adjusting screw 3 by a quarter turn (0.5 mm gap).
Hold the adjusting screw 3 in position and tighten the lock nut 2 using
the box spanner.
Screw on the sealing cap 1 and tighten it by hand.
Put on the disc brake guard.
3.5.36 Checking the indicator Iamps and Iighting
Checking the indicator Iamps
A lamp check always takes place before each start when the starter key is
in the contact position - I -. This consists of a check of the symbol and
segment fields in the display unit and the warning beeper, which beeps
twice.
After the check is complete, certain symbols and indicators remain on.
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After the engine is started and begins running, another test of the indica-
tors in the display unit takes place.
Procedure
Put the machine in the operating position. For instructions on this, see
the "Operation chapter in the Operator's manual.
Lamp check
During a "lamp check the following symbol fields are checked by the
control electronics.
Switch on the electrical system by turning the ignition key to position - I
-.
An audible signal (two beeps) sounds.
All bars on the segment fields for the fuel level display and the coolant
temperature display must appear active for the duration of the lamp test.
All the segments on the digital display must also light up during this time.
The following symbol fields light up only briefly (2.53 secs):
Indicator unit lamp check
1 Battery charging symbol field
(charge control)
2 Engine oil pressure symbol
field
3 Hydraulic oil overheating sym-
bol field
4 Parking brake symbol field
5 Travel speed diode
6 Operating hours diode
7 Time diode
8 Travel range - II - symbol field
9 Travel range - I - symbol field
10 Preglow monitor symbol field
11 Emergency steering symbol
field
12 Braking system accumulator
pressure symbol field
13 Air filter contamination symbol
field
14 Fuel supply segment field
15 Coolant temperature segment
field
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After the check has been successfully completed, the following symbol
fields must still illuminate with the key at position - I -:
The display unit after the lamp check
(charge control)
field
6 Safety belt symbol field
flashes.
Indicators after staring the engine
Start the diesel engine
As soon as the engine starts running, let go of the starting key.
The starting key automatically returns to the operating position.
When the engine starts, the following symbol fields must go out:
Display unit
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(charge control)
field
When the engine starts, the following symbol fields must be lit:
5 Emergency steering symbol field
7 The safety belt symbol field flashes for about 15 secs.
Checking the Iighting
Start the diesel engine and check that the illuminating components and
headlamps light up.
3.5.37 Checking the batteries, fIuid IeveI and terminaIs
The batteries are in the box on the left access to the cab and can be
accessed by removing the screws A and covers B.
The batteries must always be in perfect condition to guarantee the reliabil-
ity of the machine.
Make sure that:
The battery main switch is switched off and the main switch key has
been removed
Caution Batteries give off explosive gases. Battery acid is highly corrosive.
! Do not smoke. Make sure there are no naked flames when working on,
servicing and charging the batteries.
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Caution Sparks may cause explosions!
! Use special terminal brushes.
Wipe the battery surface with a clean cloth.
Clean the battery terminals and connectors.
To prevent loose connections, make sure the connectors are securely
attached to the terminals and tighten them if necessary.
Lubricate the terminal heads and connectors with an acid-resistant
grease such as vaseline.
n extremely high temperatures, differing evaporation rates can cause the
acid level in the individual cells to drop.
Open the sealing plugs of each battery cell and check the acid level.
Check the charge level using an acid density measuring device.
f the charge is too low:
Recharge the batteries.
f there is a risk of frost, it is important not to allow the batteries to go flat.
Otherwise the electrolyte in the battery may freeze and irreparably damage
the battery.
f you discover that the acid level is too low:
Top up with distilled water until the plates are covered to a depth of
approximately 10 mm.
3.5.38 Checking the tightness of the wheeI Iugs
Make sure that:
A torque wrench with a measuring range of 650 Nm is available
Procedure
Note: The one-off maintenance tasks scheduled for 50, 100 and 250
service hours should also be performed every time the wheels are
changed.
Check that the lugs on all four wheels are tightened to a torque of 650
Nm.
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3.5.39 Greasing the axIe pivot bearing and the universaI joints on
the rear axIe
Make sure that:
Put wedges under the wheels to stop the machine rolling away
Procedure
Turn the steering to the left or right to access the lubrication points of the
drive shaft universal joint on the wheel hub. You must also move the
machine into a position where you can access the grease fitting.
Turn the machine to the left and right to access the respective lubrica-
tion points.
Grease the lubrication points on the universal joint of the gear shaft at
both wheel hubs.
Grease the lubrication points on the axle pivot bearing at both wheel
hubs.
3.5.40 Lubricating the front drive shaft
Make sure that:
Procedure
Move the machine into a position where the grease fittings on the drive
shaft are tilted downwards.
Turn the machine so that it is straight.
Grease the 5 lubrication points on the drive shaft.
3.5.41 Checking the oiI IeveIs on the front axIe
Make sure that:
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Procedure
Turn the wheel hubs until the oil level marking is horizontal.
Unscrew the plug 2 and check the oil level at the wheel hubs.
Top up with the axle oil specified in the lubricants and fuels section.
Unscrew the plug 1 and check the oil level in the differential.
3.5.42 Checking the oiI IeveIs on the rear axIe
Make sure that:
Procedure
Turn the wheel hub until the oil level marking on the wheel hub is
horizontal.
Unscrew the plug 2 and check the oil level at the wheel hubs.
The transfer gear and the differential share a common oil system. The oil
level can be checked at the differential.
Unscrew the plug 1 and check the oil level in the differential.
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3.5.43 Changing the front axIe gear oiI
Make sure that:
A sufficient quantity of the axle oil specified in the lubricants and fuels
section is available
A suitable receptacle is available for disposal of the oil
Procedure for draining the oiI
Turn the wheel hubs until the plug 3 is at the bottom.
Unscrew the plug and drain off the oil into the receptacle.
Unscrew the drain plug 2 on the differential and drain off the oil into
the receptacle.
Close the drain plug.
Procedure for topping up the oiI
The wheel hubs and the differential share a common oil system. This
means the oil flows slowly between the differential and the wheel hubs.
Top up the oil in the differential to the filling inlet 1.
Top up the oil at both wheel hubs to the oil level marking.
Check the oil level at the differential and wheel hubs and top up if
needed.
Close the plugs on the differential and wheel hubs.
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3.5.44 Changing the rear axIe gear oiI
Make sure that:
A sufficient quantity of the axle oil specified in the lubricants and fuels
section is available
A suitable receptacle is available for disposal of the oil
Procedure for draining the oiI
Turn the wheel hub until the plug 3 is at the bottom.
Unscrew the plug 3 and drain off the oil into the receptacle.
Unscrew the drain plug 1 on the transfer gear and the drain plug 2 on
the differential, and drain off the oil into the receptacle.
Close the drain plugs.
Procedure for topping up the oiI
Turn the wheel hub until the oil level marking on the wheel hub is
horizontal.
After removing the plug 3, top up with oil to the filling inlet.
Check the oil level again and close the plug 3.
The transfer gear and the differential share a common oil system. This
means that when you top up at the differential, the oil flows into the
transfer gear.
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Unscrew the plug 2 on the transfer gear.
Unscrew the plug 1 on the differential and top up with oil to the filling
inlet.
Check the oil level at the differential and transfer gear and top up if
needed.
Close the plugs 1, 2 on the differential and transfer gear.
3.5.45 Setting the correct tyre pressure for the machine's use and
attachments
Make sure that the air pressure in the tyres on both axles is correct for the
tyre type, the way the machine is used and the working attachments fitted.
The reference values can be found in the Operator's manuaI in the
"Technical data section.
Procedure
Exploding tyre
The air pressure in the tyres has a significant influence on the overall
operating performance of the machine.
Warning Exploding tyres can cause serious injury!
f the tyre inflation equipment is incorrectly or careless used or if the tyre
pressure is too high, the tyres may burst or the rims may come off,
causing severe, or possibly even fatal injuries.
! Use a sufficiently long hose with a self-locking valve for pumping up the
tyres.
! Always keep well clear of the danger zone when pumping up the tyres.
Check the air pressure in all tyres with a measuring gauge and adjust
if necessary.
3.5.46 Greasing the articuIation and rear axIe osciIIating bearings
Make sure that:
The articulation lock is engaged
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Procedure
Lubrication points on the right-hand side of the central lubricating rail
1 Front oscillating bearing lubri-
cation point
2 Rear oscillating bearing lubri-
cation point
Grease the front oscillating bearing at the lubrication point 1 on the
central lubricating rail.
Grease the rear oscillating bearing at the lubrication point 2 on the
central lubricating rail.
Articulation bearing lubrication points
1 Top articulation bearing lubri-
cation point
2 Bottom articulation bearing lu-
brication point
Lubricate the articulation bearing at the top by greasing the lubrication
point 1 on the articulation bearing.
Lubricate the articulation bearing at the bottom by greasing the lubrica-
tion point 2 on the articulation bearing.
Maintenance tasks
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3.5.47 Lubricating the hinges on the rear hatch and engine
compartment hood
1 Rear hatch lubrication point 2 Engine compartment hood lu-
brication point
Lubricate the hinges on the rear hatch and engine compartment hood
3.5.48 CIeaning or repIacing the fresh air fiIter
The fresh air filter for the cab can be accessed from the outside of the cab
on the rear right-hand side.
Maintenance tasks
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Procedure
Unscrew the star grip screw 1 and take off the ventilation grille 2.
Unscrew the hex screw 3 and take off the holder 4.
Pull out the filter element 5 on the left side and take it out.
Clean the filter element 5 or replace it if necessary.
Carefully remove any dust which has collected in the fresh air filter
duct. (The area behind the filter element must be completely clean)
Put in the new or cleaned filter element 5 and fasten it with the holder
4 and screw. The holder 4 must exert slight pressure on the filter
element sealing surface. Make sure it is correctly fitted, with the arrow
pointing in the direction of air flow.
Put the ventilation grille 2 back on and fasten it with the star grip screw
1.
3.5.49 Lubricating the door hinges
Lubricate the door hinges with a grease gun.
3.5.50 Checking and Iubricating the Iift arm bearings
Lift arm maintenance position
f the lubrication points near the bucket couplings are difficult to reach,
make sure that the working attachment is detached.
Maintenance tasks
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Lubricating the Iift arm and Iift cyIinders
Z-bar Iift arm
Lift arm and lift cylinder lubrication points
1 Front lift cylinder lubrication
point
2 Rear lift cylinder lubrication
point
3 Top lift arm lubrication point
Lubricate the bearing at the top of the lift arm by greasing the left
lubrication point 3 and the right lubrication point 3.
Grease the two lubrication points 1, 2 on the left lift cylinder.
Grease the two lubrication points 1, 2 on the right lift cylinder.
P-bar Iift arm
Lift arm and lift cylinder lubrication points
1 Bottom lift arm lubrication point
2 Front lift cylinder lubrication
point
3 Rear lift cylinder lubrication
point
4 Top lift arm lubrication point
Maintenance tasks
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Lubricate the bearing at the top of the lift arm by greasing the left
lubrication point 4 and the right lubrication point 4.
Grease the two lubrication points 2, 3 on the left lift cylinder.
Grease the two lubrication points 2, 3 on the right lift cylinder.
Grease the two lubrication points on the lower lift arms 1.
Lubricating the tiIt cyIinder, Z-bar Iinkage and connecting
Iink
Z-bar Iift arm
Tilt cylinder, z-bar linkage and connecting link lubrication points
1 Z-bar linkage lubrication point
2 Front tilt cylinder lubrication
point
3 Rear tilt cylinder lubrication
point
4 Connecting link lubrication
point
Grease one lubrication point 1 on the Z-bar linkage.
Lubricate the bearing on the tilt cylinder by greasing the front lubrica-
tion point 2 and the rear lubrication point 3.
Lubricate one lubrication point 4 on the connecting link.
Maintenance tasks
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P-bar Iift arm
Tilt cylinder, Z-bar linkage and connecting link lubrication points
1, 3 Front connecting link lubrica-
tion points
2 Front Z-bar linkage lubrication
points
4 Front tilt cylinder lubrication
point
5, 6 Rear Z-bar linkage lubrication
points
7 Rear connecting link lubrica-
tion point
8 Rear tilt cylinder lubrication
point
Lubricate one lubrication point 2 on the right and left Z-bar linkage at
the front.
Lubricate two lubrication points 1, 3 on the left and right connecting link
at the front.
Lubricate the bearings on the tilt cylinders by greasing the front lubrica-
tion point 4 and the rear lubrication point 8.
Lubricate two lubrication points 5, 6 on the right and left rear Z-bar
linkage.
Lubricate one lubrication point 7 on the rear left and right connecting
link.
Maintenance tasks
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3.5.51 Checking and Iubricating the bucket bearing
The lower bucket bearings should be lubricated daily if necessary.
Z-bar Iift arms without quick-change device
Checking the bucket bearing
Bucket bearing
1 Bearing bushing for bucket
arm
2 Bearing bushing for connect-
ing link
3 Radial sealing ring
4 Bucket arm
5 Bucket bearing plate
A-A Cross-section
Check the bearing bushes 1 on the bucket arm for wear and replace
with the radial sealing rings 3 if necessary.
Check the bearing bush 2 on the connecting link for wear and replace
with the radial sealing rings if necessary.
Lubricating the bucket bearing
Bucket coupling lubrication points
Maintenance tasks
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1 Connecting link lubrication
point
2 Bucket bearing lubrication
point
A-A Cross-section
Lubricate one lubrication point 1 on the connecting link.
Lubricate one lubrication point 2 on the bottom / left bucket bearing.
Lubricate one lubrication point 2 on the bottom / right bucket bearing.
P-Iift arms with quick-change device
Quick-change device lubrication points
Lubricate one lubrication point 1 on the right bearing.
Lubricate one lubrication point 2 on the left bearing.
3.5.52 Checking the Iift arms and bucket stops
Check the stops for wear.
Maintenance tasks
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3.6 Tests, adjustment
3.6.1 Preparatory tasks before checking and adjusting
Only trained and authorised specialist technicians may perform adjustment
work on the machine during the guarantee period.
Make sure that:
The machine is warm (except for the fan test)
You know the the adjustment data specific to the devices or have it at
hand
Seals and safety caps are ready
You have the following special tools
SpeciaI tooIs
Number Description ID no.
2 0-40 bar, class 1.0 pressure gauge 7361288
2 0-600 bar, class 1.0 pressure gauge 5002866
2 4000 mm test lead 7009134
2 1500 mm test lead 7002475
1 Tachometer (Ono Sokki) 7009538
1 Temperature measuring device 7020372
1 LMS (alternative)
Safety precautions before checking and adjusting
Accident prevention reguIations must be observed at aII times during
maintenance work.
See the "Measures to ensure safe maintenance in the "Safety regulations
section.
Visual contact
Make sure that visual contact between the operator in the cab and
maintenance personnel is always maintained.
3.6.2 Checking the speed of the dieseI engine
The speed of the diesel engine can be checked using a tachometer, by
taking a pulse signal from the injection line.
Tests, adjustment
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Procedure
Measuring the engine speed
Clean any paint from the injection line 1 of the fourth cylinder (from the
flywheel side).
Connect the pulse detector 3 of the tachometer 2 (Ono Sokki) to the
injection line 1 of the fourth cylinder.
Start the diesel engine and check the top and bottom engine speeds.
Adjusting the engine speed
1 Adjusting lever
2 Compensating spring
3 Maximum limit stop
4 Minimum limit stop
5 Spindle
6 Pedal stop
7 Gas pedal
s Play
f the engine speed is too low:
Make corrections to the stops on the gas pedal and the injection pump.
Set the bottom idling speed on the minimum limit stop 4.
Set the top idling speed on the maximum limit stop 3.
Adjust the Iength compensation pIay as foIows:
Push the gas pedal 7 down by hand until you feel the speed adjust-
ment lever 1 touch the limit stop screw 3.
The play s between the limit stop screw 6 and the gas pedal 7 should
be 23 mm.
The 23 mm play by which the gas pedal can still be pushed down is
balanced by the compensating spring 2.
Tests, adjustment
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f the play s is not 23 mm:
Adjust the limit stop screw 6 accordingly.
Check and adjust the gas pedaI angIe as foIows:
Measure the distance from the top of the pedal to the cab floor
(without the floor mat). The standard factory setting is 180 mm.
You can adjust the gas pedal angle if necessary using the spindle 5.
f you need to correct the pedal angle:
Unpin the spindle 5 on the gas pedal 7 and turn the spindle 5
clockwise or anticlockwise to raise or lower the angle of the pedal.
After setting the angle of the gas pedal, readjust the limit stop screw 6
as described above.
Name VaIue Unit
Lower idling speed 83050 min-1
Upper idling speed 255050 min-1
3.6.3 Checking the pressure reIief vaIve of the fan motor and the
fan controI
The following tests must be performed on the fan drive:
Checking the pressure relief valve of the fan motor (with the propor-
tional magnet disconected)
Checking the fan with the temperature sensor disconnected
Checking the fan with the diesel engine running at top speed
Check the fan using the system pressure at the measuring connection 1 of
the gear pump 2 on the diesel engine.
The fluids must be within the temperature ranges listed below when you
check the fan.
Tests, adjustment
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Make sure that:
The hydraulic oil temperature is between 30C and 50 C
The coolant temperature is between 30C and 70 C
f the hydraulic oil temperature is above 55 C or the coolant temperature
is above 78 C the fan speed increases. This makes it impossible to
accurately test the fan controls.
Checking the pressure reIief vaIve on the fan motor
Connect the pressure gauge (250 bar) to the measuring connection 1
on the gear pump 2.
Disconnect the plug 2 on the proportional valve of the fan motor 3.
Start the diesel engine and take it to upper idling speed.
Check whether the pressure is as specified at the upper idling speed.
f the pressure is not as specified:
Adjust the pressure relief valve at the proportional valve 3 using a 5
mm open ended wrench for the adjusting screw. The counter nut is a
round nut.
Turn the screw cIockwise to increase the pressure, and anticIockwise to
reduce the pressure.
Take off the protective cap 5.
Set the adjusting screw 4 on the proportional valve 3.
Reconnect the plug 2 of the proportional valve 3.
Name VaIue Unit
Pressure at the fan pump 1755 bar
Fan speed 260050 min-1
Checking the fan with the temperature sensor disconnected
This test simulates a sensor failure. The fan runs up to a high speed.
Disconnect the plug of the hydraulic oil temperature sensor 6 (see the
diagram above).
Tests, adjustment
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dentify the fault and rectify it.
Plug the hydraulic oil temperature sensor 6 in again.
Name VaIue Unit
Checking the fan with the dieseI engine running at top speed
The proportional valve and the hydraulic oil temperature sensor must be
plugged in again for this test.
dentify the fault and rectify it.
Name VaIue Unit
3.6.4 Checking the traveI hydrauIics in the bIock condition
The block condition is required for the following testing procedures:
Checking control begin
Checking the pump outpuit at 380 bar
Checking the pressure relief and replenishing valve
Checking the pressure cut-off
Checking the variable displacement motor within the control range
Block condition means that the machine is in a blocked state. This means
you must stop the machine using the service brake and at the same time
drive against a solid obstacle.
For block condition, the inching function must be deactivated.
Procedure
Take out the retaining pin 2 from the ball joint 3.
Detach the ball joint 3 from the inch/brake pedal.
Start the machine and select the forward travel direction.
Drive the machine aginst a solid obstacle and fully engage the service
brake.
Tests, adjustment
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Danger Slipping off the brake pedal will cause the machine to drive off quickly.
Beware not to drive over people and obstacles!
conducted.
Depending on the test procedure, increase the diesel engine speed.
After completing the test, attach the joint to the inch/brake pedal again.
3.6.5 Checking the repIenishing pressure of the traveI pump
Procedure
The replenishing pressure is measured at test connection G.
Attach the pressure gauge (40 bar) to the test connection G.
Start the engine and let it run at upper idling speed.
Check whether the replenishing pressure is as specified.
Turn the adjusting screw on the replenishing pressure relief valve 1
until the replenishing pressure reaches the specified value.
Name VaIue Unit
Replenishing pressure 322 bar
3.6.6 Checking the reguIation begin of the traveI pump
When the variable displacement pump reaches regulation begin, the pump
begins to deliver oil. When in block condition, high pressure rises in
proportion to diesel engine speed.
When the regulation begin is set correctly, 50 bar high pressure will be
produced at a specific diesel engine speed.
Procedure
Attach the pressure gauge (600 bar) to the test connection MA.
Put the machine in block condition.
When in block condition, slowly increase the engine speed until the
pressure gauge reads precisely 50 bar.
Check whether the replenishing pressure is as specified.
Turn the adjusting screw on the control valve 1 until the engine speed
reaches the specified value.
The control pressure should be within the stated range.
Name VaIue Unit
Diesel engine speed 105050 min-1
Control pressure 62 bar
Tests, adjustment
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3.6.7 Checking the output of the traveI pump
The position of the control lens 1 determines the output of the variable
displacement pump. As it is adjusted, the hydraulic reaction forces of the
variable displacement pump change too.
The control lens is adjusted using the twist screw 2. The notch on the
eccentric twist screw indicates the furthest projecting point of the eccentric.
The maximum or minimum reaction force can be obtained by turning the
screw through 90.
When the pump output is set correctly, 380 bar high pressure will be
produced at a specific diesel engine speed.
Procedure
When in block condition, slowly increase the diesel engine speed until
the pressure gauge MA reads precisely 380 bar.
Check whether the diesel engine speed corresponds to the specified
value.
f the engine speed is not as specified:
Turn the twist screw 2 until the engine speed reaches the specified
value.
The control pressure should be within the stated range.
Name VaIue Unit
Diesel engine speed 1950100 min-1
Control pressure 152 bar
Tests, adjustment
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3.6.8 Checking the pressure reIief and repIenishing vaIves of the
traveI pump
The pressure relief and replenishing valves protect the variable displace-
ment pump from pressure peaks. These can arise when the machine is
braked.
When these pressure peaks are reached, oil flows from the high pressure
side to the low pressure side in a closed circuit via the pressure relief and
replenishing valve.
Procedure
To obtain the adjustment value of the pressure relief and replenishing
valves, the pressure cut-off must be re-adjusted to a higher value.
Tighten the adjusting screw 1 on the pressure cut-off by two turns.
The pressure relief and replenishing valve 2 for the reverse travel
direction must only be checked during repairs or in the event of a fault.
Caution Heat is rapidly generated as the pressure relief and replenishing valves
are tested.
Excessive temperatures can irreparably damage the pump.
! Test the pressure relief and replenishing valves for a short period only.
With the machine in block condition, increase the engine speed to the
highest speed.
Check whether the high pressure is as specified.
Turn the adjusting screw 3 on the pressure relief and replenishing
valve until the high pressure reaches the specified value.
Unscrew the adjusting screw 1 by two turns and check the pressure
cut-off.
Valid for: L512-466/0501-; L514-467/0501-0786
Name VaIue Unit
High pressure 47010 bar
Valid for: L514-467/0787-
Name VaIue Unit
Tests, adjustment
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3.6.9 Checking the pressure cut-off of the traveI pump
The pressure cut-off limits the maximum pressure in the variable displace-
ment pump. When this pressure is reached, the pump automatically regu-
lates the pump flow in order to maintain the pressure.
This reduces the engine load by a certain degree. A slight reduction in
engine load (approx. 10 min-1) indicates slight leakage in the closed
circuit. A greater reduction in engine load can indicate that there is
excessive leakage, that the pressure cut-off is not working properly or that
some other fault is present.
Procedure
With the machine in block condition, increase the engine speed to the
highest speed.
Check whether the high pressure on the pressure gauge MA is as
specified.
Turn the adjusting screw 1 on the pressure cut-off until the pressure
gauge MA reaches the specified value.
The engine pressure should be within the stated range.
Valid for: L512-466/0501-; L514-467/0501-0786
Name VaIue Unit
Maximum engine pressure to the top
idling speed
30 min-1
Valid for: L514-467/0787-
Name VaIue Unit
Maximum engine pressure to the top
idling speed
30 min-1
Tests, adjustment
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3.6.10 Checking the variabIe dispIacement motor within the
controI range
Procedure
Test the variable displacement motor while accelerating the machine.
Within a certain speed range the variable displacement motor regulates
down from Qmax to Qmin. The high pressure must be as specified during
the regulating phase.
Attach the pressure gauge (600 bar) to the test connection MA on the
A4VG variable displacement pump.
Attach the pressure gauge (600 bar) to the test connection M1 on the
variable displacement motor.
Start the engine, select the forwards travel direction and travel range 2.
Accelerate the machine at full throttle on a level track.
Check that the high pressure at the test connection MA is as specified
within the control range of the variable displacement motor (6 - 18
kmh).
f the high pressure in the control range is too high:
Loosen the adjusting screw 1.
f the high pressure in the control range is too low:
Tighten the adjusting screw 1.
Valid for: L512-466/0501-
Name VaIue Unit
Valid for: L514-467/0501-
Name VaIue Unit
3.6.11 Checking the secondary pressure reIief vaIves on the
controI vaIve bIock
Procedure
n order to check the secondary pressure relief valve you must increase
the setting of the primary pressure relief valve 1.
Tighten the adjusting screw on the primary pressure relief valve 1 on
the control valve block by two turns.
Before testing, loosen the secondary pressure relief valve 2 by a
quarter turn.
Connect the pressure gauge (600 bar) to the test connection M on the
control valve block.
Tests, adjustment
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Caution Activating the "Lower lift arms function at this point may cause irreparable
damage to the pump. This function is not equipped with a secondary
pressure relief valve.
! Do not lower the lift arms.
Activate the "Raise lift arms, "Tilt out bucket and "Tilt in bucket
functions in succession to the end positions.
Check whether the pressure in each secondary pressure relief valve is
as specified.
Turn the adjusting screw on the secondary pressure relief valve in
question until the specified pressure is reached.
After testing, tighten the secondary pressure relief valve 2 by a quarter
turn.
Re-adjust the primary pressure relief valve 1 to the specified value.
See "Checking the primary pressure relief valve.
Name VaIue Unit
Raise lift arms (Pos. 2) 2505 bar
Tilt in bucket (pos. 3) 2605 bar
Tilt out bucket (pos. 4) Z kinematics 2605 bar
Tilt out bucket (pos. 4) P kinematics 1105 bar
3.6.12 Checking the primary pressure reIief vaIve on the controI
vaIve bIock
Procedure
Attach the pressure gauge (600 bar) to the test connection M.
Activate the "Raise lift arms function to the limit position.
Check whether the pressure is as specified.
Turn the adjusting screw on the primary pressure relief valve 1 until the
pressure is correct.
Name VaIue Unit
Primary valve (pos. 1) / L512 1905 bar
Primary valve (pos. 1) / L514 2305 bar
Tests, adjustment
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3.6.13 Checking the pressure reIief vaIve of the steering system
Procedure
The pressure relief valve 2 limits the maximum pressure of the steering
system.
Attach the pressure gauge (600 bar) to the test connection M on the
valve block.
Start the engine and let it run at lower idling speed.
Turn the steering fully to the left or right and test the high pressure
using the pressure gauge.
Take off the safety cap from the pressure relief valve 2 and turn the
adjusting screw on the pressure relief valve 2 until the high pressure is
as specified.
Name VaIue Unit
3.6.14 Checking the cut-off pressure of the accumuIator charge
vaIve
Procedure
The accummulator charge valve 1 fills the hydro accummulator of the
parking brake with oil. f a certain pressure is reached in the hyro accu-
mulator, the filling process is cut off.
Attach the pressure gauge (600 bar) to the test connection G on the
valve block.
Start the engine and let it run at lower idling speed.
Engage and release the parking brake several times, thus lowering the
pressure in the hydro accumulator.
When the high presure starts to increase again, check whether it
reaches the required value.
Take off the safety cap from the accumulator charge valve 1 and turn
the adjusting screw on the accumulator charge valve 1 until the cut-off
pressure is as specified.
Name VaIue Unit
Cut-off pressure 16010 bar
Tests, adjustment
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3.7 Lubricants and fueIs
3.7.1 HandIing Iubricants and fueIs
Conscientious observance of the regulations for handling lubricants and
fuels will increase the reliability and service life of the machine.
t is especially important that the specified lubricant qualities are observed.
You can find the various specifications about the prescribed intervals in
the "Maintenance and inspection schedule and "Lubrication chart.
You can find details on lubrication, checking the oil level and changing
operating fluids in the "Maintenance section under "Maintenance tasks.
Observe the rules for the proper handling of lubricants and fuels, espe-
cially the environmental regulations.
EnvironmentaI protection measures
Always implement and observe environmental protection measures.
Observe national regulations.
Ensure that liquids can be properly disposed of before draining them.
Disposing of used materiaIs
This applies to the following types of used materials:
Oils, lubricants, brake fluids, refrigerants etc.
Fuels
Filters, oil cartridges etc.
Rubber, tyres, insulating materials etc.
Batteries
Disposal
Observe the environment regulations when disposing of used materials.
Collect and store used materials separately in suitable receptacles, and
only dispose of them at official depots in an environmentally friendly
manner.
Observe national regulations.
Conversion from mineraI oiIs to environmentaIIy
compatibIe hydrauIic fIuids
For the operation of LEBHERR earth moving machines with environmen-
tally compatible hydraulic fluids we recommend AVIA SYNTOFLUID.
Lubricants and fuels
3.7 - 1 of 10
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Caution Beware of damaging the machine's hydraulic system!
Mixing environmentally-compatible hydraulic fluids with mineral oils pro-
duces an aggressive reaction that can damage the hydraulic system!
! Avoid mixing environmentally-compatible hydraulic fluids with mineral
oils.
If you intend to convert the machine to environmentaIIy-compati-
bIe hydrauIic fIuid, you must first consuIt LIEBHERR CUSTOMER
SERVICE.
Make sure to ask LEBHERR for the INSTRUCTION SHEET and follow
the CONVERSION GUIDELINES it contains.
3.7.2 Lubricant and fueI specifications
The filling quantities listed in the tables are only guidelines:
The dipstick or level markings are always mandatory.
Check the level in the unit in question each time you replace or top up
the lubricant or fuel.
For more detailed information about the required lubricants, fuels and
filling quantities, see the "Lubrication chart, filling quantities and
"Lubricants and fuels sections.
Lubricating oiIs for the dieseI engine
Lubricating oiI quaIity Only high-alloy lubricating oils are used in modern diesel engines.
They consist of basic oils blended with additives.
The lubricating oil regulation for LEBHERR diesel engines is based on the
following specifications and regulations.
Name Specifications
ACEA (CCMC) - Classification (Associ-
ation des Constructeurs Europens de
l'Automobile)
E2-96, E3-96, (D4, D5)
AP - Classification (American Petro-
leum nstitute)
CG-4, CF-4
Specifications and regulations for diesel engine lubricating oils
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Lubricating oiI viscosity The lubricating oil viscosity is selected according to the SAE (Society of
Automotive Engineers) classification.
The decisive factor for the selection of the correct SAE class is the
ambient temperature.
The selection of SAE classification does not affect the quality of a lubricant
oil.
f the viscosity is too high, starting can be difficult; if it is too low, lubricant
efficiency may be impaired.
The temperature ranges detailed in the following graphic are guidelines -
short-term deviations are permissible.
Selection of the SAE class according to temperature
Lubricant oiI changing intervaIs Changing intervals:
First oil change and filter change using the original filling oil: see the
"Maintenance and inspection schedule.
Oil change according to climate zone, sulphur content in the fuel and
oil quality according to the following table.
Even if the specified number of service hours (h) is not reached in a given
year, the engine oil and filter should be replaced at least once a year.
CompIicating factors Various complicating factors or harsh operating conditions can affect the
maintenance intervals.
Complicating factors or harsh operating conditions include:
Frequent cold starts
A sulphur content above 0.5% in the fuel
Outside operating temperatures below - 10 C
f working under difficult conditions, the oil change intervals defined in the
"Maintenance and inspection schedule must be reduced by half, as shown
in the table below.
CompIicating factor OiI quaIity
E2-96 E3-96
D4 D5
CG-4
CF-4
Operating conditions Sulphur content in fuel nterval
Normal climate, down
to -10 C
Below 0.5% 250 h 500 h
Above 0.5% 125 h 250 h
Below - 10 C Below 0.5% 125 h 250 h
Above 0.5% 125 h
Oil change intervals in service hours (h)
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DieseI fueIs
Specifications The diesel fuels must meet the minimum requirements in the fuel speci-
fications listed below.
Authorised fuel specifications:
DN EN 590
ASTM D 975-89a 1D and 2D
Other fuel specifications are only permissible after consultation with the
Diesel Engine Development department.
The sulphur content should not exceed 0.5% by weight. Higher sulphur
content affects the oil change intervals and the engine lifetime.
Lubricity The reduction of the sulphur content in diesel fuels has raised the problem
of lubricity. t has been found that diesel fuels which conform to the
European limit of 0.05 % sulphur by weight can cause wear in the injection
system, particularly with distributor injection pumps.
Brand-name fuels in Germany therefore contain lubricity additives. The fuel
lubricity must be <400m according to the HFRR (60) test.
The additives should be added by the supplier in his capacity as agent
responsible for fuel quality. Addition of secondary lubricity additives by the
customer is not recommended.
DieseI fueI at very Iow
temperatures
When outside temperatures fall below 0C, the flow performance of sum-
mer diesel fuel may be insufficient as a result of paraffin separation. The
same problem arises with winter diesel fuels below -15 C.
Diesel fuel containing additives for operating temperatures down to -20 C
is also often available.
To avoid breakdowns, the diesel fuel must be mixed with two star petrol or
paraffin at low temperatures. Blending in two star petrol must be viewed as
an emergency remedy and may not exceed 30% vol.
Do not use not four-star petroI for bIending.
The engine power can drop in relation to the additive mixture used for cold
conditions. Blending in additives should therefore be kept to a minimum,
taking into account the outside temperatures.
For safety reasons, the fuel may only be mixed in a fuel container. When
refuelling, pour in the fuel additive with lower specific gravity before the
diesel fuel. The engine should then be run until the fuel mixture is
circulating throughout the entire fuel system.
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DieseI fueI mixture ratio (% voI.)
Outside temperature
C
Summer dieseI % Additive %
0 to -10 70 30
-10 to -15 50 50 *
-15 to -20 - - - -
-20 to -25 - - - -
Mixing ratio for summer diesel fuel
* f an additive of 50% is necessary, only paraffin may be used (not
two-star petrol).
Outside temperature
C
Winter dieseI fueI % Additive %
-15 C -20 C -15 C -20 C
0 to -10 100 100 - - - -
-10 to -15 100 100 - - - -
-15 to -20 70 100 30 - -
-20 to -25 50 70 50 * 30
Mixing ratio for winter diesel fuel
* f an additive of 50% is necessary, only paraffin may be used (not
two-star petrol).
Additives for dieseI fueI (fIow
improvers)
Flow improvers available on the market will also improve the cold weather
performance of the diesel fuel. Their use requires the observance of
quantity and application recommendations stipulated by the manufacturer.
CooIants for dieseI engines
CooIant The coolant must contain at least 50% vol. anti-freeze and corrosion
protection agent all year round. This protects against freezing down to
around -37 C.
Mixing ratio
Selection of mixing ratio of corrosion and anti-freeze protection agents
according to temperature
G Protection against freezing in
C
A Proportion of anti-freeze in %
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Fresh water quaIity when using
anti-freeze and corrosion
protection agent
Name VaIue and unit
Water hardness 0.6 to 3.6 mmol/l (3 to 20 d)
pH value at 20 C 6.5 to 8.5
Choride ion content max. 80 mg/l
Sulphate ion content max. 100 mg/l
Fresh water quality
Anti-freeze and corrosion
protection agent quaIity
Ethyl glycol base with low silicate content.
HydrauIic oiIs
MineraI oiIs
Specifications Only engine oils meeting the Mercedes Benz service fuels specifications
are permitted.
Mercedes-Benz info sheet no.: Specifications:
226.0 and 227.0 (single-grade oils): AP- CC / SF, CD / SF, CE / SF
227.1 and 228.1 (multi-grade oils): CD / SF, CE / SF,
CD+AP- CC / SF (ML-L-46152 B),
CD / SF, CE / SF (ML-L-2104 D),
CD / SF (ML-L-2104 D), CE / SF,
CD+ (ML-L-46152 B)
Mercedes-Benz service fuels requirements
Viscosity The viscosity is selected according to the SAE (Society of Automotive
Engineers) classification.
The decisive factor for the selection of the correct SAE class is the
ambient temperature.
The selection of the SAE classification has no bearing on the quality of a
hydraulic oil.
The temperature ranges presented in the graphic are only provided as
guidelines.
Selection of the SAE class according to temperature
B * = code designation = container labelling, see the "Bl * Standard
lubricants section.
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Warming up For temperatures up to 10 C below the specified limit:
Adjust the diesel engine to roughly half speed after starting
Activate the hydraulic cylinders and engines and briefly move the
cylinders to their stops
Warming up takes roughly 10 minutes
At even lower temperatures:
Before starting the engine, prewarm the oil tank
1) = Exception for transfer gear (AVG - powershift transmission):
SAE 30 may only be used iff the outside temperature is not below
+10 C.
EnvironmentaIIy compatibIe
hydrauIic fIuids
When operating LEBHERR earth moving machines with environmentally
compatible hydraulic fluids, we recommend AVIA SYNTOFLUID with the
viscosity specified by LEBHERR.
Caution!
Failure to carry out the conversion of the hydraulic system to an
environmentally compatible hydraulic fluid may cause damage to the
machine's hydraulic system!
See the "Conversion from mineral oils to environmentally harmless
hydraulic fluids section.
Machines which were fiIIed with environmentaIIy compatibIe hydrauIic
fIuids at the factory have an appropriate sign (CAUTION decaI) at-
tached to the driver's cab and hydrauIic tank.
Conversion of the hydrauIic system:
See the section on "Conversion of the hydraulic system from mineral
oils to environmentally compatible hydraulic fluids for guidelines on
retrofitting your machine to adapt it to an environmentally compatible
hydraulic fluD
Brake oiI
Service brake Use SAE 10W engine oil as brake oil for all ambient temperatures.
3.7 - 7 of 10
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Lubricating oiIs for the transmission
AxIes Gear oils must comply with the AP-GL-5-90 and ML-L-2105 B, C or D
specifications and the viscosity class SAE 90 LS *.
* = Gear oil with limited-slip additives for disc brakes and self-locking
differentials.
For the viscosity class SAE 90, an oil of the viscosity class SAE 80 W 90
can also be used.
Comparison to Bl * code designation:
SAE 90 LS / Bl * GO 90 LS
SAE 80 W - 90 / Bl * GO 90
lubricants section.
Transfer gear Use lubrication oil for the transfer gear as listed in the "Axles section.
Grease for generaI Iubrication points
This grease must meet the KP2k specification consistency 2 of the NL
G class according to DN 51818 and DN 51825 or EP 2 according to
NF-T-60 132.
The grease must be made of a lithium complex with a a four ball tester
value of at least 2300 N according to DN 51350 or ASTM D 2596.
Comparison to Bl * code designation:
NL G class 2 / Bl * MPG - A
lubricants section.
LIEBHERR CTK speciaI paste Bonding, water resistant, complex saponified paste with high-pressure
additives and improved corrosion protection characteristics.
Contains ingredients which counteract frictional and vibrational corrosion.
Especially recommended for use in roller live ring connections.
Range of application: -30 C to +100 C.
Re-order from your LEBHERR dealer under D no. 8613 3101.
This grease is not suitable for use in automatic central lubricating systems.
Lubricant grease for automatic centraI Iubrication systems
Use grease complying with the KP2k specification consistency 2 of the
NL Gl class according to DN 51818 is suitable.
Composition: Lithium-saponified multi-purpose grease with a mineral oil
base with EP active ingredients, without colouring.
Grease with high-pressure additives (EP greases) are recommended.
Only use greases with the same type of saponification.
Greases with solid lubricant particles such as graphite may not be used.
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Approved greases LEBHERR 9610 special grease is a milling resistant, aging resistant
lithium grease, providing protection against corrosion with excellent lubric-
ity over a wide temperature range.
The molecular composition yields high degrees of shearing and milling
stability and good flow properties in long pipes.
Description ID no. Quantity
LH 9610 special grease 8613 01308 25 kg (drum)
LH 9610 special grease 8613 02908 400 g (cartridge)
Corrosion protection grease
Non-acidic corrosion protection greases should be used to protect exposed
piston rods.
LEBHERR CTK special paste is especially recommended.
Refer to the "LEBHERR CTK special paste section.
Anti-seize agent for boIt fitting
A molybdenum sulphide paste is recommended as anti-seize agent for the
bolts.
BI * standard Iubricants
See the "STANDARD LUBRCANTS for construction machines and
vehicles brochure.
Published by the German Construction ndustry Federation (Hauptverband
der Deutschen Bauindustrie e.V.)
Bauverlag GmbH Wiesbaden and Berlin.
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4 DieseI engine, pump
distributor gear
Chapter contents
4 Diesel engine, pump distributor gear 4.0 - 1
4.1 Diesel engine (D 9739000, 9739001) 4.1 - 1
4.1.1 njection pump 4.1 - 5
4.2 Fuel system 4.2 - 1
4.2.1 Fuel tank (D 7621711) 4.2 - 2
4.2.2 Fuel level sensor (D 7621802) 4.2 - 3
4.2.3 Fuel pre-filter (D 7090480) 4.2 - 5
4.2.4 Fine fuel filter (D 7090244) 4.2 - 6
4.3 Air filter system 4.3 - 1
4.4 Coupling (D 5715895, 5717325) 4.4 - 1
4.0 - 1 of 2
Diesel engine, pump distributor gear Service manual
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4.1 DieseI engine
(ID 9739000, 9739001)
Layout
The diesel engine is a water-cooled, four stroke in-line engine with direct
injection and turbocharger (L514 only).
The diesel engine is installed transversely on the rear section and elas-
tically mounted on rubber bearings. The flywheel end faces to the left.
Cylinder 1 is on the water pump side and cylinder 4 is on the flywheel
side.
Diesel engine components, seen from the starter (rear view)
1 Flywheel side flange for the
travel and working pump
2 Fuel water separator
3 Fine fuel filter
4 Filter bleeder screw
5 Fuel delivery pump
6 ntake manifold
7 Air preheater
8 Turbocharger (L 514 only)
9 Lubricating oil filler neck
10 Engine preheater relay
11 Three-phase alternator
12 V-belt tensioner
13 Water pump
14 Heat exchanger intake
15 ntake side water pump
16 Cooling water drain valve
17 Fan gear pump
18 Engine oil cooler
19 Oil pan
20 Engine oil filter
21 Dipstick
22 Engine oil drain valve
23 Starter
24 Crankcase ventilation
Diesel engine
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Diesel engine components, seen from the injection pump (front view)
1 Crankcase
2 Cold start solenoid valve Y4
3 njection pump
4 Motor stop solenoid Y5
5 50C cold start thermo switch
B20a
6 Thermostat
7 Water pump outlet
8 Exhaust manifold
9 Turbocharger (L 514 only)
10 njection nozzle
11 Sender unit and thermo switch
coolant temperature B20
12 Valve cover
13 Cylinder head
14 Valve block
15 Flange for the travel and work-
ing pump
16 Motor bearing fixing
17 Oil pressure switch B7
Design features of the diesel engine:
Water-cooled four-stroke diesel engine with direct injection
Turbocharger (L 514 only)
Maintenance-free lubricant pump gear drive and auxiliary power take-
off for gear pumps
Block cylinder head
Wet cylinder liners
Oil cooled light alloy pistons
Engine oil cooler
Engine oil filter
Tilt-proof oil pan
Fine fuel filter
Cast crankshaft on sliding bearings
Forged connecting rods on sliding bearings
Balancer shafts
Function description
Basic function
The diesel engine converts the chemical energy in the fuel into mechanical
energy and transfers it via the flywheel and torsion absorber to the travel
hydraulics and working hydraulics pumps.
A small proportion of the power is taken off at the accessory drive side of
the diesel engine to drive the gear pumps of the hydraulic fan drive.
Diesel engine
4.1 - 2 of 6
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TechnicaI data
Valid for: L512-466/0501-, ID 9739000
Name VaIue Units
Engine type D 504 NA
Combustion process Diesel, four stroke,
direct injection
gnition sequence 1-3-4-2
Bore diameter 106 mm
Stroke 127 mm
-1
-1
302 Nm
50
min
-1
+50
min
-1
Begin delivery before TDC 9
Compression pressure 24 bar
njection pressure - jet pressure 225 bar
Coolant thermostat opening
temperature
82 C
Direction of rotation looking towards
flywheel
Anti-clockwise
Number of teeth on flywheel ring gear 129
temperature
82 C
Distributor injection pump Stanadyne
Operating voltage of starter 12 V
Power consumption of starter 4.8 kW
Coolant quantity in engine 8.5 l
Auxiliary output ratio 1: 0.9677
Mass 387 kg
Emission limit values comply with SO /EPA
Diesel engine
4.1 - 3 of 6
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TechnicaI data
Valid for: L514-467/0501-, ID 9739001
Name VaIue Units
Engine type D 504 T
Combustion process Diesel, four stroke,
direct injection,
turbocharger
gnition sequence 1-3-4-2
Bore diameter 106 mm
Stroke 127 mm
-1
-1
395 Nm
50
min
-1
+50
min
-1
Begin delivery before TDC 6
Compression pressure 24 bar
njection nozzles - jet pressure 260 bar
Direction of rotation looking towards
flywheel
Anti-clockwise
Number of teeth on flywheel ring gear 129
temperature
82 C
Distributor injection pump Stanadyne
Operating voltage of starter 12 V
Power consumption of starter 4.8 kW
Auxiliary output ratio 1: 0.9677
Mass 396 kg
Emission limit values comply with SO /EPA
Diesel engine
4.1 - 4 of 6
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4.1.1 Injection pump
Layout
1 njection lines
2 Maximum speed stop
3 Diesel feed line from filter
4 njection pump
5 Cold start solenoid valve
6 Throttle cable spring
7 Minimum speed stop
8 Speed adjusting lever
9 Ground terminal of motor stop
solenoid
10 Positive terminal of motor stop
solenoid
11 50C cold start thermo switch
plug B20a
Design: Distributor injection pump
The moment of injection can only be tested and adjusted using the special
Time Trac tool.
The motor stop solenoid is located in the housing of the injection pump 4.
The ground terminal of the motor stop solenoid 9 is connected to the
housing of the injection pump 4 angeschlossen.
The injection pump is supplied with oil by the fuel pump. The supply
pressure is between 0.25 and 0.30 bar.
The injection pump pistons apply additional pressure to the fuel. The fuel,
which is now under high pressure, then flows through pressure lines to the
injection nozzles.
When the ignition is ON the positive terminal 10 of the motor stop solenoid
is energised. When it is not energised the fuel supply is interrupted.
f the motor stop solenoid is defective, the entire injection pump 4 must be
replaced.
The cold start solenoid valve 5 adjusts the moment of injection at coolant
temeperatures up to 50 C in order to ensure the most efficient combus-
tion at any given speed or load.
The injection pump is fuel-lubricated.
Diesel engine
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4.2 FueI system
Layout
The fuel system consists of the fuel tank, the fuel pre-filter, the fuel pump,
the fine fuel filter, the injection pump and the injection nozzles.
Fuel system
A View from the starter
B View from the injection pump
1 Fuel tank
2 Drain valve
3 Tank filler cap
4 Fuel level sensor
5 Plug (additional function)
6 Return line
7 njection nozzles
8 Line from fine filter to injection
pump
9 High pressure lines
10 Engine speed adjusting lever
11 njection pump
12 Motor stop solenoid
13 Return line from injection
nozzles
14 Fuel pre-filter
15 Component for manual pump
operation
16 Fuel pump
17 Bleeder screw
18 Fitting for special components
19 Fine fuel filter
20 Forward flow line
The fuel pump 16 takes fuel from the fuel tank 1 via the fuel pre-filter 14
and pumps it via the fine fuel filter 19 to the injection pump 11.
The injection pump 11 pumps the fuel under high pressure via the high
pressure lines 9 to the injection nozzles 7.
The injection nozzles 7 spray fuel into the combustion chambers.
There is a valve on the bottom of the fuel tank for draining condensated
water and sediment from the fuel.
The drain hose supplied in the tool kit can be used for draining.
Fuel system
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4.2.1 FueI tank
(ID 7621711)
Layout
The plastic fuel tank is located behind the right-hand cab access.
Fuel tank
1 Tank
2 Drain valve
3 Tank filler cap
4 Fuel level sensor
5 Plug
6 Return flow line
7 Forward flow line
TechnicaI data
Name VaIue Units
Tank level FULL 140 l
Tank RESERVE 10 l
Fuel system
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4.2.2 FueI IeveI sensor
(ID 7621802)
Layout
The fuel level sensor is fitted vertically in the fuel tank.
Fuel tank with fuel level sensor
1 Fuel level sensor
2 Seal
3 Fuel tank
The fuel level sensor 1 transmits a resistance value to the display unit.
The tube of the fuel level sensor contains a float which rises and falls with
the fuel level. The level of the float determines the resistance. The lower
the fuel level, the higher the resistance.
The "reserve fuel level is displayed flashing in the first bar of the left
segment field.
Fuel system
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Fuel level bar display
Bar Litres Ohm
1 0 - 20 62.6 - 57
2 20 - 39 56.9 - 48
3 40 - 54 47.9 - 40
4 55 - 71 39.9 - 32
5 72 - 89 31.9 - 24
6 90 - 109 23.9 - 15.5
7 110 - 122 15.4 - 8.5
8 123 - 140 8.4 - 1.2
Fuel system
4.2 - 4 of 8
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4.2.3 FueI pre-fiIter
(ID 7090480)
The fuel pre-filter is an in-line filter between the fuel tank and the fuel
pump. t must be replaced after every service.
Layout
Fuel pre-filter installation
The fuel pre-filter is designed as an in-line filter and has a transparent
housing.
The filter is fastened to the fuel forward flow hose with hose clips. A short
section of hose connects the outlet to the fuel pump.
Fuel can flow through the filter in both directions, and in this installation
the 90 port faces the fuel pump.
The fuel pump sucks the diesel fuel through the fuel pre-filter. Any foreign
particles are caught in the filter net. The transparent housing enables you
to view the particles and assess the degree of contamination.
You can also see how the fuel flows. This is useful when you are servicing
the fuel system, for example to judge whether it needs bleeding.
TechnicaI data
Name VaIue Units
Filter type n-line filter
Filter designation AL 67 975
Maximum flow rate 80 l/h
Filtration grade min.0.6 mm
max.0.8 mm
Fuel system
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4.2.4 Fine fueI fiIter
(ID 7090244)
This filter has a quick-change fixing ring to enable you to service it without
using any tools. The fixing ring, the filter cartridge and the water separator
can be removed, disassembled and fitted by hand during servicing.
Layout
The fuel filter unit is designed as a fine filter with a water separator, and is
fitted between the fuel pump and the injection pump.
The filter element is a cartridge with a retaining ring on the top of the filter.
This is a disposable filter cartridge which must be replaced after each
service.
The water separator is cleaned during each service and does not need to
be replaced.
Fine fuel filter
1 Filter insert
2 Filter insert fixing ring
3 Filter outlet
4 Fitting for special components
5 Filter base
6 Filter intake
7 Bleeder screw
8 Water separator fixing ring
9 Water separator sight glass
10 Drain valve
The diesel fuel is pumped under pressure from the fuel pump via the filter
intake into the upper section of the filter housing. A concentrically aligned
half pipe guides it through the base to the bottom section of the filter
element itself.
At the bottom of the filter element, the fuel flows outwards and upwards
between the filter element and the cartridge housing on the outside of the
element.
The pressure of the fuel pump then forces the fuel inward, thus filtering it.
Fuel system
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The fuel is then pumped through the staggered holes in the rising pipe to
the fuel line and on to the injection pump.
The water separator located below is coaxially connected to the fine filter.
Since the fuel flows directly down towards the water separator, heavy
media such as water or impurities collect at the lowest point of the
container.
The container also serves as a sight glass for the water separator and can
be emptied during maintenance by opening the drain valve.
TechnicaI data
Name VaIue Units
Type Fine fuel filter with
water separator
Fuel system
4.2 - 7 of 8
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4.3 Air fiIter system
The degree of wear on the engine depends to a large degree on how
clean the inlet air is. t is therefore important to inspect and service the air
filters on a regular basis.
The main element and the safety element of the dry air filter are designed
to ensure the maximum air supply for the diesel engine in order to protect
it from wear.
Layout
Air filter
1 Safety element
2 Main element
3 Air cleaner cover
4 Dust unloader valve
5 Air filter contamination vacuum
switch
The main element 2 is made of folded paper and the safety element 1 is
made of blue plastic. Both elements can be used for medium to high
pulsation.
The safety element 1 is coaxially fitted in the main element 2. Both
elements are situated at the front of the air filter housing on a short port,
and are sealed with the air outlet by a soft rubber seal.
The air cleaner cover 3 is fastened to the filter housing with three clips. At
the same time, the axial force of the clips on the air filter cover keeps the
two filter elements pressed against the filter housing and holds them in
place.
The untreaed inlet air flows into the filter housing and passes through the
main element and the safety element. This filters the air, which then
passes through the connecting port on the way to the intake manifold or
turbocharger.
Since the inlet port on the filter housing is attached at a tangent, the
incoming air forms a clockwise vortex. This vortex causes a cycIone
separation effect in the air cleaner cover 3. The heavier particles such as
dust collect in the dust unloader valve 4 below.
The main purpose of the safety element 1 is to provide backup protection
for the diesel engine in the event of the main element 2 failing.
An additional function is that it can indicate a faulty area on the main
element. n such a case, the faulty area projects a stain on the opposite
part of the safety element 1.
The dust unloader valve 4 essentially works like a check valve (on suction
motors only) and provides more or less automatic emptying of dust from
the air cleaner cover 3 due to the pulsation in the intake duct.
Air filter system
4.3 - 1 of 2
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The positive waves of the pulsations are conducted outward via the rubber
edges of the dust unloader valve 4, while the negative waves are blocked.
This one-way air flow blows out dust particle which have collected in the
air cleaner cover 3.
With the turbo engine, the dust unloader valve is opened and emptied by
the pressure impulses which are generated during the starting and shut-
down phase. However, in both cases, manual emptying is recommended
or even necessary (see the maintenance manual).
The vacuum switch 5 is for the air filter contamination display which can
be used for maintenance. When the switching point is reached, the air
contamination symbol field on the display unit lights up.
TechnicaI data
Name VaIue Units
Filter type FLG10-0311
Air throughput min.8 m/min
max.14 m/min
Air filter contamination vacuum
switching point
50 mbar
Air filter system
4.3 - 2 of 2
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4.4 CoupIing
(ID 5715895, 5717325)
Layout
The coupling is fitted as a connecting element between the flywheel on the
diesel engine and the tandem pump.
Location of the coupling
1 Flywheel
2 Fixing screw
3 Elastic element
4 Hub star
5 Hub star shoulder
6 Screws
Notes on location and fitting:
The elastic element 3 is fitted with its ribs facing the flywheel. The
smooth side faces outward.
The hub star 4 is fitted with its shoulder 5 facing the travel hydraulics
pump.
All screws are glued with LOCTTE 241.
The coupling provides an elastic connection between the diesel engine
and the tandem pump.
TechnicaI data
Valid for: L512-466/0501-0797, ID 5715895; L514-467/0501-0797, ID 5715895
Name VaIue Units
Type CF-K 125-10-A
Tightening torque for the 8 torsion
absorber screws
50 Nm
Tightening torque for hub star fixing
screws
70 Nm
Coupling
4.4 - 1 of 2
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TechnicaI data
Valid for: L512-466/0798-, ID 5717325; L514-467/0798-, ID 5717325
Name VaIue Units
Type CF-K 125-10-63843
Tightening torque for the 8 torsion
absorber screws
46 Nm
Tightening torque for hub star fixing
screws
70 Nm
Coupling
4.4 - 2 of 2
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5 CooIing system
Chapter contents
5 Cooling system 5.0 - 1
5.1 Gear pump (D 5716901) 5.1 - 1
5.2 Gear motor (D 5716902) 5.2 - 1
5.3 Temperature sensor (D 6004344) 5.3 - 1
5.0 - 1 of 6
Cooling system Service manual
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Layout
The cooling system is fitted between the diesel engine and the driver's cab
on the rear section.
Cooling system components
1 Water cooler (engine circula-
tion cooling)
2 Hydraulic oil cooler
3 Coolant temperature sensor
B21
4 Steering return flow valve
block
5 Oil cooler return flow filter
6 Working hydraulics return flow
7 Hydraulic oil temperature sen-
sor B8
8 Oil cooler bypass line
9 Gear motor
10 Proportional pressure relief
valve
11 Gear motor tank line
12 Gear motor pressure line
13 System pressure test
connection
14 Pressure connection
15 Suction line
16 Gear pump
17 Hydraulic tank
18 Cooler bypass check valve
19 Collector block
20 Ol filling inlet return strainer
21 Return suction filter
Basic function
The cooling system cools the coolant and the hydraulic oil.
The two coolers form a single unit.
The hydrostatically driven fan draws in cool air via the cooler duct and the
cooling fins on the cooler and blows it at the diesel engine.
The speed of the hydrostatically driven fan depends on the temperature of
the coolant or hydraulic oil and the engine speed.
5.0 - 3 of 6
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Hydraulics plan of the fan drive
1 Water cooler
2 Coolant temperature sensor B
21
3 Hydraulic oil cooler
4 Hydraulic oil temperature sen-
sor B 8
5 Fan gear motor
valve compl.
7 Proportional valve Y13
8 Pressure relief valve
9 Bypass valve
10 Bleeder filter
11 Return strainer
12 Hydraulic tank
14 Fan gear pump
15 Working hydraulics return flow
P Fan drive system pressure
HydrauIic controI of the fan speed
The fan pump 14 draws oil from the hydraulic tank 12 and pumps it to the
gear motor 5.
The proportional valve 7 provides continuous control of the integrated
pressure relief valve 8 of the gear motor.
At low temperatures the opening pressure of the pressure relief 8 is low.
Most of the pump flow goes to the tank via the pressure relief valve 8. The
fan rotates at a reduced rate (minimum speed = dragging speed).
As the temperature rises the opening pressure of the pressure relief 8
increases continuously. This causes the gear motor 5 to turn the fan
faster.
f the power to the proportional valve 7 fails, the opening pressure in-
creases to the mechanically set value and the fan motor turns at maximum
speed (failsafe function).
EIectric controI of the fan speed
The control electronics A1 determine an output current from the tempera-
tures measured by the hydraulic oil sensor B8 and the coolant sensor B21.
This current controls the proportional pressure relief valve Y13 on the gear
motor and hence the fan speed.
When there is no current the fan rotates at the maximum speed.
When the temperature of the fluid is high this means the resistance in the
temperature sensor is high.
The resistance is almost exactly proportional to the temperature of the
liquD
f the temperature at one of the sensors B8 or B21 surpasses 94 C, the
warning beeper B9 sounds.
The beep sounds 5 times with 5-second breaks
5.0 - 4 of 6
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Note: This warning sounds is not accompanied by a symbol field on the
display unit lighting up. To see which sensor (B8 or B21) has triggered the
warning sound, look at the LEDs on the control borad A1.
H13 The red LED indicates overheating of the cooIant B21
H14 The green LED indicates overheating of the hydrauIic oiI B8
Fan controI System pressure Current Fan speed
At low engine speed, hydraulic oil up to 55 C
and coolant up to 78 C
35 10 bar 1100 mA 1000 50 min -1
At high engine speed, hydraulic oil up to 55 C
and coolant up to 78 C
40 10 bar 1100 mA 1100 50 min -1
Hydraulic oil 55-73 C, coolant 78-84 C 40-155 10 bar 360-1100 mA 1100-2430 min-1
At low engine speed, hydraulic oil above 73 C
and coolant above 84 C
40 10 bar 360 mA 1100 50 min -1
At top engine speed, hydraulic oil above 73 C
and coolant above 84 C
155 10 bar 360 mA 2430 50 min -1
Proportional magnet not energised 175 5 bar 0 mA 2600 50 min -1
5.0 - 5 of 6
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5.1 Gear pump
(ID 5716901)
Layout
Arrangement of gear pumps
1 System pressure test
connection
2 Pressure line
3 Fan gear pump
4 Suction line
The fan gear pump 3 is mounted on the auxiliary drive of the diesel engine
and driven at a set ratio via the spur gear transmission.
The fan gear pump 3 draws oil from the hydraulic tank and pumps it to the
gear motor.
Basic function
Gear pump components
1 Gearwheel fixing nut
2 Snap ring
3 Shaft seal ring
4 Flange
5 Seals
6 Bearing bushings
7 Feather key
8 Gearwheels
9 Housing
10 Housing cover
11 Screw
Gear pump
5.1 - 1 of 2
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The gear pump consists of two meshing gearwheels 8 enclosed in a
housing 9. One of the two gears 8 is driven by the external shaft (driving
gear), the other is driven via the meshed teeth (driven wheel).
The hydraulic fluid drawn in is trapped in the gaps between the teeth and
is pumped outside along the housing 9 from the suction port to the outlet
port.
Pressure reIief
The pressure in the gear pump cooling system is relieved by the pressure
relief valve on the gear motor.
TechnicaI data
Name VaIue Units
Type Bosch 0 510 525
340
Displacement 11 cm
Flow at rated engine speed 26.4 l/min
Speed at rated engine speed 2550 min
-1
Ratio 0.9677
Gear pump
5.1 - 2 of 2
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5.2 Gear motor
(ID 5716902)
The gear motor is mounted on the protective grille of the cooler. The gear
motor drives the fan blade via a shaft.
The proportional pressure limiting valve mounted on the gearwheel motor
controls the fan speed.
Layout
Gear motor with proportional pressure relief valve
1 Gear motor
2 Fan drive shaft
valve
Gear motor with proportional pressure relief valve
1 Bearing cover
2 Seal set
3 Bearing bushings
4 Gearwheels
5 Bearing bushings
6 Motor housing
7 Seal set
valve connection housing
valve
10 O-ring
11 O-ring
12 Shaft
13 Roller bearing
14 Shaft seal ring
15 Bearing cover
Gear motor
5.2 - 1 of 4
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Proportional pressure relief valve
1 Pressure relief adjusting screw
2 Counter nut
3 Protective cap
4 Electromagnet
5 Connection for electromagnet
6 Secondary spring
7 Housing
8 Secondary piston
9 Secondary restrictor
10 Housing
11 Primary spring
12 Main piston
13 Primary restrictor
14 Strainer
Basic function
The gear motor 1 is driven by the gear pump flow.
The proportional pressure relief valve 3 integrated on the gear motor 1
controls the speed of the gear motor and hence the fan speed.
1 Gear motor
valve compl.
valve
P nlet from the pump
T Return flow to the tank
Gear motor
5.2 - 2 of 4
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Pressure controI with the proportionaI pressure reIief vaIve
How the proportional pressure relief valve works
When the solenoid 1 is not energised, the proportional pressure relief
valve works like a pilot-controlled pressure relief valve.
The pressure at "P passes through the primary restrictor 8 to the spring
area of the main piston 7 and is also present via the secondary restrictor 5
at the secondary piston 4. The pressure relief at the main piston 7 causes
the primary spring 6 to close the main piston.
f the pressure at the secondary piston 4 reaches such a level that the set
force of the secondary spring 2 is exceeded, the secondary piston 4 opens
and oil can flow into the tank chamber. This causes a difference in
pressure on either side of the main piston 7, which causes the main piston
7 to open.
f the solenoid 1 is energised, a different magnetic force is generated
according to the strength of the current.
This magnetic force affects the iron core 3 and pulls it back with a force
proportional to the strength of the current.
The magnetic force reduces the set spring force of the secondary spring 2
by the strength of the magnetic force. This opens the proportional valve
when the system pressure is low.
Fan speed controI
The proportional pressure relief valve opens a bypass on the gear motor.
When the temperature is low, the bypass is almost completely open. Most
of the pump flow is delivered to the tank via the bypass valve. The fan
rotates at a reduced rate (minimum speed = dragging speed).
As the temperature rises, the bypass valve closes in proportion to the
temperature. The gear motor turns the fan at a higher speed.
FaiIsafe function
The failsafe function means that when a power failure occurs in the
proportional pressure relief valve, the bypass valve closes. The gear motor
is driven by the full flow of the gear pump. The fan rotates at the
maximum speed.
Gear motor
5.2 - 3 of 4
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TechnicaI data
Name VaIue Units
Displacement of the gear motor 8 cm
Direction of rotation of gear motor
(looking towards the shaft)
Clockwise
5
bar
Solenoid current (cold medium) 1.0 A
Solenoid current (hot medium, also
sensor failure)
0.380.4 A
Coil resistance at 20 C 4.7 Ohm
Screw tightening torque 124
+41
Nm
Spanner size 41 mm
Gear motor
5.2 - 4 of 4
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5.3 Temperature sensor
(ID 6004344)
The temperature sensor is used to measure the temperature of the coolant
and the hydraulic oil.
Layout
Temperature sensor
The sensor element of the temperature sensor consists of a thin-layer
nickel resistor encapsulated in epoxy resin.
Temperature measurement
Temperature / resistance curve
As the temperature rises, so does the resistance in the sensor.
The resistance curve of the temperature sensor is almost a straight line.
TechnicaI data
Name VaIue Units
Measuring range min.- 30 C
max.130 C
Resistance at 0C 1000 Ohm
Temperature sensor
5.3 - 1 of 2
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Name VaIue Units
Tapped bore M 14 x 1.5
Connector Bosch Jet plug,
2-pin
Temperature sensor
5.3 - 2 of 2
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6 TraveI hydrauIics
Chapter contents
6 Travel hydraulics 6.0 - 1
6.1 Variable displacement pump (D 5716673, 5717296) 6.1 - 1
6.2 Variable displacement motor (D 5716672, 5716674) 6.2 - 1
6.3 nching function 6.3 - 1
6.3.1 nching valve (D 5715911) 6.3 - 2
6.0 - 1 of 6
Travel hydraulics Service manual
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Layout
Main components of the travel hydraulics
1 Hydraulic tank
2 Variable displacement pump
3 Working hydraulics pump
4 Variable displacement motor
5 nching valve
6 nch/brake pedal
6.0 - 3 of 6
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Basic function
Hydraulic plan of the travel hydraulics
1 Hydraulic tank
2 Return strainer
3 Bleeder filter
5 Replenishing valve
6 Pressure retension valve
7 Bypass valve
8 nching valve
9 Temperature switch
20 Variable displacement pump,
complete
22 Travel direction valve
23 Swivel restrictor
24 Servo cylinder
25 Pressure relief and replenish-
ing valve A
ing valve B
27 Pressure cut-off
28 Restrictor
30 Replenishing pump
31 Replenishing pressure relief
valve
32 Orifice
33 Control valve
34 Orifice
35 Check valve 2 bar
49 Orifice
50 Variable displacement pump,
complete
52 Check valve
53 Travel direction solenoid valve
54 Travel range 1 solenoid valve
55 Control piston
56 Servo piston
58 Discharge valve
59 Orifice
MA High pressure test connection
(forwards)
MB High pressure test point (re-
verse)
G Replenishing pressure test
connection
PST Control pressure test
connection
M1 Servo pressure test connection
6.0 - 4 of 6
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The hydrostatic travel drive operates as a closed circuit. The variable
displacement pump 20 delivers oil directly to the variable displacement
motor 50. The oil flowing back from the variable displacement motor is fed
back to the suction side of the variable displacement pump.
The pump swivelling action depends on the diesel engine speed and the
load. As the engine speed increases, the displacement pump swivels out
and the machine begins to move. The travel direction valve 22 determines
the direction in which the displacement pump operates and hence the
travel direction of the machine.
When the inch/brake pedal is pressed, the control pressure of the variable
displacement pump 20 is continuously reduced. This means the speed and
tractive force of the machine can be continuously reduced.
n travel range 1 the travel range 1 solenoid valve 54 on the variable
displacement motor is activated. At the same time, the control oil supply to
the variable displacement motor is interrupted. By doing this, the variable
displacement motor moves to a wide swivel angle and the machine drives
slowly.
The discharge valve 58 is employed in the closed circuit to avoid heat
buildup. n the process, oil is discharged from the low pressure side of the
closed circuit and fed to the hydraulic tank. The replenishing pump re-
places this oil quantity with cooled oil.
VariabIe dispIacement pump
The variable displacement pump operates in the closed circuit. t pumps
the oil directly to the variable displacement motor. The oil flowing back
from the variable displacement motor is fed back to the suction side of the
pump.
load. The speed-dependent flow of the supply pump 30 generates the
control pressure at the control valve 1, which activates the servo cylinder
2.
When the diesel engine is idling, the swivel angle of the variable displace-
ment pump is 0 (the pump output is zero). The variable displacement
pump swivels out with increasing control pressure (speed increase) and
increases its flow.
As the resistance to movement increases, the high pressure in the closed
circuit increases. The pump is adjusted to a lower displacement by the
reaction forces from the high pressure. This protects the diesel engine
against being overloaded.
The travel direction valve 3 determines the direction in which the displace-
ment pump operates and hence the travel direction of the machine.
The pressure cut-off 4 limits the maximum operating pressure within the
closed circuit.
See the detailed description in the "Variable displacement pump chapter.
6.0 - 5 of 6
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VariabIe dispIacement motor
The flow from the displacement pump reaches the variable displacement
motor via pressure connection A or B. n the process, the regulating
pistons which move along the cylinder of the rotary group are subjected to
pressure. The resulting force turns the drive shaft and generates a certain
torque.
The regulation and adjustment unit installed in the connecting housing 2
adjusts the swivel angle of the variable displacement motor via the operat-
ing pressure. The adjustment depends on the control pressure of the
variable displacement pump and from the operating pressure in the vari-
able displacement motor.
The travel direction solenoid valve 3 ensures that even if the high pressure
side changes (for example when driving downhill) the preselected pressure
side of the variable displacement motor controls the swivel angle. This
prevents the variable displacement motor from swinging out to a greater
displacement.
n travel range 1 the travel range 1 solenoid valve 4 is activated and the
control oil supply to the variable displacement motor is blocked. By doing
this, the variable displacement motor moves to a wide swivel angle and
the machine drives slowly.
The discharge valve 1 in the closed circuit serves to prevent overheating.
n the process, oil is discharged from the low pressure side of the closed
circuit and fed to the hydraulic tank. The replenishing pump replaces this
oil quantity with cooled oil.
See the detailed description in the "Variable displacement motor chapter.
Inching vaIve
When the inch/brake pedal is actuated the inching valve opens. Control oil
flows into the hydraulic tank. The control pressure is continuously reduced
and the variable displacement pump is turned so that it delivers a smaller
volume.
The speed and tractive force of the machine can also be continuously
adjusted.
See the detailed description in the "nching valve chapter.
HydrauIic tank
The hydraulic tank provides filtered oil for the replenishing pump of the
travel hydraulics. The replenishing pump draws up oil from the hydraulic
tank via the connection 5.
A pre-tension valve in the return suction filter 1 preloads the suction side
of the replenishing pump with a pressure of 0.5 bar. The replenishing
pump is better able to draw up the oil for cold starts. This means that the
pressure in the hydrostat control circuit increases more quickly and a
better drive performance is achieved.
The oil flows back from the travel hydraulics via the collector pipe 4 and
return strainer 3 to the hydraulic tank. The bleeder filter 2 compensates for
pressure differences inside the hydraulic tank by providing appropriate
ventilation.
See the detailed description in the "Hydraulic tank chapter.
6.0 - 6 of 6
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6.1 VariabIe dispIacement pump
(ID 5716673, 5717296)
Layout
Main components of the variable displacement pump
1 Replenishing pump
2 Connection housing
3 Pump housing
4 Servo cylinder
The variable displacement pump is flange-mounted on the flywheel hous-
ing of the diesel engine.
The variable displacement pump is an axial piston pump with a swash
plate design. The variable displacement pump contains a pressure cut-off
valve, control valve, replenishing pressure relief valve, pressure relief and
replenishing valves and a replenishing pump.
The following diagrams illustrate the design of the variable displacement
pump:
6.1 - 1 of 14
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Components of the variable displacement pump, side view
1 Drive shaft
2 Snap ring
3 Shaft seal ring
4 Pump housing
5 Servo cylinder
7 Swivel restrictor
8 Pressure cut-off
10 Washer
11 Replenishing pump housing
12 Feather key
13 Bearing bushing
14 nternal gear
15 External gear
16 Bearing bushing
17 Coupling hub
18 Bearing bushing
19 Bushing
20 Control lens
21 Pressure spring
22 Cylinder
23 Piston
24 Return ball
25 Disc springs
26 Return plate
27 Glide shoe
28 Swash plate
29 Swash plate bearing
30 Guide pin
31 Pin
32 Roller bearing
33 Snap ring
6.1 - 2 of 14
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Components of the variable displacement pump, servo cylinder and servo valve view
1 Servo cylinder
2 Pump housing
3 Disc spring
4 Pressure spring
5 Pressure spring
6 Turcon-Glyd seal
7 Guide ring
8 Solenoid
9 Pressure cut-off
ing valve
13 Control valve
14 Twist screw
15 Solenoid
16 Receptacle ring
17 Pump zero position adjusting
screw
18 Counter nut
19 Disc spring
20 Snap ring
21 Cover
6.1 - 3 of 14
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Components of the variable displacement pump, front view
ing valve
valve
3 Control valve
4 Restrictor
ing valve
6 Pressure cut-off
6.1 - 4 of 14
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Basic function
Hydraulic plan of the variable displacement pump
3 Swivel restrictor
4 Servo cylinder
ing valve A
6 Pressure relief and
replenishing valve B
7 Pressure cut-off
8 Restrictor
valve
12 Orifice
13 Control valve
14 Check valve
15 Control oil to the inching valve
16 Restrictor
bearing lubrication
The variable displacement pump is designed for hydrostatic drives in the
closed circuit.
The pump delivers directly to the variable displacement motor. The oil
flowing back from the variable displacement motor is fed back to the
suction side of the pump.
load.
When the diesel engine is idling, the swivel angle of the variable displace-
ment pump is 0 (the pump output is zero). The variable displacement
pump swivels out with increasing control pressure (speed increase) and
increases its flow.
The travel direction valve determines the direction in which the displace-
ment pump operates and the travel direction of the machine.
The pressure cut-off limits the maximum operating pressure within the
closed circuit.
6.1 - 5 of 14
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Servo piston and swash pIate
The servo piston 3 turns the swash plate 2 on its roller bearing and thus
controls the pump flow.
Servo piston and swash plate
1 Swash plate bearing
2 Swash plate
3 Servo piston
4 Cylinder with piston
As the swivel angle increases, the pump flow is increased. The drive
torque is increased.
When the swivel angle is reduced, the flow of the pump is also reduced.
The drive torque is reduced.
When in the zero position, the pump flow is also zero. The strong spring
centering in the servo cylinder keeps the swash plate in the zero position if
no control signals are present. The zero position can be mechanically
adjusted.
Sectional view of the servo cylinder
1 Servo cylinder
2 Pressure spring
3 Servo cylinder
4 Control oil supply for forward
travel direction
5 Control oil supply for reverse
travel direction
6 Pressure spring
7 Zero position adjusting screw
6.1 - 6 of 14
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On traversing the zero position, the flow direction of the hydraulic oil is
smoothly reversed.
ControI of the pump
The pump is regulated by the following factors:
nput speed
Operating pressure
Travel direction valve
Speed-dependent controI (DA
controI)
The speed-dependent flow of the replenishing pump is channelled through
the test orifice 7 on the control valve.
n the speed-dependent control valve, the control pressure is determined
by the pressure difference at the measuring orifice.
Sectional view of the control valve
1 Adusting screw
2 Valve housing
3 Valve piston
4 Replenishing pressure
connection
5 Oil return flow to the hydraulic
tank
6 Control pressure connection
7 Test orifice
8 Oil from the replenishing pump
The control valve is set so that when the diesel engine is idling, the control
pressure does not exceed the force of the servo piston springs. This
means that when the variable displacement pump is at idling speed, it
does not deliver any oil.
When the engine speed increases, the control pressure also rises, the
variable displacement pump swivels out and starts pumping oil.
6.1 - 7 of 14
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Functional diagram with control of the variable displacement pump
1 Replenishing pump
2 Test orifice
3 Control valve
4 Restrictor
valve
6 Pressure cut-off
7 nching valve
9 Forward travel direction
solenoid
10 Reverse travel direction
solenoid
11 Control oil to the servo cylinder
for forward travel
12 Return flow oil from the servo
cylinder for reverse travel
The speed-dependent control pressure from the control valve 3 is chan-
nelled via the restrictor 4 to the travel direction valve 8.
The travel direction valve 8 directs the control pressure into one of the two
servo chambers in the servo cylinder. The opposite chamber remains
connected to the drain.
When the inch/brake pedal is pressed, the inching valve 7 opens to the
hydraulic tank and the control pressure inscontinuously reduced. The
restrictor 4 only lets a small quantitly of oil flow from the control valve 3.
The reduced control pressure adjusts the variable displacement pump to a
low flow.
ControI by the operating
pressure
The operating pressure acts on the pump pistons which rest on the swash
plate and exert a reaction force. This force inhibits the swash plate from
turning.
As the travel resistance increases, the operating pressure increases as
does the drive torque of the pump. f the torque exceeds its permitted
value, the speed of the diesel engine drops. The control pressure is
thereby reduced. The piston forces (reaction forces) acting on the swash
plate now exceed the control pressure. The pump swivels back.
6.1 - 8 of 14
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TraveI direction vaIve The travel direction valve determines the direction in which the pump
swivels out.
The travel direction valve directs the control pressure into one of the two
servo chambers in the servo cylinder. The opposite chamber remains
connected to the drain.
Sectional view of the travel direction valve
solenoid
2 Control oil supply
solenoid
4 Swivel restrictor
5 Control oil supply for forward
travel direction
6 Control oil supply for reverse
travel direction
7 Servo cylinder
When the variable displacement pump is swivelling back, the swivel
restrictor 4 prevents it from moving too quickly.
RepIenishing pump
The replenishing pump is an internal gear pump.
The replenishing pump draws oil from the hydraulic tank and delivers it to
the control valve 1. The delivery volume of the pump is proportional to the
drive speed.
Front view of the replenishing pump
1 Control valve
2 nternal gear pump
3 Suction side of the replenish-
ing pump
The maximum replenishing pressure is limited by the replenishing pressure
relief valve.
6.1 - 9 of 14
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RepIenishing pressure reIief vaIve
This directly actuated pressure relief valve protects the replenishing pump
against excess pressure.
Cross section of the replenishing pressure relief valve
1 Tank outlet
2 Oil from the control valve
3 Adusting screw
4 Oil to the pressure relief and
replenishing valve
5 Valve piston
Excess oil that is not fed into the closed circuit flows via the replenishing
pressure relief valve to the pump housing. At the same time, this oil cools
the rotary group of the variable displacement pump.
Pressure cut-off
The pressure cut-off valve limits the operating pressure in the closed
circuit.
Sectional view of the pressure cut-off
1 Pressure spring
2 Valve piston
3 Control oil supply
4 Control edge
5 Tank outlet
6 Tappet
7 Low pressure / closed circuit
8 Check valve
9 Bore hole
10 High pressure / closed circuit
The operating pressure controls the valve. When the maximum operating
pressure is reached, the tappet 6 and the valve piston 2 are pressed
against the pressure springs 1. The control pressure channel 3 is linked to
the tank outlet 5 and servo oil drains off. The control pressure drops and
the variable displacement pump swivels back to reduce the flow. The
variable displacement pump then delivers just enough oil to attain the
maximum pressure.
6.1 - 10 of 14
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Pressure reIief and repIenishing vaIve
The pilot-controlled pressure relief and replenishing valves prevent excess
pressure arising in the closed circuit.
The high pressure from the system acts via the nozzle 6 on the pilot
control piston 2. When the set value is exceeded, the pilot control piston
opens. At the same time, the rear piston chamber is opened via the relief
channel 8 towards the low pressure side. The main piston 4 now opens
and the high pressure oil can flow to the low pressure side 5.
Pressure relief and replenishing valve at high pressure
1 Pressure spring
2 Pilot control piston
3 Rear piston chamber
4 Main piston
5 Low pressure side
6 Nozzle
7 High pressure
8 Relief channel
At the same time, the valves act as replenishing valves for the closed
circuit.
n the process, the oil leakage losses in the closed circuit cause a
pressure drop on the low pressure side. This opens main piston and
replenishing oil can now flow into the closed circuit.
Pressure relief and replenishing valve during replenishment
1 Main piston
2 Pressure spring
3 Main cylinder control edge
4 Replenishing oil intake
5 Replenishing closed circuit
6.1 - 11 of 14
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TechnicaI data
Valid for: L512-466/0501-; L514-467/0501-0786
Name VaIue Units
Type A4VG 90 DA
Max. swivel angle (on both sides) 20
Power output 65 kW
pump
19 cm
Control valve orifice diameter 7.5 mm
Swivel restrictor diameter 1.0 mm
nlet restrictor diameter 1.8 mm
Current consumption of travel
direction solenoid valve
2.5 A
Resistance of travel direction solenoid
valve
5 Ohm
Mass 60 kg
Replenishing pressure 32
2
bar
Regulation begin at 50 bar 1050
50
min
-1
Pump output at 380 bar 1950
100
min
-1
Pressure relief and replenishing
valves
470
10
bar
5
bar
TechnicaI data
Valid for: L514-467/0787-
Name VaIue Units
Type A4VG 90 DA
Max. swivel angle (on both sides) 20
Power output 65 kW
pump
19 cm
Control valve orifice diameter 7.5 mm
Swivel restrictor diameter 1.0 mm
nlet restrictor diameter 1.8 mm
direction solenoid valve
2.5 A
Resistance of travel direction solenoid
valve
5 Ohm
6.1 - 12 of 14
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Name VaIue Units
Mass 60 kg
Replenishing pressure 32
2
bar
Regulation begin at 50 bar 1050
50
min
-1
Pump output at 380 bar 1950
100
min
-1
Pressure relief and replenishing
valves
500
10
bar
5
bar
6.1 - 13 of 14
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6.2 VariabIe dispIacement motor
(ID 5716672, 5716674)
Layout
Main components of the variable displacement motor
1 Discharge valve
2 Control unit
3 Motor housing
4 Drive shaft
7 Regulating unit
The variable displacement motor is flange-mounted on the transfer gear.
The inclined axial tapered piston rotary group and the variable displace-
ment are all integrated in the variable displacement motor.
The travel direction solenoid valve 5 and the travel range 1 solenoid valve
6 are fitted in the regulating unit.
Variable displacement motor
6.2 - 1 of 8
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Components of the variable displacement motor
1 Drive shaft
2 Snap ring
3 Shaft seal ring
4 U-connection
5 Motor housing
6 T-connection
7 Piston
8 Cylinder
9 Control lens
10 Q min. adjusting screw
12 Control housing
13 Travel range 1 valve
14 Control bushing
15 Control piston
16 Adjusting screw for regulation
begin
17 Spring bolt
18 Regulating spring
19 Spring bushing
20 Return spring
21 Connecting housing
22 Control pin
23 Threaded pin
24 Servo piston
25 Socket-head screw
26 Servo piston seal
27 Discharge valve housing
28 Discharge valve
29 Orifice
31 Pressure spring
32 Valve insert
33 Pressure spring
34 Centre pin
35 T-connection
36 Drive shaft bearing
37 Adjusting washer
38 Snap ring
39 Travel range 1 solenoid
41 Valve insert
42 Check valve
43 Test connection M1
44 Washer
45 Return spring
46 nternal and external restrictor
screw
6.2 - 2 of 8
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Components of the variable displacement motor
6.2 - 3 of 8
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Basic function
Hydraulic plan of the variable displacement motor
2 Check valve
5 Control piston
6 Servo piston
7 Swivel restrictor
8 Discharge valve
9 Orifice
11 Control oil connection
12 Bearing lubrication connection
The variable displacement motor drives the transfer gear.
The flow from the displacement pump reaches the variable displacement
motor via pressure connection A or B. n the process, the regulating
pistons which move along the cylinder of the rotary group are subjected to
pressure. The resulting force turns the drive shaft and generates a certain
torque.
The torque at the drive shaft depends on the swivel angle and on the
operating pressure in the closed circuit.
The speed of the drive shaft depends on the pump flow and on the swivel
angle of the variable displacement motor.
As the swivel angle decreases, the speed increases and the potential
torque is reduced.
As the swivel angle increases, the torque increases and the potential
speed is reduced.
The regulation and control unit installed in the connecting housing adjusts
the swivel angle of the variable displacement motor by means of the
operating pressure. The adjustment depends on the control pressure of
the variable displacement pump and the operating pressure in the variable
displacement motor.
The travel direction solenoid valve 3 only lets the operating pressure of the
selected travel direction act on the control piston 5. This prevents inadver-
tent adjustment of the variable displacement motor when driving downhill.
The travel range 1 solenoid valve 4 blocks the control oil suppy in travel
range 1. This prevents adjustment of the variable displacement motor and
the machine drives slowly.
6.2 - 4 of 8
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Speed-dependent controI (DA controI)
Regulation and control unit
The regulation and control unit and the "speed-dependent control adjust
the variable displacement motor to the required swivel angle.
The speed-dependent control pressure of the variable displacement pump
is directed via the connection X1 to the variable displacement motor. f the
travel range 1 valve 1 is not activated, the control pressure acts on the
control piston 3 against the pressure springs 4 the high pressure.
When the control pressure increases with the engine speed, the control
piston 3 moves towards the pressure spring 4 and the high pressure.
This opens the way for the high pressure oil via the control edge of the
control piston 3 to the large control piston face 7. The larger area of the
piston causes the control piston 5 to push the cylinder towards a the
narrower swivel angle via the control pin 8 and the control lens 9. This
increases the output speed and the machine moves more quickly.
The high pressure counteracts the control pressure via a differential sur-
face on the control piston 3 in a set ratio. As the high pressure increases,
the control piston 3 is displaced towards the control pressure. The large
control piston face 7 is relieved of pressure via the control edge of the
control piston 3 to the tank. The high pressure acting on the small control
piston face 6 pushes the control piston 5 and the cylinder towards a wider
swivel angle. This reduces the output speed and the machine slows down.
The regulation begin of the variable displacement motor can be set using
the adjusting screw 2. Proper adjustment ensures optimum machine per-
formance.
Servo piston with swivel restrictor
The swivel restrictor 1 ensures that the variable adjustment motor performs
smoothly during adjustment. The swivel restrictor 1 prevents the swivel
angle of the variable displacement motor from widening too quickly. During
regulation, the oil from the large piston face 2 flows slowly over the lip of
the swivel restrictor.
When regulating down from a large to a small swivel angle, the hydraulic
oil can flow unhindered via the swivel restrictor 1 to the large control
cylinder face 2.
Machine in traveI range 1
When the driver pushes the control lever towards travel range 1, the travel
drive switches the machine to travel range 1.
The travel range 1 solenoid valve 1 is energised and the control oil supply
from the connection 2 is blocked. The travel range 1 solenoid valve 3
relieves the pressure from the control piston 4 to the tank.
The relief of the pressure to the tank causes the regulating spring 5 to
push the control piston 4 to its resting position. This relieves the pressure
on the large surface of the control piston via the channel 6 to the housing,
and the variable adjustment motor moves to a wider swivel angle. The
speed of the motor is kept low by the large displacement volume (travel
range 1).
6.2 - 5 of 8
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Regulating unit in travel range 1
CooIing by the discharge vaIve
The discharge valve is used in the closed circuit to avoid excessive heat
build-up. n the process, oil is discharged from the low pressure side of the
closed circuit and fed to the hydraulic tank. The replenishing pump re-
places this oil quantity with cooled oil.
When the machine is at rest, the pressure is the same on both faces of
the valve piston 4. The two return springs 5 push the valve piston 4 into
the central position. No oil is discharged in this position.
Discharge valve when activated
When the machine moves, the pressure increases in channel 6 or channel
7 and displaces the valve piston 4 against one of the return springs 5. The
low-pressure side opens and a fixed quantity of oil flows via the orifice 1,
pressure relief valve 2 and channel 3 to the housing of the variable
displacement motor.
TechnicaI data
Valid for: L512-466/0501-, ID 5716672
Name VaIue Units
Type A6VM 160 DA
Max. swivel angle 25
Min. swivel angle 7.6
Max.speed 4980 min
-1
6.2 - 6 of 8
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Name VaIue Units
Swivel restrictor (size) 0.55
Control dimension X (adjusting screw
Q min.)
16 mm
Length (adjusting screw Q min.) 90 mm
Regulating piston surface ratio 8 : 100
Discharge valve orifice diameter 2.4 mm
direction + travel range 1 solenoid
valves
2.5 A
Resistance of travel direction + travel
range 1 solenoid valves
5 Ohm
Mass 64 kg
10
bar
TechnicaI data
Valid for: L514-467/0501-, ID 5716674
Name VaIue Units
Type A6VM 200 DA
Max. swivel angle 25
Min. swivel angle 6.5
Max.speed 4005 min
-1
Swivel restrictor (size) 0.4
Control dimension X (adjusting screw
Q min.)
14 mm
Length (adjusting screw Q min.) 90 mm
Regulating piston surface ratio 8 : 100
Discharge valve orifice diameter 2.4 mm
direction + travel range 1 solenoid
valves
2.5 A
Resistance of travel direction + travel
range 1 solenoid valves
5 Ohm
Mass 80 kg
10
bar
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6.3 Inching function
Layout
Main components of the inching function
1 nching valve
2 nch/brake pedal
3 Hydraulic tank
Hydraulic plan of the inching function
1 nching valve
2 Control line to the variable dis-
placement motor
4 nlet restrictor
The inch/brake pedal can be used to smoothly adjust the control pressure
of the hydrostatic travel drive. This means the speed and tractive force of
the machine can be continuously reduced.
The speed-dependent control pressure of the variable displacement pump
3 is connected via the PS connection to the inching valve 1. Control oil
also flows through the connection 2 to the variable displacement motor.
nching function
6.3 - 1 of 4
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When the inch/brake pedal is not actuated the inching valve 1 is closed.
The entire control pressure is available for regulation of the variable
displacement motor and pump. At high engine speeds, the machine can
attain a high travel speed or tractive force.
When the inch/brake pedal is actuated the inching valve 1 opens towards
the hydraulic tank. The control pressure is smoothly reduced according to
the position of the pedal. The variable displacement pump 3 reduces the
flow quantity and the motor increases the displacement. This slows down
the machine and reduces the tractive force.
See the detailed description in the "Variable displacement pump chapter.
6.3.1 Inching vaIve
(ID 5715911)
Layout
Components and connections on the inching valve
1 Housing
2 Rotary piston
3 Control notch
4 Snap ring
5 O-ring
6 O-ring
7 Stop pin
8 Lever
T Return flow to the hydraulic
tank
X Variable displacement pump
connection
The inching valve is connected to the inch/brake pedal by means of an
adjustable linkage.
nching function
6.3 - 2 of 4
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Function
The inching valve is actuated via the inch/brake pedal and the linkage.
When the inch/brake pedal is pressed, the linkage turns the lever 8 and
the rotary piston 2 of the inching valve.
The inching valve smoothly controls the tractive force and speed of the
machine. When the inch/brake pedal is pressed, the inching valve opens
connection X to connection T. This allows control oil to flow from the
variable displacement pump to the hydraulic tank and reduces the dis-
placement.
The control notch 3 allows the operator to continuously regulate the control
pressure by gently pressing the inch/brake pedal. This facilitates smoother
regulation of the variable displacement pump.
When the inch/brake pedal is not pressed, the inching valve is closed, and
the flow from connection X to connection T is blocked.
nching function
6.3 - 3 of 4
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7 Working hydrauIics
Chapter contents
7 Working hydraulics 7.0 - 1
7.1 Working hydraulics pump (D 5716753) 7.1 - 1
7.1.1 Valve block (D 7622992) 7.1 - 2
7.2 Control valve block (D 5716815) 7.2 - 1
7.3 Pilot control 7.3 - 1
7.3.1 Pilot control unit (D 5716785) 7.3 - 5
7.3.2 Pilot control solenoid valve (D 5716155) 7.3 - 9
7.3.3 Pilot control solenoid valve (D 5716694) 7.3 - 11
7.3.4 Pilot control hydro accumulator (D 5719063) 7.3 - 13
7.4 Lift cylinder and tilt cylinder 7.4 - 1
7.4.1 Lift cylinder / Z-bar kinematics (D 9913473,
9925130) 7.4 - 1
7.4.2 Lift cylinder / P-bar kinematics (D 9913472) 7.4 - 3
7.4.3 Tilt cylinder / Z-bar kinematics (D 9913471,
9913469) 7.4 - 4
7.4.4 Tilt cylinder / P-kinematics (D 9916704) 7.4 - 6
7.5 Hydraulic tank (D 9654892) 7.5 - 1
7.5.1 Return suction filter (D 7621815) 7.5 - 3
7.5.2 Return suction filter (D 7623206) 7.5 - 7
7.5.3 Return strainer (D 7620143) 7.5 - 11
7.5.4 Bleeder filter (D 7620534) 7.5 - 12
7.5.5 Collector pipe (D 7622425) 7.5 - 13
7.5.6 Hydraulic oil temperature switch (D 6905421) 7.5 - 14
7.6 Hydraulic quick-change device (D 9658197) 7.6 - 1
7.6.1 Quick-change device solenoid valve (D 5716155) 7.6 - 2
7.6.2 Quick-change device pressure switch (D 6905690) 7.6 - 4
7.6.3 Quick-change device cylinder (D 5716801) 7.6 - 5
7.0 - 1 of 8
Working hydraulics Service manual
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Layout
Main components of the working hydraulics
1 Pilot control unit
2 Hydraulic tank
3 Oil cooler
4 Valve block
with replenishing pump
7 Solenoid valve block
8 Pilot control hydro accumulator
9 Quick-change device solenoid
valve
10 Quick-change device pressure
switch
11 To the quick-change device
cylinder
12 Control valve block
7.0 - 3 of 8
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Basic function
Hydraulic plan of working hydraulics
7.0 - 4 of 8
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1 Hydraulic tank
2 Return strainer
3 Bleeder filter
7 Bypass valve
9 Pilot control solenoid valve
11 Check valve
12 Bypass valve
13 Oil cooler
14 Temperature sensor B8
15 Fan motor, complete
16 Gear motor
17 Proportional valve Y13
19 Fan blade
20 Valve block
21 Orifice
22 Flow dividing valve
23 Filter
25 Accumulator charge valve
26 Orifice
27 Orifice
28 Check valve
29 Orifice
30 Filter
31 Servostat connection
32 Parking brake hydro accumu-
lator connection
33 Servostat LS connection
34 Temperature switch B6
37 1.5 mm orifice
38 1.0 mm orifice
39 Fan gear pump
41 Lowering valve
42 Tilt-out valve
43 Lifting valve
44 Tilt-in valve
45 Bucket return-to-dig solenoid
46 Lifting limit switch solenoid
47 Float position solenoid
48 Additional equipment control
49 Additional equipment control
50 Control valve block, complete
51 Additional equipment spool
valve
52 Tilt cylinder spool valve
53 Lift cylinder spool valve
54 Load retaining valve
55 Primary pressure relief valve
56 Lifting pressure relief valve
57 Tilt-in pressure relief valve
58 Tilt-out pressure relief valve
59 Additional equipment pressure
relief valve
61 Lift cylinder
62 Tilt cylinder
63 Additional equipment
connection
64 Emergency steering pressure
switch
65 Check valve 6 bar
valve
switch
68 Quick-change device cylinder
The working hydraulics are equipped with the following standard functions:
Working movements with the lift and tilt cylinders
Float position
Automatic bucket return-to-dig
Lifting limit switch
Hydraulic quick-change device (optional with Z-bar kinematics)
The working hydraulics system operates in an open circuit. The working
hydraulics pump 35 draws oil from the hydraulic tank 1 and pumps it
through the valve block 20 to the control valve block 50. The returning oil
is pumped through the oil cooler 13 and the return suction filter 4 back to
the hydraulic tank 1.
The control valve block is controlled via the hydraulic pilot control. The
spool valves for the lift and tilt cylinders are integrated in the control valve
block. n addition to this, the lifting cylinder spool valve 53 facilitates the
"float position function.
7.0 - 5 of 8
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HydrauIic tank
The hydraulic tank provides filtered oil for the working hydraulics. The
working hydraulics pump draws up oil from the hydraulic tank via the
connection 1. The returning oil is pumped through the return suction filter 2
back to the hydraulic tank. The bleeder filter compensates for pressure
differences inside the hydraulic tank by providing appropriate ventilation.
Working hydrauIics pump
The working hydraulics pump is a gear pump. t draws the oil from the
hydraulic tank and delivers it via the valve block to the control valve block.
See the detailed description in the "Working hydraulics pump chapter.
VaIve bIock
The valve block distributes the oil flow from the working hydraulics pump
to the steering system, the working hydraulics and the parking brake. The
steering system and the parking brake are the primary components for the
oil supply. The remaining oil flows to the working hyraulics.
See the detailed description in the "Valve block chapter.
ControI vaIve bIock
The spool valves for the lift cylinder 2 and tilt cylinder 1 are integrated in
the control valve block. The spool valves in the control valve block are
hydraulically controlled by the pilot control unit.
The secondary pressure relief valves protect the hydraulic system from
pressure peaks from the consumer units. The primary pressure relief valve
protects the working hydraulics pump from excess pressure.
See the detailed description in the "Control valve block chapter.
OiI cooIer
The oil returning from the control valve block is pumped though the
connection 3 to the oil cooler 1. The hydrostatically driven fan cools the
oil. The cooled oil flows back to the hydraulic tank via the connection 2.
See the detailed description in the "Cooling system chapter.
7.0 - 6 of 8
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PiIot controI
The working hydraulics are actuated by an independent control circuit. The
spool valves are hydraulically actuated in the control valve block 1 by the
pilot control unit 2. The required servo oil is obtained from the variable
adjustment pump 6 (replenishing pump) of the travel hydraulics and di-
rected via the working hydraulics block solenoid valve 4 to the pilot control
unit 2.
The pilot control hydro accumulator 3 and the check valve in the solenoid
valve block 5 mean that the control valve block 1 can be activated when
the diesel engine is not running.
See the detailed description in the "Pilot control chapter.
The hydraulic quick-change device is installed as standard on machines
with P-bar kinematics and as an option on machines with Z-bar kinemat-
ics.
The quick-change device is supplied with oil via the valve block 7 by the
working hydraulics pump. Pressure is continuously applied to the bottom of
the quick-change device cylinder. This ensures that the quick-change
device is safely locked.
The quick-change device is monitored by means of the quick-change
device pressure switch 2.
f the quick-change device solenoid valve 3 is activated, pressure is
applied to the rod side of the quick-change device cylinder. This unlocks
the working attachment.
See the detailed description in the "Hydraulic quick-change device chap-
ter.
7.0 - 7 of 8
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7.1 Working hydrauIics pump
(ID 5716753)
Layout
Working hydraulics pump components
1 Drive shaft and gearwheel
2 Housing
3 Shaft seal ring
4 Bushing
5 Sealing plate
6 O-ring
7 Middle housing section
8 Housing cover
8 Seal with support ring
The working hydraulics pump is flange-mounted on the travel hydraulics
pump and is driven via this unit by the diesel engine.
Basic function
The gear pump consists of two meshing gears enclosed in a housing. One
of the two gearwheels - the driving gear - is driven by the external shaft,
while the other is driven via the meshed teeth.
The incoming hydraulic fluid is trapped in the gaps between the teeth and
is pumped outside along the housing from the intake to the discharge
connection.
OiI suppIy for the working hydrauIics, steering system and
brake system
The working hydraulics pump 2 draws oil from the hydraulic tank 1 and
pumps it to the valve block 3. The speed-dependent pump flow is distrib-
uted by the valve block to the working hydraulics, steering system and
parking brake.
The steering and brake systems are first supplied with oil, and the remain-
der is pumped to the working hydraulics.
Working hydraulics pump
7.1 - 1 of 2
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Oil supply for the working hydraulics, steering system and brake system
TechnicaI data
Name VaIue Units
Type P 330
Displacement 48.4 cm
Power output 40.6 kW
Mass 17 kg
7.1.1 VaIve bIock
(ID 7622992)
Basic function
Functions of the valve block:
Distributes oil to the steering system, parking brake and working
hydraulics
Pressure relief for the steering
Charging the hydro accumulator for the parking brake
Distribution of the oiI fIow in the working hydrauIic pump
The priority valve in the valve block distributes the oil flow from the
working hydraulics pump to the steering system, the working hydraulics
and the parking brake.
The steering system and the parking brake are supplied with oil first. The
remaining oil flows to the working hyraulics.
See the detailed description in the "Steering system chapter under "Valve
block.
Working hydraulics pump
7.1 - 2 of 2
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7.2 ControI vaIve bIock
(ID 5716815)
Layout
Main components of the control valve block
2 Float position cover
3 Secondary pressure relief
valves
6 End plate
The control valve block is installed in the front section of the machine.
Further elements for activating a 3rd and 4th control circuit can be added
to the existing control cylinder block if necessary.
Sectional view of the controil valve block A - A
4 Housing cover
6 Spool valve housing
7 Plug
8 nterior spring cup
9 Housing cover
10 Exterior spring cup
11 Pressure springs
Control valve block
7.2 - 1 of 6
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Control valve block, cross-section
1 Exterior spring cup
2 Pressure springs
3 nterior spring cup
5 Closing element
7 Housing cover
10 Connecting element
11 Primary valve
12 Housing cover
13 Float position spring cup
14 Pressure spring
15 Adusting screw
16 Counter nut
Basic function
Hydraulic plan of the control valve block
valve
Control valve block
7.2 - 2 of 6
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relief valve
relief valve
12 Lifting pressure relief valve
13 Hydraulic tank connection
14 Pump connection
15 Lift cylinder connection
16 Tilt cylinder connection
17 Additional equipment
connection
The spool valves for the lift and tilt cylinders are integrated in the control
valve block. The spool valve for the lift cylinder is equipped with the float
position function. A third control circuit is available as an option and can
be attached to the existing dual control valve block.
When the working hydraulics are not activated, the working hydraulics
pump delivers the oil through the control block and back to the hydraulic
tank. When the working hydraulics are activated, the pump directs the oil
through the spool valves to the consumer units.
The spool valves in the control valve block are hydraulically controlled by
the pilot control unit.
Secondary pressure relief valves for the individual functions protect the
working attachments, cylinders, hoses and the control valve block from
excessive loads. At the same time, the secondary pressure relief valves
act as replenishing valves.
The primary valve protects the working hydraulics pump from excess
pressure.
Working hydrauIics in inactive condition
Control valve block in inactive condition
When the diesel engine is running and the working hyraulics are not
activated, the working hydraulics pump delivers oil to the control valve
block. The pumped oil flows from connection P via the appropriate spool
valve to the closing element 3 and back via connection T to the hydraulic
tank.
Connections 1 and 2 to the lifting cylinder are closed.
Working hydrauIics in active condition
The spool valves in the control valve block are hydraulically controlled by
the pilot control unit.
Control valve block
7.2 - 3 of 6
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Spool valve for tilting function in active condition
When the tilt-in function is activated, control oil flows from the pilot control
unit to connection b2. The spool valve 5 is pushed to the right.
The spool valve 5 cuts off the connection from the pump channel 4 to the
tank channel 5. Now pressure can accumulate in the pump channel 2,
which opens the load retaining valve 1. Oil flows from the pump channel 2
via the load retaining valve 1 and the spool valve to connection B2 and to
the tilt cylinder. The oil returning from the tilt cylinder flows though
connection A2 and the spool valve to the tank channel.
f the spool valve 5 is only slightly activated, only a part of the pumped oil
flows to the consumer unit (tilt cylinder). The excess flow is diverted via
the control notch 3 to the tank channel 5.
Working hydrauIics in the fIoat position
n the float position, the full weight of the working attachment lies on the
ground. The lift arm can move freely up and down depending of the
unevenness of the ground.
Control valve block in the float position
At the maximum deflection of the LH control lever for lowering the lift arm,
the maximum control pressure is present at the connection a1. The spool
valve 3 is pushed all the way to the left against the regulating springs 4
and float position spring 5.
When the spool valve 3 is in this position, the bottom of the lifting cylinder
B1 and the rod side of the lifting cylinder A1 are connected to the tank
channel.
Control valve block
7.2 - 4 of 6
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Primary pressure reIief vaIve
The primary valve protects the working hydraulics pump from excess
pressure. f there is excess pressure, part of the oil flows back to the tank
channel.
The primary pressure relief valve is a pilot controlled valve with a replen-
ishing function.
Secondary pressure reIief vaIves
The secondary pressure relief valves prevent excess pressure when the lift
arms are raised or the bucket is tilted in or out. High pressure can be
caused by external forces, for example if a large rock falls into the bucket.
No secondary pressure relief valve is necessary for lowering the lift arms.
The secondary pressure relief valves are pilot operated valves with an
integrated replenishing function.
f the pressure is too high, the secondary pressure relief valve on the
consumer unit side opens towards the tank connection.
TechnicaI data
Name VaIue Units
Type SM 18
Control piston diameter 18 mm
Piston stroke on both sides 9.5 mm
5
bar
5
bar
Secondary pressure relief valve for
lifting
250
5
bar
tilting in
260
5
bar
tilting out (Z-bar kinematics)
260
5
bar
tilting out (P-bar kinematics)
110
5
bar
Mass 19.3 kg
Control valve block
7.2 - 5 of 6
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7.3 PiIot controI
Layout
Valid for: L512-466/0501-0705; L514-467/0501-0705
Components of the pilot control
2 Check valve
Pilot control
7.3 - 1 of 14
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Valid for: L512-466/0706-; L514-467/0706-
Components of the pilot control
Basic function
Pilot control hydro accumulator
2 Additional equipment valve
3 Additional equipment valve
4 Tilt-in valve
5 Lifting valve
6 Tilt-out valve
7 Lowering valve
10 Check valve
valve
Pilot control
7.3 - 2 of 14
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The working hydraulics are actuated by an independent control circuit. The
spool valves are hydraulically actuated in the pilot control unit 1. The
required control oil is taken by the replenishing pump 11 from the travel
hydraulics. The replenishing pressure relief valve limits the control pres-
sure to the prescribed value.
The pilot control solenoid valve 8 is installed to guarantee the operating
safety of the machine. The working hydraulics lockout switch 2 must be
actuated before maintenance work or road travel in order to prevent
accidental movement of the working attachment. This blocks operation of
The pilot control hydro accumulator 10 with its check valve 9 enables the
lift arm to be lowered or the bucket to be tilted out, even when the diesel
engine is not running.
The bucket return-to-dig, lift kick-out and float position functions are all
controlled via retaining magnets in the pilot control unit 1 and proximity
switches.
PiIot controI unit
The pilot control unit actuates the spool valves in the control valve block.
The control pressure builds up smoothly according to the lever deflection.
Retaining magnets for bucket return-to-dig, lift kick-out and float position
are integrated in the pilot control unit. These magnets hold the control
lever in the maximum deflected position until the solenoid current is
switched off.
See the detailed description in the "Pilot control unit" chapter.
VariabIe dispIacement pump with repIenishing pump
The replenishing pump is integrated in the variable displacement pump 2
for the travel hydraulics. The oil from the replenishing pump flows through
the pilot control connection 1 back to the working hydraulics.
The following components and functions are supplied with oil from the
replenishing pump:
Control circuit of the travel hydraulics
Pilot control of the working hydraulics
Bearing lubrication of the variable displacement motor
The maximum replenishing pump pressure is limited by the replenishing
pressure relief valve.
See the detailed description in the "Travel hydraulics chapter under "Vari-
able displacement pump.
ControI vaIve bIock
The spool valves for the lift cylinder 2 and tilt cylinder 1 are integrated in
the control valve block. The spool valves in the control valve block are
hydraulically controlled by the pilot control unit.
The spool valves are smoothly moved in the appropriate direction accord-
ing to the level of the pilot control pressure.
See the detailed description in the "Control valve block chapter.
Pilot control
7.3 - 3 of 14
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Hydro accumuIator with check vaIve
The hydro accumulator 4 with check valve 2 enables the lift arm to be
lowered and/or the working attachment to be tilted out, even when the
diesel engine is not running. The check valve 2 prevents oil flowing back
from the hydro accumulator 4 to the replenishing pump.
See the detailed description in the "Hydro accumulator with check valve
chapter.
Valid for: L512-466/0501-0705; L514-467/0501-0705
PiIot controI soIenoid vaIve
When the diesel engine is started, the pilot control solenoid valve 1 is
automatically activated. The pilot control unit is supplied with servo oil via
the connection 2 and the working hydraulics can thus be operated.
The working hydraulics lockout switch 2 deactivates the pilot control sole-
noid valve. Connection 2 from the pilot control unit to the hydraulic tank is
relieved of pressure via connection 3, thus blocking the operation of the
working hydraulics.
The pilot control hydro accumulator also enables the lift arm to be lowered
and/or the working attachment to be tilted out, even when the ignition is
off. To do this, press and hold down working hydraulics lockout switch 1
and at the same move the control lever in the appropriate direction.
See the detailed description in the "Pilot control solenoid valve chapter.
Valid for: L512-466/0706-; L514-467/0706-
PiIot controI soIenoid vaIve and hydro accumuIator
When the diesel engine is started, the pilot control solenoid valve 6 is
automatically activated. The pilot control unit is supplied with servo oil via
the connection 3 and the working hydraulics can thus be operated.
The working hydraulics lockout switch 2 deactivates the pilot control sole-
noid valve 6. Connection 3 from the pilot control unit to the hydraulic tank
is relieved of pressure via connection 1, thus blocking the operation of the
working hydraulics.
The pilot control hydro accumulator 4 also enables the lift arm to be
lowered and/or the working attachment to be tilted out, even when the
ignition is off. To do this, press and hold down working hydraulics lockout
switch 1 and at the same move the control lever in the appropriate
direction.
See the detailed descriptions in the "Pilot control solenoid valve and "pilot
control hydro accumulator chapters.
Pilot control
7.3 - 4 of 14
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7.3.1 PiIot controI unit
(ID 5716785)
Layout
Main components of the pilot control unit
1 Housing
2 Control valve
3 Electromagnetic lock
4 Control plate
5 Control lever
The pilot control unit is integrated in the operating panel to the right of the
driver's seat.
A further pilot control unit for optional functions (3rd control circuit) can be
fitted on the existing pilot control.
Pilot control
7.3 - 5 of 14
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Components of the pilot control unit
1 Pressure spring
2 Spring sleeve
3 O-ring
4 Brass bushing
5 Sealing ring
6 O-ring
7 Plastic bushing
8 O-ring
9 Tappet guide
10 Retaining ring
11 Electromagnet with bushings
12 Threaded rod with universal
joint
13 Ring
14 Tappet with universal joint
15 Washer
16 Lock nut
17 Connecting piece
18 Counter nut
19 Control lever
20 Control plate
21 Shim
22 Adjusting sleeve
23 Nut
24 Counter nut
25 Adusting screw
26 Snap ring
27 Tappet
28 Guide bushing
29 Tappet
30 Retaining plates
31 Spring cup
32 Return spring
33 Regulating spring
34 Regulating piston
35 Plug
36 Bore hole
37 Housing
38 Connection 2
39 Connection 4
Pilot control
7.3 - 6 of 14
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Basic function
Hydraulic plan of the pilot control unit
1 Lowering valve
2 Tilt-out valve
3 Lifting valve
4 Tilt-in valve
5 Float position solenoid
6 Lifting limit switch solenoid
7 Bucket return-to-dig solenoid
The pilot control unit hydraulically actuates the control piston in the control
valve block. t operates via directly actuated pressure relief valves. When
the control lever is deflected, control pressure is supplied smoothly to the
respective connection.
Pressure regulation of the individual valves in the pilot control unit depends
on:
The deflection of the control lever
The characteristics of the individual regulating springs
Retaining solenoids enable each function to be electromagnetically locked.
This means that magnetic force holds the control lever in the end position.
Resting condition n its resting position, the control lever is held in the zero position by the
return springs 2. The connection 6 is linked via the bore hole 5 to the tank
connection T.
Control valve at rest / control valve in the regulating phase
Pilot control
7.3 - 7 of 14
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ReguIating phase When the control lever is moved, the tappet 7 presses against the return
spring 8 and the regulating spring 9. The regulating spring 9 pushes down
the regulating piston 10 and cuts off the connection 12 from the tank
connection T. At the same time, the bore hole 11 links the connection 12
to the connection P.
The regulating phase begins as soon as the force of the regulating spring
9 is the same as the force of the hydraulic pressure at the connection 12.
This means the regulating piston 10 is in equilibrium.
The interaction between the regulating piston 10 and the regulating spring
9 means that the pressure at the connection 12 is proportional to the
stroke of the tappet 7 and therefore the position of the control lever. This
kind of pressure control, which depends on the position of the control
lever, makes proportional hydraulic actuation of the spool valve in the
control valve block possible.
EIectromagnetic Iock
The following functions have an electromagnetic lock:
Lifting limit switch
Bucket return-to-dig
Float position
The pressure spring 1 is installed below the tappet 3 and the spring sleeve
2. When the the plunger and the control lever are almost at their end
positions, the operator must use additional force against the pressure
spring 1. This means the operator can feel that the control lever is almost
at its end position.
At the end position (maximum deflection) of the control lever, the ring 5
touches the magnetic lock 4. f the solenoid is activated, magnetic force
holds the control lever in its end position.
Unlocking occurs automatically when the solenoid current is switched off
via the proximity switch or if the control lever is moved in a different
direction.
TechnicaI data
Name VaIue Units
Type 4 THF 5
Retaining solenoid voltage 12 V
Retaining solenoid current
consumption
560 mA
Mass 5.7 kg
Pilot control
7.3 - 8 of 14
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7.3.2 PiIot controI soIenoid vaIve
(ID 5716155)
Layout
3 Parking brake solenoid valve
4 From the hydro accumulator
5 Tank connection
6 To the pilot control unit
The solenoid valves are mounted on the left in the rear section.
Basic function
The pilot control solenoid valve is a 4/2-way valve.
The pilot control solenoid valve 2 makes it possible to block the working
hydraulics, for example when driving on roads or during maintenance
work. The pilot control unit 1 is depressurised and the operation of the
working hydraulics thus locked.
When the pilot control solenoid valve 2 is not energised, connection B to
the tank connection is open. The pilot control unit 1 is depressurised and
the operation of the working attachment thus locked.
Hydraulic plan with pilot control solenoid valve
4 Check valve
Pilot control
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When the pilot control solenoid valve 2 is energised, connection P is
connected to connection B. Oil is pumped from the pilot control hydro
accumulator 3 to the pilot control unit 1 and the operation of the working
attachment thus locked.
TechnicaI data
Name VaIue Units
Current consumption 2.5 A
Resistance 5 Ohm
Pilot control
7.3 - 10 of 14
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7.3.3 PiIot controI soIenoid vaIve
(ID 5716694)
Layout
6 From the replenishing pump
7 Tank connection
8 To the pilot control unit
The solenoid valve block is mounted on the left in the rear section.
Basic function
The pilot control solenoid valve is a 4/2-way valve.
The pilot control solenoid valve 2 makes it possible to block the working
hydraulics, for example when driving on roads or during maintenance
work. The pilot control unit 1 is depressurised and the operation of the
working hydraulics thus locked.
When the pilot control solenoid valve 2 is not energised, connection B to
the tank connection is open. The pilot control unit 1 is depressurised and
the operation of the working attachment thus locked.
Hydraulic plan with pilot control solenoid valve
4 Check valve
Pilot control
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When the pilot control solenoid valve 2 is energised, connection P is
connected to connection B. Oil is pumped from the pilot control hydro
accumulator 3 to the pilot control unit 1 and the operation of the working
attachment thus locked.
TechnicaI data
Name VaIue Units
Resistance 8 Ohm
Pilot control
7.3 - 12 of 14
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7.3.4 PiIot controI hydro accumuIator
(ID 5719063)
Layout
Components of the hydro accumulator
1 Plug
2 Membrane
3 Closing button
4 Accumulator
A membrane 2 stretched in the accumulator 4 acts as an elastic dividing
wall bewteen the hydraulic fluid and the nitrogen. The closing button 3
prevents the membrane from being pressed into the intake opening when
the hydro accumulator is completely empty. The plug 1 permits the pres-
sure of the contents to be checked and the accumulator to be refilled
using the filling and checking device.
Basic function
The purpose of the hydro accumulator is to store hydraulic energy and
release it as needed.
There are various specific areas of application:
As an attenuator to smooth off pressure peaks, for example in the ride
control or the steering damper.
As an energy accumulator to release energy as needed, for example in
the brake system.
Pilot control
7.3 - 13 of 14
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Storing pressure for the piIot controI
Hydraulic plan with pilot control hydro accumulator
The hydro accumulator 3 permits operation of the working hydraulics even
when the diesel engine is not running. n this case, only the lowering of
the lift arm or the tilting out of the working attachment are possible.
Press and hold down the working hydraulics lockout switch 1 and at the
same move the control lever in the appropriate direction.
TechnicaI data
Name VaIue Units
Pilot control
7.3 - 14 of 14
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7.4 Lift cyIinder and tiIt cyIinder
7.4.1 Lift cyIinder / Z-bar kinematics
(ID 9913473, 9925130)
Layout
Main components of the lift cylinder
1 Rod-end cylinder bearing
2 Piston rod bearing
3 Cylinder tube
4 Piston rod
5 Piston
6 Bottom cylinder bearing
The cylinder base is welded to the cylinder tube 3.
The rod-end cylinder bearing 1 is shaped like a fork.
The bottom cylinder bearing 6 is in the form of a bracket with a bearing
bushing.
The piston rod bearing 2 is screwed to cylinder tube 3.
The piston 5 and piston rod bearing 2 are fitted with O-rings and glyd,
rimseal and stepseal sealing rings.
The O-rings are fitted with support rings.
Extending and retracting
The hydraulic cylinder is a double-action cylinder with a piston rod at one
end.
The maximum forces in the cylinder depend on the maximum operating
pressure and the active surfaces.
When extending, the piston face is active; when retracting, the smaller ring
face is active.
This means the force when extending is greater than when retracting.
The piston speed is inversely proportional to the force. The speed is
higher when retracting than when extending.
Piston rod guide The piston rod 4 is guided by the guide rings on the piston 5 and in the
piston rod bearing 2.
Lift cylinder and tilt cylinder
7.4 - 1 of 8
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SeaIing The scraper ring in the piston rod bearing 2 prevents dirt from entering the
piston rod 4.
The O-rings and Glyd, Rimseal and Stepseal sealing rings seal the pres-
sure chambers inside and out.
TechnicaI data
Valid for: L512-466/0501-; L514-467/0501-0786
Name VaIue Units
Rod diameter 60 mm
Min. installation length 965 mm
Mass 51.5 kg
Lifting time at nominal load 4.6 secs
Lowering time unloaded 3.2 secs
TechnicaI data
Valid for: L514-467/0787-
Name VaIue Units
Rod diameter 60 mm
Mass 64.5 kg
7.4 - 2 of 8
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7.4.2 Lift cyIinder / P-bar kinematics
(ID 9913472)
Layout
Main components of the lift cylinder
3 Cylinder tube
4 Piston rod
5 Piston
The rod-end cylinder bearing 1 is shaped like a fork.
bushing.
end.
face is active.
piston rod 4.
7.4 - 3 of 8
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TechnicaI data
Name VaIue Units
Rod diameter 60 mm
Mass 59 kg
7.4.3 TiIt cyIinder / Z-bar kinematics
(ID 9913471, 9913469)
Layout
Main components of the tilt cylinder
3 Cylinder tube
4 Piston rod
5 Piston
The rod-end cylinder bearing 1 is shaped like a bracket.
The bottom cylinder bearing 6 is in the form of a bracket with a swivel
bearing.
7.4 - 4 of 8
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end.
face is active.
piston rod 4.
TechnicaI data
Valid for: L512-466/0501-, ID 9913471
Name VaIue Units
Rod diameter 60 mm
Mass 55 kg
Tilting out time at nominal load 1.0 secs
TechnicaI data
Valid for: L514-467/0501-, ID 9913469
Name VaIue Units
Rod diameter 60 mm
Mass 56 kg
Tilting in time at nominal load 1.6 secs
7.4 - 5 of 8
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7.4.4 TiIt cyIinder / P-kinematics
(ID 9916704)
Layout
Main components of the tilt cylinder
3 Cylinder tube
4 Piston rod
5 Piston
The rod-end cylinder bearing 1 is shaped like a bracket.
bushing.
end.
face is active.
piston rod 4.
7.4 - 6 of 8
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TechnicaI data
Name VaIue Units
Rod diameter 45 mm
Mass 44 kg
7.4 - 7 of 8
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7.5 HydrauIic tank
(ID 9654892)
Layout
Main components of the hydraulic tank
2 Bleeder filter
3 Return strainer
4 Collector pipe
5 Oil level sight glass
6 Steel container
7 Fixing brackets
The hydraulic tank is mounted on the rear section. The fixing brackets for
the exhaust system and for the cooling system are integrated on the steel
section of the hydraulic tank.
Basic function
The hydraulic tank contains the hydraulic oil required by the hydraulic
system. t supplies the travel hydraulics, the working hydraulics, steering
system and parking brake with hydraulic oil.
Return suction fiIter
The return suction filter cleans the oil as it flows back from the working
hydraulics. The oil flows from the inside outwards through the filter.
The filter acts simultaneously as a suction filter for the replenishing pump
of the hydrostatic travel drive.
A magnetic rod is fitted on the cover of the return suction filter.
See the detailed description in the "Return suction filter chapter.
Hydraulic tank
7.5 - 1 of 16
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Return strainer
The return strainer filters some of the oil returning from the hydraulic
system. The filtered oil then flows back to the hydraulic tank.
The bleeder filter is screwed to the return suction filter housing.
See the detailed description in the "Return suction filter chapter.
BIeeder fiIter
An exchange of air with the outside atmoshphere is required in order to
prevent excessive pressure changes inside the hydraulic tank.
To prevent oil contamination, the air drawn in from outside is passed
through a fine filter.
See the detailed description in the "Bleeder filter chapter.
CoIIector pipe
The collector pipe directs the oil returning from the various consumer units
to the return strainer. The filtered oil then flows into the hydraulic tank.
See the detailed description in the "Collector pipe chapter.
TechnicaI data
Name VaIue Units
Hydraulic tank Steel container
Filling quantity 65 l
Hydraulic tank
7.5 - 2 of 16
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7.5.1 Return suction fiIter
(ID 7621815)
Layout
Main components of the return suction filter
1 Cover with magnetic rod
2 Filter housing
3 Filter casing
4 Filter element
The return suction filter is integrated in the hydraulic tank.
The sealing with the steel container is by means of an O-ring.
Hydraulic tank
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Components of the return suction filter
1 Filter housing
2 Cover
3 O-ring
4 Pressure spring
5 Oil return flow connection
6 O-ring
7 Hydraulic tank
8 Magnetic rod
9 Filter casing
10 Manifold
11 Safety strainer
12 Filter element
13 Bypass valve
14 Suction tube
15 Replenishing pump inlet
connection
16 Return flow bypass valve
17 Return flow pre-tension valve
18 Pre-tension valve
Hydraulic tank
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Basic function
The filter acts as a return suction filter and replenishing filter for the
hydrostatic travel drive system replenishing pump.
The oil returning from the working hydraulics flows through the connection
1 to the filter element. The oil flows from the inside outwards through the
filter 4 and is cleaned in the process.
The outside of the filter is connected to the intake connection 2 of the
replenishing pump.
More oil flows from the working hydraulics to the return suction filter than
is drawn in by the replenishing pump. The excess fuel flows through the
pre-tension valve 3 into the tank.
Pressure preIoading on the suction side
The pre-tension valve 3 preloads the intake side of the replenishing pump
with a pressure of 0.5 bar. The remaining quantity is directed via the
pre-tension valve 3 into the hydraulic tank 2.
The replenishing pump is better able to draw up the oil for cold-starts. This
means the pressure in the hydrostat control circuit increases more quickly
and a better drive performance is achieved.
Pressure reIief by the bypass vaIve
The bypass valve 3 prevents excess pressure in the return flow system.
f a certain excess pressure is reached, the bypass valve opens. The oil
now flows through the return strainer 2, the bypass valve 3 and the
connection 4 into the hydraulic tank.
Excess pressure can arise if the filter element is dirty or the viscosity of
the oil is low.
TechnicaI data
Name VaIue Units
Type SR 200 L-01
Hydraulic tank
7.5 - 5 of 16
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Name VaIue Units
Pre-tension valve 0.5 bar
Bypass valve 4.5 bar
Hydraulic tank
7.5 - 6 of 16
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7.5.2 Return suction fiIter
(ID 7623206)
Layout
Main components of the return suction filter
1 Cover with magnetic rod
2 Filter housing
3 Filter casing
4 Filter element
The return suction filter is integrated in the hydraulic tank.
The sealing with the steel container is by means of an O-ring.
Hydraulic tank
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Components of the return suction filter
1 Filter housing
2 Cover
3 O-ring
4 Pressure spring
5 Oil return flow connection
6 O-ring
7 Hydraulic tank
8 Magnetic rod
9 Filter casing
10 Manifold
11 Safety strainer
12 Filter element
13 Bypass valve
14 Suction tube
15 Replenishing pump inlet
connection
16 Replenishing strainer with re-
plenishing valve
17 Return flow pre-tension valve
18 Pre-tension valve
Hydraulic tank
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Basic function
The filter acts as a return suction filter and replenishing filter for the
hydrostatic travel drive system replenishing pump.
The oil returning from the workingn hydraulics flows through the
connection 1 to the filter element. The oil flows from the inside outwards
through the filter 5 and is cleaned in the process.
The magnetic rod 2 attracts larger metal particles from the oil flowing past.
This further increases the lifetime of the filter.
The outside of the filter is connected to the intake connection 3 of the
replenishing pump.
More oil flows from the working hydraulics to the return suction filter than
is drawn in by the replenishing pump. The excess fuel flows through the
pre-tension valve 4 into the tank.
Pressure preIoading on the suction side and repIenishing
function
The filtered oil then flows throught the channel 3 to the intake connection
4 of the replenishing pump. The pre-tension valve 6 preloads the intake
connection 4 of the replenishing pump with a pressure of 0.5 bar. The
remaining oil flows through channel 2, channel 7 and the pre-tension valve
6 into the hydraulic tank.
The increased pressure of the intake connection 4 enables the replenish-
ing pump draws up the oil more easily for cold starts. This means the
pressure in the hydrostat control circuit increases more quickly and a
better drive performance is achieved.
f there is not enough oil to supply the replenishing pump, the replenishing
pump can draw up oil from the hydraulic tank. Oil flows through the
replenishing strainer 5 and the integrated replenishing valve to the suction
connection 4 of the replenishing pump. There may be insufficient oil in the
filter element, for example after changing the filter.
The bore hole 8 makes it easier to change the filter. After you carefully
open the cover with the magnetic rod, part of the oil can slowly drain into
the hydraulic tank via the bore hole 8.
Hydraulic tank
7.5 - 9 of 16
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Pressure reIief by the bypass vaIve
The bypass valve 3 prevents excess pressure in the return flow system.
f a certain excess pressure is reached, the bypass valve opens. The oil
now flows through the safety strainer 2, the bypass valve 3 and the
pre-tension valve 5 into the hydraulic tank.
The safety strainer 2 catches dirt particles in the filter. This prevents
contamination of the hydraulic tank.
Excess pressure can arise if the filter element 1 is dirty or the viscosity of
the oil is low.
TechnicaI data
Name VaIue Units
Type SR 200 L-03
Pre-tension valve 0.5 bar
Replenishing valve 0.04 bar
Replenishing strainer 160 m
Hydraulic tank
7.5 - 10 of 16
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7.5.3 Return strainer
(ID 7620143)
Layout
Components of the return strainer
1 Flat seal
2 Snap ring
3 Housing
4 O-ring
5 Cover
6 Bleeder filter
7 Strainer insert
The return strainer is integrated in the hydraulic tank.
An flat seal 1 is fitted between the return strainer and the steel container
to serve as a sealing.
Hydraulic tank
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Basic function
The hydraulic oil is pumped through the collector pipe 1 to the return
strainer 2.
The return strainer filters a part of the returning oil of the entire hydraulic
system. The filtered oil then flows back to the hydraulic tank.
Hydraulic oil is topped up via the return strainer.
The bleeder filter 3 is attached to the return suction filter housing.
TechnicaI data
Name VaIue Units
Type SK 3774/2
7.5.4 BIeeder fiIter
(ID 7620534)
Layout
The bleeder filter consists of a star-form folded filter element mounted in
an oil-resistant non-corroding plastic housing.
The bleeder filter is screwed on to the return strainer. A flat seal seals the
breather filter to the return strainer hosing.
1 Housing
2 O-ring
3 Pressure spring
4 nlet valve
5 Air inlet opening
6 O-ring
7 Outlet valve
8 Pressure spring
9 Fine filter
10 Housing cover
Hydraulic tank
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Function
An exchange of air with the outside atmoshphere is required in order to
prevent excessive pressure changes inside the hydraulic tank.
To prevent oil contamination, the air drawn in from outside is passed
through the fine filter 1.
The spring-loaded outlet valve 2 and inlet valve 3 reduce the exchange of
air. This minimises any oil contamination and increases the lifetime of the
fine filter element.
TechnicaI data
Name VaIue Units
Type L 1.0506-91
nlet opening pressure 0.03 bar
Outlet opening pressure 0.35 bar
7.5.5 CoIIector pipe
(ID 7622425)
Layout
Components of the collector pipe
The collector pipe 2 is fitted to the return strainer 3. The collector pipe 2 is
integrated in the bypass valve 1.
Hydraulic tank
7.5 - 13 of 16
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Function
The collector pipe directs the oil returning from the various consumer units
to the return strainer. The filtered oil then flows into the hydraulic tank.
Connections on the collector pipe
There are connections to the following components:
1 Return strainer connection
2 Travel hydraulics variable displacement pump
3 Cold start and pilot control solenoid valve
4 Fan motor
7 nching valve
8 Servostat
9 Oil cooler
10 Closed connection
A bypass valve is integrated in the oil cooler connection 9. The bypass
valve protects the oil cooler from excess pressure. When the pressure
gets too high, the bypass valve opens. The oil flows from the working
hydraulics directly through the collector pipe and the return strainer to the
hydraulic tank.
TechnicaI data
Name VaIue Units
7.5.6 HydrauIic oiI temperature switch
(ID 6905421)
Layout
Components of the temperature switch
1 Connection contact
2 Switch housing
3 Switch contacts
4 Transfer piston
5 Membranes
6 Heat-expanding material
The hydraulic oil temperature filter is installed in the suction line of the
replenishing pump.
Hydraulic tank
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Basic function
Temperature switches are used to switch an electrical circuit on and off.
The temperature of the pumped fluid acts on the heat-expanding material
6 via a membrane against an adjustable spring. When a certain tempera-
ture is reached, the heat-expanding material 6 presses against the mem-
brane, the transfer piston 4 and the switch lever. The electronic switch
contacts 3 are closed and the circuit is activated.
The temperature switch is an N/O type switch.
HydrauIic oiI overheat warning function
The temperature switch triggers a warning signal if a certain hydraulic oil
temperature is reached. The machine also switches to travel range 1.
f the temperature of the hydraulic oil rises above the switching point of the
temperature switch, the electrical contacts in the temperature switch are
closed. This generates a negative signal to the electronic control unit A13
and the relay K28.
The display unit then switches on the buzzer and the hydraulic oil overheat
symbol field.
n addition to this, the K28 relay switches the travel range 1 solenoid valve
and the machine drives slowly.
TechnicaI data
Name VaIue Units
Type Behr-Thomson
Switching point 100 C
Connecting thread M 22 x 1.5 mm
Hydraulic tank
7.5 - 15 of 16
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7.6 HydrauIic quick-change device
(ID 9658197)
The hydraulic quick-change device is installed as standard on machines
with P-bar kinematics and as an option on machines with Z-bar kinemat-
ics.
Layout
Components of the hydraulic-quick change device
1 Quick-change device
switch
valve
4 6 bar check valve
5 Tank connection
6 1 mm orifice
7 Valve block
The quick-change device cylinder is integrated in the steel frame of the
quick-change device 1. The quick-change device solenoid valve 3 is
situated in the front section.
Basic function
The hydraulic quick-change device is used for attaching and detaching
various working attachments.
Hydraulic plan of the quick-change device
switch
valve
4 1 mm orifice
5 6 bar check valve
6 Valve block
7.6 - 1 of 6
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The quick-change device is supplied with oil via the valve block 6 by the
working hydraulics pump 7. Oil flows through the orifice 4 to the quick-
change device solenoid valve 3 and the quick-change device cylinder 1.
The job of the quick-change device pressure switch 2 is to monitor the
quick-change device. f a fault occurs or the quick-change device is
unlocked, a warning signal sounds.
The quick-change device when Iocked
When the diesel engine is running there is a constant pressure of around
20 bar at the bottom side of the quick-change device cylinder 1. f the
steering or the working hydraulics are activated, the pressure increases to
a much higher value, depending on the load. This ensures that the
quick-change device is safely locked.
f the pressure at the bottom side of the quick-change device cylinder 1
falls below 5 bar (for example, if a line ruptures), the quick-change device
pressure switch 2 opens its electrical contact. A warning signal sounds.
ReIeasing the quick-change device
When the quick change device is pressed, the quick-change device sole-
noid valve is energised. The bottom side of the quick-change device
cylinder 1 is connected to the hydraulic tank via the check valve 5. The
rod side of the quick-change device cylinder is connected to the P connec-
tion.
f actuation of the working hydraulics (for example tilting in the bucket)
causes the pressure to increase, the quick-change device cylinder unlocks
7.6.1 Quick-change device soIenoid vaIve
(ID 5716155)
Layout
Quick-change device solenoid valve
switch
valve
The quick-change device solenoid valve is situated in the front section.
7.6 - 2 of 6
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Basic function
The quick-change device solenoid valve is a 4/2-way valve.
The quick-change device is activated by pressing the quick-change device
switch.
When it is not energised, the P - A channel and the B - T channel are
connected.
Quick-change device soIenoid vaIve
The quick-change device solenoid valve and hydraulic plan
switch
valve
4 6 bar check valve
5 1.0 mm orifice
6 Oil supply from valve block
When it is not energised, the quick-change device solenoid valve 3 directs
oild to the bottom side of the quick-change device cylinder 1. The rod side
of the quick-change device cylinder 1 is relieved of pressure via the
solenoid valve and the check valve 4 towards the tank. The quick-change
device is locked.
When it is energised, connection P is connected to connection B. The rod
side of the quick-change device cylinder 1 is pressurised and the bottom
side of the quick-change device cylinder 1 is connected to the tank. When
the pressure increases, the working attachment is unlocked.
TechnicaI data
Name VaIue Units
Resistance 5 Ohm
7.6 - 3 of 6
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7.6.2 Quick-change device pressure switch
(ID 6905690)
Layout
Components of the pressure switch
2 Adusting screw
3 Pressure spring
4 Switch contact
5 Membranes
6 Housing
The quick-change device pressure switch 1 is installed on the quick-
change device solenoid valve 2 in the front section.
Basic function
The membrane pressure switches are used to turn an electrical circuit on
and off. Hydraulic pressure acts via a membrane on an adjustable spring.
When the required value is reached, the electrical contact closes and the
circuit is completed.
This membrane switch is an N/O type switch.
Quick-change device monitoring function
The pressure switch monitors the quick-change device. This function en-
sures that the quick-change device is safely locked.
f the pressure at connection A falls below 5 bar (for example due to a
ruptured pipe), the pressure switch opens its contact. An audible warning
signal sounds.
7.6 - 4 of 6
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TechnicaI data
Name VaIue Units
Type Suco
Switching point 5
1
bar
7.6.3 Quick-change device cyIinder
(ID 5716801)
Layout
Main components of the quick-change device cylinder
3 Cylinder tube
4 Piston rod
5 Piston
The rod-end cylinder bearing 1 and the bottom cylinder bearing 6 are
shaped like forks.
The quick-change device cylinder is installed in the steel component of the
quick-change device 1.
end.
face is active.
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Piston rod guide The piston rod 4 is guided by the guide ring on the piston 5 and in the
piston rod 4.
Sealing rings seal the pressure chambers inward and outward.
TechnicaI data
Name VaIue Units
Rod diameter 22 mm
7.6 - 6 of 6
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8 Steering system
Chapter contents
8 Steering system 8.0 - 1
8.1 Steering pump 8.1 - 1
8.1.1 Valve block (D 7622992) 8.1 - 1
8.1.2 Cold start solenoid valve (D 5716155) 8.1 - 6
8.1.3 Cold start solenoid valve (D 5716694) 8.1 - 8
8.2 Servostat (D 5716757) 8.2 - 1
8.3 Steering cylinder (D 9913474) 8.3 - 1
8.4 Emergency steering 8.4 - 1
8.4.1 Emergency steering pump (D 5716888) 8.4 - 3
8.4.2 Emergency steering pressure switch (D 6905534) 8.4 - 5
8.4.3 Emergency steering check pressure switch (D
6905535) 8.4 - 6
8.0 - 1 of 8
Steering system Service manual
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Layout
Main components of the steering system
1 Steering cylinder
2 Servostat
3 Hydraulic tank
4 Emergency steering pump
6 Valve block
switch
8 Emergency steering check
pressure switch
The machine is articulated with additional rear axle steering. The steering
cylinder pushes the front and rear section together via the articulated joint.
The kingpin steering of the rear axle is actuated by connecting rods.
8.0 - 3 of 8
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Articulated steering with rear axle steering
1 Front section
2 Rear section
3 Steering rods
4 Rear axle
5 Steering cylinder
8.0 - 4 of 8
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Basic function
Hydraulic plan of the steering system
1 Hydraulic tank
2 Return strainer
3 Bleeder filter
7 Bypass valve
11 Electric motor
12 Gear pump
check pressure switch
15 Check valve
16 Restrictor check valve
switch
20 Valve block
21 Orifice
23 Filter
26 Orifice
27 Orifice
28 Check valve
29 Orifice
30 Filter
31 Working hydraulics connection
connection
33 Parking brake accumulator
connection
35 Servostat
36 Right replenishing valve
37 Left replenishing valve
38 Right pressure relief valve
39 Left pressure relief valve
40 Metering pump
41 Spool
42 Steering cylinder
8.0 - 5 of 8
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The steering system operates as an open circuit. The working hydraulics
pump 7 draws oil from the hydraulic tank 1 and pumps it through the valve
block 20 to the servostat 35. The servostat supplies the steering cylinder
with oil when the steering wheel is moved.
Thanks to the load sensing controller, the valve block 20 only delivers as
much oil to the servostat as the steering system requires.
The emergency steering system makes it possible to continue steering
even when the working hydraulics pump breaks down. The emergency
steering pump 10 delivers oil to the servostat 30.
HydrauIic tank
The hydraulic tank provides filtered oil for the steering system. The work-
ing hydraulics pump draws up oil from the hydraulic tank via the
connection 1. The emergency steering pump draws up oil from the hydrau-
lic tank via the connection 3.
The oil returning from the servostat is pumped through the connection 2
back to the hydraulic tank via the return strainer.
The working hydraulics pump provides the steering system, working hy-
draulics and parking brake with oil.
The pump draws oil from the hydraulic tank and delivers it via the valve
block to the servostat and the other consumer units.
VaIve bIock
The job of the valve block is to distribute the oil flow from the working
hydraulics pump to the steering, working hydraulics and the parking brake.
The flow dividing valve first supplies the steering system and the parking
brake with oil. The load sensing system ensures that the steering system
and parking brake only receive as much oil as they actually need. The
remaining oil flows to the working hyraulics.
A pressure relief valve in the valve block limits the maximum pressure in
the steering system.
8.0 - 6 of 8
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Servostat
The servostat is connected to the steering column. The metering pump 2
and the spool in the servostat are actuated and the steering movement
initiated via the steering wheel.
The pressure relief valves 1 protect the steering cylinder and the servostat
from excessive pressure peaks.
See the detailed description in the "Servostat chapter.
Steering cyIinder
The steering cylinder is connected to the front and rear sections. The
steering cylinder pushes the front and rear section together via the articu-
lated joint.
When steering, the steering cylinder is actuated by oil from the servostat.
When steering to the right, pressure is applied to the the bottom side of
the steering cylinder, and to the rod end when steering to the left. The
different piston surfaces of the steering cylinder mean that the steering
speed is slightly different to the left and right.
See the detailed description in the "Steering cylinder chapter.
Emergency steering function
The emergency steering function enables the steering to be operated if the
diesel engine or working hydraulics pump fail. The emergency steering
pump is activated by the control electronics.
See the detailed description in the "Emergency steering chapter.
Emergency steering pump
The gear pump 4 of the emergency steering pump is driven by the electric
motor 2. The electric motor is switched on via the relay 1.
For emergency steering, the emergency steering pump draws oil from the
hydraulic tank and delivers it via a check valve to the servostat.
The pressure relief valve 3 protects the pump from excess pressure.
See the detailed description in the "Emergency steering pump chapter.
8.0 - 7 of 8
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8.1 Steering pump
Steering system oiI suppIy
The steering system is supplied with oil via the working hydraulics pump.
The flow of oil from the pump is distributed at the valve block as required
to the working hydraulics, steering system and parking brake.
8.1.1 VaIve bIock
(ID 7622992)
Layout
Components of the valve block
1 Valve block housing
2 Pressure spring
3 Plug
4 Valve insert with check valve
5 Strainer
6 Sealing cap
7 Valve insert with strainer
10 Plug
11 Priority valve
The valve block is mounted on the flywheel housing of the diesel engine.
Steering pump
8.1 - 1 of 10
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Basic function
Hydraulic plan and connections on the valve block
1 Orifice
3 Filter
6 Orifice
7 Orifice
8 Check valve
9 Orifice
10 Filter
11 Pressure connection from gear
pump
connection
14 Return flow to the hydraulic
tank
16 Parking brake accumulator
connection
hydraulics
The valve block provides a priority flow for the steering system and
charges the hydro accumulator for the parking brake. When the hydro
accumulator is filled or the steering actuated, the remaining pumped flow
is available for the working hydraulics.
f the parking brake hydro accumulator is full and the steering is not
actuated, then all of the pumped flow is available to the working hydrau-
lics. When the steering is actuated part of the pump flow is directed to the
steering system depending on the load sensing signal, and the remaining
flow is available for the working hydraulics.
The oil flow to the steering is limited to a set value by a pressure relief
valve.
The accummulator charge valve fills the hydro accummulator of the park-
ing brake. When a certain oil pressure is reached, the accumulator charg-
ing function is switched off.
Distribution of the oiI fIow in the working hydrauIics pump
The priority valve 2 supplies the steering system and the parking brake
with oil first. The remaining flow of the working hydraulics pump is avail-
able for the working hydraulics.
Steering pump
8.1 - 2 of 10
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Priority valve with steering activated and hydraulic plan
When the steering is actuated the pressure builds up at the connection 6
via the load sensing line LS1. This pressure acts via the open accumulator
charge valve 5 on the left side 3 of the priority valve 2. The priority valve 2
is pushed to the right to allow the required quantity of oil to flow to the
steering via the connection P. The remaining oil returning is pumped
though the connection EF to the control valve block.
f the steering is not actuated, the pressure on the left side 3 of the priority
valve 2 decreases. The oil pressure which then acts via the orifice 1 on
the right side of the priority valve 2 pushes the priority valve 2 to the left.
The entire oil flow of the working hydraulics pump can now flow through
the connection EF to the control valve block of the working hydraulics.
DieseI engine starting procedure
The cold start solenoid valve makes it easier to start the diesel engine.
Hydraulic plan with valve block and cold start valve
The cold start solenoid valve 1 is not energised during the diesel engine
starting procedure. This relieves the LS2 connection via the cold start
solenoid valve 1 to the tank.
Oil from the working hydraulics pump flows through the flow dividing valve
4 and applies pressure on the right side of the pressure dividing valve.
This pushes the flow dividing valve to the left against the spring force.
Steering pump
8.1 - 3 of 10
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The entire oil flow of the working hydraulics pump can now flow through
the EF connection to the control valve block and on to the working
hydraulics. This causes a low current consumption in the working hydrau-
lics pump and hence a low dragging load at the diesel motor during the
starting procedure.
The cold start solenoid valve 1 is energised after the diesel engine starting
procedure. The cold start solenoid valve closes the connection to the
hydraulic tank.
The build-up of pressure at the LS2 connection and the spring force push
the flow dividing valve 4 slightly to the right. This means the pump flow is
available for charging the accumulator and for the steering system. The
remaining oil returning is pumped though the EF connection to the control
valve working hydraulics.
Pressure reIief for the steering
The pressure relief valve protects the steering system from excess pres-
sure.
Steering system pressure relief valve and hydraulic plan
f the pressure in the steering system reaches the maximum value, the
pressure relief valve 3 opens. This pressure acts via the left channel 1 on
the priority valve 5. The slightly higher pressure on the right side of the
priority valve 5 pushes it to the left, so that only the oil that is required to
maintain the maximum pressure flows to the steering system.
The strainer 2 protects the pressure relief valve 3 from contamination.
When the pressure relief valve 3 is opened, oil flows through the channel
4 to the hydraulic tank.
FiIIing the parking brake hydro accumuIator
The accummulator charge valve fills the parking brake hydro accum-
mulator to a set pressure
Steering pump
8.1 - 4 of 10
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Accumulator charge valve during filling and hydraulic plan
f the hydro accumulator is empty, the accumulator charge valve 2 is
closed by the spring 1. When the accumulator charge valve 2 is closed,
the pressure acts on the left side of the flow dividing valve 7. This pushes
the flow dividing valve 7 slightly to the right, and the accumulator charging
process via the check valve 6 begins. The pump flow is determined by the
orifice 5. The strainer 4 protects the parking brake from contamination.
When the set cut-off pressure at the accumulator charge valve 2 is
reached, the pressure moves the accumulator charge valve 5. The accu-
mulator charge valve 2 opens and the left side of the flow divider valve 7
is relieved via the connection LS1 and the servostats to the tank. This
pushes the flow dividing valve 7 to the left and the oil from the working
hydraulics pump flows through the connection EF to the working hydraulics
control valve block.
f the pressure in the brake accumulator fall below the set cut-in pressure
for the accumulator charge valve 2, then the accumulator charging process
begins again.
f the pressure in the steering system rises above the set cut-off level for
the accumulator charge valve 2, then the accumulator is filled to the
maximum steering pressure - limited by the pressure relief valve 3.
TechnicaI data
Name VaIue Units
Type STAC
Accumulator charge valve cut-in point 130
10
bar
Accumulator charge valve cut-off
point
160
10
bar
Steering pressure relief valve 180
10
bar
Mass 7 kg
Steering pump
8.1 - 5 of 10
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8.1.2 CoId start soIenoid vaIve
(ID 5716155)
Layout
4 Tank connection
5 Valve block connection
6 Parking brake pressure switch
Basic function
The cold start solenoid valve is a 4/2-way valve.
The cold start solenoid valve makes it easier to start the diesel engine. t
prevents pressure from building up in the hydraulic system during the
starting procedure.
While the diesel engine is being started, the oil flow of the hydraulic pump
is switched to a pressureless circuit.
CoId start soIenoid vaIve
The cold start solenoid valve is not energised during the diesel engine
starting procedure. The cold start solenoid valve is only activated when the
diesel engine is running and the alternator voltage from terminal 61 is
present.
Steering pump
8.1 - 6 of 10
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Hydraulic plan with cold start solenoid valve
2 Hydraulic tank
3 Valve block
When the cold start solenoid valve 1 is not energised, connection P is
connected to connection A and hence also to the hydraulic tank 2. The left
face of the flow dividing valve 4 is relieved of pressure and the oil flow of
the working hydraulics pump can flow through the control valve block
under no pressure.
When the cold start solenoid valve 1 is energised, connection P is con-
nected to connection B. At the same time. pressure can build up at the left
face of the flow dividing valve 4, which means the flow dividing valve 4 is
ready for operation. The steering system and brake system are now
supplied with hydraulic oil.
TechnicaI data
Name VaIue Units
Resistance 5 Ohm
Steering pump
8.1 - 7 of 10
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8.1.3 CoId start soIenoid vaIve
(ID 5716694)
Layout
4 Valve block connection
5 Tank connection
Basic function
The cold start solenoid valve is a 4/2-way valve.
The cold start solenoid valve makes it easier to start the diesel engine. t
prevents pressure from building up in the hydraulic system during the
starting procedure.
While the diesel engine is being started, the oil flow of the hydraulic pump
is switched to a pressureless circuit.
CoId start soIenoid vaIve
The cold start solenoid valve is not energised during the diesel engine
starting procedure. The cold start solenoid valve is only activated when the
diesel engine is running and the alternator voltage from terminal 61 is
present.
Steering pump
8.1 - 8 of 10
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Hydraulic plan with cold start solenoid valve
2 Hydraulic tank
3 Valve block
When the cold start solenoid valve 1 is not energised, connection P is
connected to connection A and hence also to the hydraulic tank 2. The left
face of the flow dividing valve 4 is relieved of pressure and the oil flow of
the working hydraulics pump can flow through the control valve block
under no pressure.
When the cold start solenoid valve 1 is energised, connection P is con-
nected to connection B. At the same time. pressure can build up at the left
face of the flow dividing valve 4, which means the flow dividing valve 4 is
ready for operation. The steering system and brake system are now
supplied with hydraulic oil.
TechnicaI data
Name VaIue Units
Resistance 8 Ohm
Steering pump
8.1 - 9 of 10
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Steering pump
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8.2 Servostat
(ID 5716757)
Layout
2 Control spindle
4 Housing with spool valve
5 Metering pump
Components of the servostat
1 Shaft seal ring
2 nternal rotary slide valve
3 Guide ring
4 Needle bearing
5 Spring
6 Housing
7 External valve sleeve
8 Driver
9 ntermediate flange
10 O-ring
11 Metering pump
12 nternal gear
13 O-ring
The servostat is integrated in the steering console in the cab. The steering
column is meshed with the gearing of the internal internal rotary slide
valve 2. The internal rotary slide valve in the servostat is operated via the
steering wheel and steering column.
Servostat
8.2 - 1 of 4
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Basic function
1 Left replenishing valve
3 Right replenishing valve
5 Metering pump
6 Spool
7 Return flow to the hydraulic
tank
8 Steering cylinder connection
9 Steering cylinder connection
10 Oil from valve block
11 Load sensing signal
When activated, the servostat directs the oil from the valve block to the
steering cylinder. t doses the oil quantity to the steering cylinder precisely
according to the steering wheel speed.
When the steering wheel is activated, the position of the internal rotary
slide valve is turned in relation to the external valve sleeve. The valve
opens, allowing a corresponding amount of oil to flow through the metering
pump to the steering cylinder.
FIow demand controI (Ioad sensing)
The flow demand control (load sensing) system ensures that the valve
block only supplies the oil quantity currently required to the steering. The
servostat of the valve block relays the oil requirement via the LS connec-
tion.
Steering in inactive condition When the steering is not activated, the connection P in the servostat is
blocked. The connection LS for controlling the flow dividing valve 3 is
relieved by the spool 2 to the tank connection T. This pushes the flow
dividing valve 3 to the left and all the oil from the working hydraulics pump
5 flows to the control valve block 4 of the working hydraulics.
Steering in inactive condition
1 Servostat
2 Spool
3 Valve block with flow dividing
valve
4 To the control valve block
P Connection
LS Connection
T Tank connection
Servostat
8.2 - 2 of 4
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Steering in active condition When the steering is actuated, the spool 2 is moved. The connection P is
connected to the connection LS and to the steering cylinder. The in-
creased pressure at the connection LS pushes the flow dividing valve 3 far
enough to the right to allow sufficient oil to flow through the connection P
to the servostat. The remaining oil is pumped though the connection 4 to
the control valve block.
Steering in active condition
1 Servostat
2 Spool
3 Valve block with flow dividing
valve
4 To the control valve block
P Connection
LS Connection
T Tank connection
Pressure reIief
The pressure relief valves prevent excessive pressure peaks in the steer-
ing system. Pressure peaks can arise from sudden loads during driving
mode. Depending on the direction of the load, either the pressure relief
valve 1 for the left steering cylinder or the pressure relief valve 2 for the
right steering cylinder opens.
When the preset pressure is reached, the valve cone 6 opens towards the
pressure spring 4. This causes oil to flow from the consumer unit 7 to the
tank connection 5.
The opening pressure of the pressure relief valve can be set using the
adjusting screw 3.
Servostat
8.2 - 3 of 4
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RepIenishing function
Two replenishing valves are installed in the servostat for steering to the
left and right.
The replenishing valves prevent a vacuum from forming in the steering
cylinder under certain operating conditions. Oil flows through the check
valve 2 from the tank channel 1 to the steering cylinder (channel 3). The
pin 4 prevents the check valve 2 moving too far from the valve seat.
TechnicaI data
Name VaIue Units
Type Eaton 263 - 4392
Displacement 370 cm
Secondary pressure relief 240
10
bar
Servostat
8.2 - 4 of 4
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8.3 Steering cyIinder
(ID 9913474)
Layout
Main components of the steering cylinder
1 Rod-side cylinder bearing
3 Cylinder tube
4 Piston rod
5 Piston
The rod-side cylinder bearing 1 is shaped like a bracket.
The bottom cylinder bearing 6 is in the form of a bracket with a swivel
bearing.
end.
face is active.
piston rod 4.
Steering cylinder
8.3 - 1 of 2
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TechnicaI data
Name VaIue Units
Rod diameter 40 mm
Mass 22.5 kg
Steering cylinder
8.3 - 2 of 2
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8.4 Emergency steering
Layout
Main components of the emergency steering
1 Emergency steering switch
field
3 Control electronics A1
pressure switch B3a
switch B3
7 Valve block
The emergency steering pump 4 is mounted on the right in the rear
section. The valve block 7 with the emergency steering check pressure
switch 5 and emergency steering pressure switch 6 is mounted on the
flywheel housing of the diesel engine. The control electronics 3 are in-
tegrated in the control panel in the right of the cab.
Basic function
Function diagram of the emergency steering
1 Electric motor M8
field
3 Emergency steering button
4 Control electronics A1
5 To the servostat
connection
7 Valve block
switch B3
pressure switch B3a
Emergency steering
8.4 - 1 of 8
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The emergency steering system makes it possible to continue steering
even when the working hydraulics pump or the diesel engine fails. The
emergency steering pump delivers oil to the servostat 5.
The emergency steering pump is controlled by the control electronics 4.
The emergency steering pressure switch 8 and the emergency steering
pressure switch 9 provide the appropriate signals for the control electron-
ics. The emergency steering button 3 is for repeat starting of the emer-
gency steering pump.
Emergency steering function check
A short safety test of the emergency steering system is automatically
conducted whenever the engine is started. The safety test is onIy started
once the alternator has generated a positive signal at terminal 61. This
prevents the starting procedure being affected by the high current input of
the emergency steering pump.
The emergency steering pump is activated during the safety test. The
pump runs for around 2 seconds, until a pressure of 5 bar is reached at
the emergency steering check pressure switch 9. During the safety test,
the "Check symbol field lights up. The emergency steering system is then
operational and the "Check symbol field goes out.
f the pressure of 5 bar is not reached at the emergency steering check
pressure switch 9 , the "Check symbol field remains lit until the ignition is
turned off. The safety test is interrupted after approximately 4 seconds. f
the "Check symbol field is lit, the driver can see that the emergency
steering system is not working.
Activated emergency steering system
Function diagram of the emergency steering
The emergency steering function is started automatically if the diesel motor
or the working hydraulics pump fails. The emergency steering pressure
switch 8 opens its contact if the pressure drops. The control electronics 4
no longer receive a negative signal from the emergency steering pressure
switch 8 and the emergency steering pump begins delivering oil. The
symbol field for emergency steering lights up and an audible signal
sounds. The emergency steering function is available for approximately 50
seconds. Then the control electronics 4 automatically switch off the electric
motor 1 of the emergency steering pump.
Restarting is only possible with the emergency steering button 3. This
function is only available for approximately 2 minutes if the ignition is
switched on.
A temperature switch integrated in the emergency steering pump protects
the emergency steering pump from overheating. The electric motor 1 is
switched off if a certain temperature is reached.
Emergency steering
8.4 - 2 of 8
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8.4.1 Emergency steering pump
(ID 5716888)
Layout
Main components of the emergency steering pump
1 Relay
2 Electric motor
4 Gear pump
The emergency steering pump is installed at the back on the right in the
rear section.
Components of the emergency steering pump
1 Relay
2 Electric motor
3 Connecting piece
4 Sealing ring
5 Flange
6 Seals
7 Bushing
8 Gearwheels
9 Housing
10 Valve housing
Emergency steering
8.4 - 3 of 8
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Basic function
The gear pump of the emergency steering pump is driven by an electric
motor. The electric motor is switched on and off via a relay.
A temperature sensor monitors the temperature of the electric motor during
the operation of the emergency steering pump. The electric motor is
automatically switched off if a certain temperature is reached.
The gear pump draws oil from the hydraulic tank and delivers it to the
servostat. A pressure relief valve protects the pump from excess pressure.
Gear pump with pressure reIief vaIve
The gear pump 1 of the emergency steering pump is protected by a
pressure relief valve. By restricting the maximum pressure it also prevents
excess current consumption by the electric motor.
The system pressure acts on the valve piston 2 against the pressure
springs 3. f the maximum pressure is reached the valve piston 2 opens.
Pressurised oil can then flow to the suction side of the gear pump.
The maximum pressure is determined by the pressure spring 3 and the
adjusting discs 4.
ReIay and overheating protection
The electric motor 8 of the emergency steering pump is switched on and
off via the relay 1. The relay 1 is controlled by the control electronics A1.
The relay is designed to switch large currents.
The temperature sensor 5 monitors the temperature of the electric motor
directly in the winding. The high current input causes the electric motor to
heat up after it has been running for just a few minutes. f a certain
temperature is reached, the temperature sensor 5 generates a signal to
the control electronics A1. This switches off the relay 1 and the emergency
steering pump comes to a standstill. The emergency steering pump can
only be restarted once the electric motor has cooled down again.
Emergency steering
8.4 - 4 of 8
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TechnicaI data
Name VaIue Units
Type Bosch A541 020
319
Displacement 4 cm
5
bar
Max. current consumption 150 A
Mass 10 kg
8.4.2 Emergency steering pressure switch
(ID 6905535)
Layout
2 Adusting screw
3 Pressure spring
4 Switch contact
5 Membranes
6 Housing
The emergency steering pressure switch 1 is mounted on the valve block
3.
Location of the pressure switch
Emergency steering
8.4 - 5 of 8
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Basic function
Membrane pressure switches are used to switch an electrical circuit on
Switching on the emergency steering function
The emergency steering pressure switch checks the system pressure of
the steering system.
f the diesel engine or working hydraulics pump fails, the pressure at the
emergency steering pressure switch drops. The pressure switch opens if
the pressure drops. This interrupts the negative signal to the control
electronics and activates the emergency steering system.
TechnicaI data
Name VaIue Units
Type Suco
Switching point 5
1
bar
8.4.3 Emergency steering check pressure switch
(ID 6905535)
Layout
2 Adusting screw
3 Pressure spring
4 Switch contact
5 Membranes
6 Housing
The emergency steering check pressure switch 2 is mounted on the valve
block 3.
Emergency steering
8.4 - 6 of 8
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Location of the pressure switch
Basic function
Checking the emergency steering system
The job of the emergency steering check pressure switch is to monitor the
emergency steering system.
Once the diesel engine is started, the emergency steering pump begins to
deliver oil. When the pressure reaches 5 bar, the pressure switch closes.
This sends a positive signal to the control electronics and the emergency
steering check is successfully completed.
TechnicaI data
Name VaIue Units
Type Suco
Switching point 5
1
bar
Emergency steering
8.4 - 7 of 8
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9 Brake system
Chapter contents
9 Brake system 9.0 - 1
9.1 Service brake 9.1 - 1
9.1.1 Main brake cylinder (D 7621940) 9.1 - 3
9.1.2 Equalising reservoir (D 7621941) 9.1 - 3
9.1.3 Brake light pressure switch (D 6905534) 9.1 - 4
9.2 Parking brake 9.2 - 1
9.2.1 Valve block (D 7622992) 9.2 - 4
9.2.2 Parking brake hydro accumulator (D 7619022) 9.2 - 5
9.2.3 Parking brake solenoid valve (D 5716155) 9.2 - 7
9.2.4 Parking brake solenoid valve (D 5716694) 9.2 - 9
9.2.5 Parking brake pressure switch (D 6905531) 9.2 - 11
9.3 Disc brake 9.3 - 1
9.0 - 1 of 6
Brake system Service manual
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Layout
Components of the brake system
1 nch/brake pedal
2 nching valve
3 Main brake cylinder
4 Brake light pressure switch
5 Hydraulic tank
6 Equalising reservoir
9 Parking brake hydro
accumulator
10 Valve block
11 Drive shaft
12 Rear brake disc
14 Rear brake carrier
15 ntermediate piece
17 Front brake disc
19 Front brake carrier
20 Main brake carrier
21 Disc brake guard
22 Front axle
9.0 - 3 of 6
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Basic function
Hydraulic plan of the brake system
1 Front axle
3 First service brake circuit
caliper
4 Second service brake circuit
caliper
5 nching valve
accumulator
12 Hydraulic tank
13 Return strainer
14 Valve block
16 Filter
17 Orifice
18 Check valve
connection
G Accumulator charge pressure
test connection
M2 Parking brake test connection
M Pump operating pressure test
connection
The service brake is a hydraulic double-circuit system. t acts on two fixed
caliper disc brakes, which are arranged on two brake discs one behind the
other on the input shaft of the front axle.
The brake is closed by oil pressure, which is built up via the main brake
cylinder 6 when the inch/brake pedal is pressed.
When the inch/brake pedal is pressed down to less than half its full extent,
the machine is hydrostatically braked by the inching valve 5.
9.0 - 4 of 6
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f the pedal is pressed down further, the oil pressure is increased via the
main brake cylinder 6. This activates the two brake calipers 3 and 4 of the
service brake.
The parking brake is an accumulator brake. The parking brake is opened
by oil pressure and closed by spring force.
The parking brake is supplied with oil by the working hydraulics pump 24.
The accummulator charge valve 19 in the control valve block 14 fills the
hydro accummulator 11 with oil. When the parking brake opens, oil flows
under pressure through the parking brake solenoid valve 10 to the brake
caliper 2.
9.0 - 5 of 6
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9.1 Service brake
Layout
Service brake components
1 nch/brake pedal
2 nching valve
6 Drive shaft
7 Rear brake disc
12 Front brake disc
The double disc brake is mounted on the front axle. t is connected to the
rear axle via the drive shaft 6.
Basic function
1 Front axle
5 nching valve
Service brake
9.1 - 1 of 6
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The service brake acts on the front axle via two brake discs and the brake
calipers 3 and 4. The connection via the drive shaft means that the rear
axle is also braked.
When the inch/brake pedal is pressed down, the oil pressure in the main
brake cylinder 6 increases. This acts on the brake pistons of the two
service brake brake calipers 3 and 4, thus generating the required braking
torque.
The brake light pressure switch 7 switches on the brake lights when the oil
pressure has built up.
EquaIising reservoir
The equalising reservoir supplies the main brake cylinder with oil. A
partition divides the equalising reservoir into two halves. This means that
each brake circuit is supplied with oil independently.
Brake oil is topped up via the sealing cap. The sealing cap contains a
valve which equalises the pressure to the atmosphere.
See the detailed description in the "Equalising reservoir chapter.
Main brake cyIinder
The main brake cylinder has 2 separate brake circuits. This means braking
is still possible if one circuit fails.
When the inch/brake 1 pedal is pressed, hydrostatic braking first takes
place via the inching valve. Once the pedal is pressed down more than
half way, the main brake cylinder 2 is activated. Pressure builds up in both
brake circuits.
pressure has built up in the second circuit.
See the detailed description in the "Main brake cylinder chapter.
Disc brake
The service brake caliper 4 (brake circuit 1) and the parking brake caliper
5 act on the front brake disc 3. The service brake caliper 2 (brake circuit
1) acts on the rear brake disc 1.
The parking brake caliper 5 is closed by spring force and opened by oil
pressure.
See the detailed description in the "disc brake chapter.
Service brake
9.1 - 2 of 6
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9.1.1 Main brake cyIinder
(ID 7621940)
Layout
The main brake cylinder is fitted with the inch/brake pedal on the cab floor.
Basic function
The main brake cylinder 3 is supplied with oil from the equalising reservoir.
When the inch/brake pedal 1 is pressed the inching valve 2 is first
actuated. Once the pedal is pressed down more than half way, the main
brake cylinder 3 is activated. Pressure builds up in two separate brake
circuits.
pressure has built up in the second circuit.
TechnicaI data
Name VaIue Units
Type Safim
Brake pressure (at 60 kg pedal force) 120 bar
Overlap inching / service brake 100
20
bar
9.1.2 EquaIising reservoir
(ID 7621941)
Layout
Equalising reservoir with connections
2 Sealing cap
3 Air valve
4 Oil level marking
5 Partition
6 Brake circuit 1 line
7 Brake circuit 2 line
The equalising reservoir 1 is mounted on the hydraulic tank.
Service brake
9.1 - 3 of 6
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Basic function
The equalising reservoir provides brake oil for the double circuit service
brake.
The equalising reservoir is divided by a partition 5. This means brake oil
can only flow back and forth in the top of the reservoir. f one of the brake
circuits loses oil, there is always enough brake oil available in the other
brake circuit.
The markings 4 indicate the correct filling level of the equalising reservoir.
Pressure baIance in the equaIising reservoir
When the service brake is activated the oil level in the equalising reservoir
fluctuates. The air valve 3 in the sealing cap 2 enables air to flow in or out
of the equalising reservoir.
TechnicaI data
Name VaIue Units
Capacity 200 cm
9.1.3 Brake Iight pressure switch
(ID 6905534)
Layout
2 Adusting screw
3 Pressure spring
4 Switch contact
5 Membranes
6 Housing
The brake light pressure switch 3 is screwed on to the main brake cylinder
2 below the cab.
Service brake
9.1 - 4 of 6
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Basic function
Switching on the brake Iights
The job of the brake light pressure switch is to switch on the brake lights
when the service brake is actuated.
When the service brake is actuated, the pressure on the switch increases.
This causes the pressure switch to close its contact and send a positive
signal to the brake lights.
TechnicaI data
Name VaIue Units
Type Suco
Switching point 10
1
bar
Service brake
9.1 - 5 of 6
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9.2 Parking brake
Layout
Components of the parking brake
1 Hydraulic tank
accumulator
6 Valve block
7 Drive shaft
8 Rear brake disc
11 Front brake disc
The double disc brake is mounted on the front axle. t is connected to the
rear axle via the drive shaft 7.
Parking brake
9.2 - 1 of 12
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Basic function
1 Front axle
accumulator
8 Valve block
10 Filter
11 Orifice
12 Check valve
14 Steering pressure relief valve
G Accumulator charge pressure
test connection
M2 Parking brake test connection
M Pump operating pressure test
connection
The parking brake is opened by oil pressure and closed by spring force.
The hydraulic steering is supplied with oil from the working hydraulics
pump 15 via the valve block 8. The flow dividing valve 9 first directs oil
through the filter 10 and the check valve 12 to the parking brake hydro
accumulator 7.
When the parking brake hydro accumulator 7 is filled to a set pressure,
the accumulator charge valve 13 stops the filling process. Only when the
pressure in the parking brake hydro accumulator 7 falls to a certain level
does the filling process begin again.
The parking brake hydro accumulator 7 provides oil to release the parking
brake solenoid valve 6. The parking brake solenoid valve 6 is actuated
using the parking brake switch.
Parking brake
9.2 - 2 of 12
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How the parking brake switch works
Parling brake symbol field and parking brake switch
The parking brake can only be released when the diesel engine is running.
When the parking brake switch 2 is pressed ot the diesel engine shut
down, the brake is closed by the spring force in the brake cylinder and
produces the required braking torque at the brake disc. The parking brake
symbol field 1 lights up.
After the motor is started and the parking brake switch 2 is pressed, the
parking brake solenoid valve is activated. The brake pressure acts on the
brake cylinder via the open parking brake solenoid valve and opens the
brake against the spring force in the brake caliper. The parking brake
symbol field 1 goes out.
HydrauIic tank
The hydraulic tank provides filtered oil for the parking brake. The working
hydraulics pump draws up oil from the hydraulic tank via the connection 1.
The returning oil is pumped through the connection 2 and the return
strainer back to the hydraulic tank. The bleeder filter compensates for
pressure differences inside the hydraulic tank by providing appropriate
ventilation.
The working hydraulics pump is a gear pump. t draws the oil from the
hydraulic tank and delivers it via the valve block to the parking brake.
VaIve bIock
The valve block distributes the oil flow from the working hydraulics pump
to the steering system, the working hydraulics and the parking brake. The
steering system and the parking brake are the primary components for the
oil supply. The remaining oil flows to the working hyraulics.
The parking brake hydro accumulator is supplied with oil by the accumula-
tor charge valve.
Parking brake
9.2 - 3 of 12
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Parking brake soIenoid vaIve and hydro accumuIator
When it is not energised, the parking brake solenoid valve 3 is open
towards the tank connection. The brake caliper 1 is not pressurised and
the parking brake is closed by spring force.
When the parking brake solenoid valve 3 is energised, braking pressure
from the hydro accumulator 4 acts on the brake caliper 1 and opens the
parking brake against the spring force.
See the detailed description in the "Parking brake solenoid valve chapter.
9.2.1 VaIve bIock
(ID 7622992)
Basic function
hydraulics
Charging the accumuIator for the parking brake
The accummulator charge valve in the valve block fills the parking brake
hydro accummulator to a set pressure.
f the pressure in the hydro accumulator is low, the charging process
begins. When a certain pressure is reached in the hyro accumulator, the
filling process is stopped.
See the detailed description in the "Steering system chapter under "Valve
block.
Parking brake
9.2 - 4 of 12
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9.2.2 Parking brake hydro accumuIator
(ID 7619022)
Layout
Components of the hydro accumulator
1 Plug
2 Membrane
3 Closing button
4 Accumulator
A membrane 2 stretched in the accumulator 4 acts as an elastic dividing
wall bewteen the hydraulic fluid and the nitrogen. The closing button 3
prevents the membrane from being pressed into the intake opening when
the hydro accumulator is completely empty. The plug 1 permits the pres-
sure of the contents to be checked and the accumulator to be refilled
using the filling and checking device.
Basic function
The purpose of the hydro accumulator is to store hydraulic energy and
release it as needed.
There are various specific areas of application:
As an attenuator to smooth off pressure peaks, for example in the ride
control or the steering damper.
As an energy accumulator to release energy as needed, for example in
the brake system.
Storing pressure for the parking brake
The parking brake is closed by spring force and opened by oil pressure
from the hydro accumulator.
The hydro accumulator (starter switch in position 1) enables the release of
the parking brake even when the diesel engine is not running. When the
parking brake switch is moved to the "OFF position, brake oil flows from
the hydro accumulator and releases the parking brake. Safe opening of
the parking brake can only be guaranteed when the parking brake symbol
field is not lit.
Parking brake
9.2 - 5 of 12
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TechnicaI data
Name VaIue Units
Parking brake
9.2 - 6 of 12
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9.2.3 Parking brake soIenoid vaIve
(ID 5716155)
Layout
2 From the hydro accumulator
3 Tank connection
4 To the parking brake
Basic function
The parking brake solenoid valve is a 4/2-way valve.
The parking brake solenoid valve is activated by pressing the parking
brake switch.
Parking brake soIenoid vaIve
Hydraulic circuit plan with parking brake solenoid valve
1 Parking brake
accumulator
Parking brake
9.2 - 7 of 12
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n the non-energised condition, connection B to the tank connection is
open. The parking brake 1 is not pressurised and is closed by spring
force.
When it is energised, connection P is connected to connection B. The
parking brake 1 is supplied with pressure and opened.
TechnicaI data
Name VaIue Units
Resistance 5 Ohm
Parking brake
9.2 - 8 of 12
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9.2.4 Parking brake soIenoid vaIve
(ID 5716694)
Layout
4 Parking brake connection
5 Tank connection
Basic function
The parking brake solenoid valve is a 4/2-way valve.
The parking brake solenoid valve is activated by pressing the parking
brake switch.
Parking brake soIenoid vaIve
Hydraulic circuit plan with parking brake solenoid valve
1 Parking brake
accumulator
n the non-energised condition, connection B to the tank connection is
open. The parking brake 1 is not pressurised and is closed by spring
force.
When it is energised, connection P is connected to connection B. The
parking brake 1 is supplied with pressure and opened.
Parking brake
9.2 - 9 of 12
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TechnicaI data
Name VaIue Units
Resistance 5 Ohm
Parking brake
9.2 - 10 of 12
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9.2.5 Parking brake pressure switch
(ID 6905531)
Layout
2 Adusting screw
3 Pressure spring
4 Switch contact
5 Membranes
6 Housing
The parking brake pressure switch is screwed on to the parking brake
solenoid valve in the rear section.
Basic function
Parking brake monitoring function
The parking brake pressure switch monitors the pressure of the parking
brake.
When the parking brake is released the pressure on the parking brake
pressure switch increases and the contact closes. A positive signal is
generated to the pressure switch relay and the travel direction can then be
selected.
When the parking brake is closed there is no pressure on the parking
brake pressure switch and the contact is open. The pressure switch relay
is not energised, which means the travel direction can not be selected.
TechnicaI data
Name VaIue Units
Type Suco
Parking brake
9.2 - 11 of 12
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Name VaIue Units
Switching point 100
5
bar
Parking brake
9.2 - 12 of 12
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9.3 Disc brake
Layout
The disc brake is mounted on the front axle.
Components of the disc brake
1 Front axle
2 Disc brake guard
6 Front brake disc
8 ntermediate piece
10 Rear brake disc
12 Drive shaft
The main brake carrier 3, the front brake carrier 4 and the rear brake
carrier 9 are screwed on to the front axle 1. The individual brake calipers
for the service brake and parking brake are fitted on the brake carriers.
The front brake disc 6, the intermediate piece 8 and the rear brake disc 10
are screwed to the flange on the axle input of the front axle 1. These
means these components rotate at the same speed as the drive shaft. The
drive shaft 12 forms the connection to the rear axle.
The guard 2 mounted on the front section. ts job is to protect the disc
brake from damage.
When the service brake is actuated, brake pressure is applied to the brake
calipers 5 and 11. The brake calipers are pressed together and the
necessary braking torque is applied to the wheels via the front and rear
brake discs.
The parking brake caliper 7 is an accumulator brake. The strong cup
springs in the brake caliper close the parking brake. The required braking
torque is transferred via the front brake disk 6 to the wheels. The parking
brake is opened by oil pressure.
Disc brake
9.3 - 1 of 2
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TechnicaI data
Name VaIue Units
Parking brake / brake pad gap 1.0
0.5
mm
Disc brake
9.3 - 2 of 2
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10 Electrical System
10.0
Chapter contents
10 Electrical System............................................................... 10.0-1
10.1 Electrical system with circuit diagrams.........................................10.1-3
10.1.1 Circuit diagrams..................................................................10.1-3
10.1.2 Circuit diagrams..................................................................10.1-5
10.2 Wiring harnesses..........................................................................10.2-5
10.2.1 Side cover switch wiring harness .......................................10.2-5
10.2.2 Side cover switch wiring harness .......................................10.2-5
10.2.3 Cab wiring harness.............................................................10.2-5
10.2.4 Dashboard wiring harness..................................................10.2-5
10.2.5 Heating wiring harness.......................................................10.2-5
10.2.6 Cab wiring harness.............................................................10.2-5
10.2.7 Cab roof wiring harness......................................................10.2-5
10.2.8 Cab roof wiring harness......................................................10.2-5
10.2.9 Central wiring harness........................................................10.2-5
10.2.10 Central wiring harness........................................................10.2-5
10.3 Control electronics A1...................................................................10.3-5
10.4 Control board A2...........................................................................10.4-5
10.5 Battery installation ........................................................................10.5-5
10.5.1 Battery ................................................................................10.5-5
Service Manual Electrical System
Electrical system with circuit diagrams
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10.1 Electrical system with circuit diagrams
10.1.1 Circuit diagrams
Valid for: L512 - 466 / 0501 8173; L514 - 467 / 0501 - 8173
Design
Control panel, right side
1 Cab ground point
A1 Control electronics
A2 Control board (fuses and
relays)
B31 Buzzer
F03 50A starter circuit fuse from
serial no. 0564
K4 Preglow relay
K6 Starter relay
K23a Forwards safety relay
K24a Reverse safety relay
K30 Quick change device relay
ST1 15-pin connector A1 (plug)
ST2 A1 12-pin connector (socket)
ST3 A1 15-pin connector (socket)
Electrical System Service Manual
10. 1- 4 of 56 L512 - 466 / 0501 - 8173
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MJFCIFSS
1 Power supply: Battery, alternator, ignition starter switch, battery main switch, starter
2 Engine control: Engine stop, preglow, cold start solenoid valve, output speed sensor
3 Engine monitoring: Display unit A13, temperature switch, pressure switch, fuel level sensor
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Item Description Step
A5 LCD display for travel speed, operating hours, clock B3
A13 Display unit B3
B1 Travel gear speed sensor H2
B4 Air filter contamination vacuum switch H3
B7 Pressure switch for engine oil pressure H3
B9 Warning buzzer E2
B20 Coolant temperature thermo switch and sender unit H3
B20a Water pump thermo switch / fuel quantity
CN3 Green 12-pin connector E1
CN5 Green 15-pin connector -
CN6 Yellow 15-pin connector -
CN8 White 4-pin connector -
CN12 White 12-pin connector E3
CN13 Red 12-pin connector C1
D2 1 A diode D1
D7 1 A diode D1
D10 1 A diode D1
D15 1 A diode E1
D16 1 A diode B2
D50 6 A diode C2
D51 1 A diode C2
F01 125 A main fuse (MEGA fuse) E1
F03 50 A starter circuit fuse from serial no. 0564 C1
F04 125 A preglow fuse G2
F4A 7.5 A cold release valve fuse supply via D+ A1
F4C 3 A display unit fuse (battery +30) 3A
F5B 5 A display unit fuse (ignition +15) A2
F6B 3 A engine stop relay fuse, display unit, preglow relay A2
F8C 10 A engine stop fuse C2
G1 Alternator with controller F1
G2 Batteries G1
H2 Preglow symbol field B3
H3 Forwards symbol field A3
H4 Engine oil pressure symbol field A3
H5 Working hydraulics lock symbol field B3
H6 Charge control symbol field A3
H7 Air filter contamination symbol field B3
H8 Emergency steering symbol field B3
H9 Reverse symbol field A9
H10 Direction indicator system symbol field B3
H11 Parking brake symbol field A3
H12 High beam driving light symbol field B3
H13 Engine overheating symbol field B3
H19 Braking system accumulator pressure symbol field B3
H23 Hydraulic oil overheating symbol field A3
H25 Travel range 1 symbol field B3
H26 Travel range 2 symbol field B3
H27 Safety belt symbol field B3
H28 Special function symbol field B3
K2 Engine start relay C1
K2a Not assigned E1
K3 Engine stop relay E2
K4 Preglow and afterglow relay E2
K6 Engine start relay E1
K8 Ignition supply relay B2
K27 Start release relay E1
10. 1- 6 of 56 L512 - 466 / 0501 - 8173
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K29 Preglow power relay G2
M1 Starter G1
P3 Fuel supply segment field B3
P6 Coolant temperature segment field B3
R3 Preglow spark plug H2
R4 Tank encoder H3
R5 Field resistor (alternator) C2
S15 Battery main switch H1
S101 Mode button (clock, travel speed, operating hours) C3
X1 9-pin connector -
X3 11-pin connector C3
X5 2-pin connector H3
X59 2-pin connector D2
Y4 Cold start solenoid valve H2
Y5 Motor stop solenoid H2
Y27 Cold start solenoid valve H1
10. 1- 8 of 56 L512 - 466 / 0501 - 8173
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4 Travel drive: Parking brake system, travel direction selection, travel ranges, backing-up alarm, down shift
hydraulic oil overheating
L512 - 466 / 0501 - 8173 10. 1- 9 of 56
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A13 Display unit A4
B5 Parking brake pressure switch D4
B6 Hydraulic oil overheating thermo switch H4
B16 Backing up alarm H4
CN1 Green 9-pin connector F4
CN5 Green 15-pin connector C4
CN13 Red 12-pin connector -
D6 1 A diode E4
D8 1 A diode C4
D9 1 A diode E4
D19 1 A diode E4
D22 1 A diode F4
D23 1 A diode F4
D25 1 A diode C4
D26 1 A diode E4
D28 1 A diode B4
D30 1 A diode B4
F5C 15 A travel hydraulics fuse A4
K22 Parking brake relay E4
K22a Travel lockout relay C4
K23 Forwards relay E4
K23a Forwards relay E4
K24 Reverse relay E4
K24a Reverse relay E4
K28 Hydraulic oil overheating relay B4
S2 Travel range / travel direction control lever A4
S12 Additional equipment button (optional) A4
S17 Parking brake switch C4
X3 11-pin connector B4
Y2 Forward travel direction solenoid valve H4
Y3 Reverse travel direction solenoid valve H4
Y6 Travel range 1 solenoid valve H4
Y10 Parking brake solenoid valve H4
Y26 Travel direction detection solenoid valve H4
10. 1- 10 of 56 L512 - 466 / 0501 - 8173
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The travel hydraulics are controlled by means of the LH control lever, the
display unit and relays.
Driving forwards
If forward travel is selected on the travel switch S2, a positive signal is sent
to the display unit connection X3 pin 3.
The electronics in the display unit send a negative signal from output X4 pin
1 via the safety relay K23a to the travel direction relay K23 connection 85.
When the parking brake is open, the pressure switch B5 closes and actuates
the relay K22a.
The energised relay K22a supplies positive voltage from fuse F5C to the
travel direction relay K23.
The relay K23 picks up and energises the forward travel solenoid valve Y2.
The two safety relays K23a and K24a are controlled by fuse F5b via relay
K8. When there is no power supply to the display unit, the control of both
travel directions is also interrupted.
Driving in reverse
If reverse travel is selected on the control lever S2, a positive signal is sent
the relay K22a.
The relay K24 picks up and energises the reverse travel direction solenoid
valve Y3 on the pump and the travel direction detection solenoid valve Y26
on the travel motor.
Switching between travel ranges 1 and 2
When the diesel engine is started, travel range 2 is always selected.
If travel range 1 is selected on the control lever S2, a positive signal is sent
The electronics in the display unit send a positive signal from output X4 pin
19 via the travel range 1 solenoid valve Y6 on the travel motor.
When the travel range 1 solenoid valve Y6 is energised, the travel motor is
held at the maximum pivot angle.
The output X4 pin 19 of the display unit becomes de-energised again, as
does the travel range 1 solenoid valve Y6.
When the travel range 1 solenoid valve Y6 is not energised, the travel motor
can move from the maximum, to the minimum swivel angle.
If the hydraulic oil overheats, the system automatically switches to travel
range 1.
If the hydraulic oil reaches a temperature above 100 C, the temperature
switch B6 closes.
The temperature switch B6 switches the relay K28 and energises the travel
range 1 solenoid valve Y6.
hydraulics
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The machine continues moving in travel range 1 until the hydraulic oil
temperature falls back below 100 C.
In this condition, the pilot lamps H25 and H26 for both travel ranges light up.
Directional change lockout
The directional change lockout is active at speeds above 13 km/h.
If the driver attempts to change direction at a speed above 13 km/h, the
pump is first switched to neutral.
The speed is reduced when the pump is in the neutral position.
When the speed is below 13 km/h, the travel direction is then changed.
Parking brake switch S17 with switch positions 2, 0, 1
Position 1 (OFF)
After the diesel engine is started, position 1 (OFF) must be briefly selected in
order to release the brake. This safety procedure prevents accidental
release of the brakes. When the ignition is switched on, voltage is present
via the fuse F5C at the switch S17 connection 7 and at the relay K22
connection 30.
If the switch S17 is moved to position 1 the contact in the switch closes
connections 7 and 5, the relay K22 picks up, the contact on K22 closes a
seal-in circuit and the connection to S17 connection 6.
After the button on switch S17 is released, it is in position 0, connections 4
and 6 are connected and the solenoid valve Y10 is energised.
At the same time, the pressure switch B5 closes and the relay K22a
deactivates the travel lockout, which means the travel direction can be
selected. The relay K22 remains energised by the seal-in circuit.
The brake can be released even when the engine is not running, provided
accumulator pressure is available.
Position 0
In position 0 contacts 4 and 6 are connected and the brake is actuated.
To open the brake again (parking brake OFF), the switch S17 must be
switched to position 0 again.
Position 2 (ON)
In position 2 (ON) contacts 4 and 6 are connected and the brake is closed.
If the switch S17 is actuated in position 2 (snap-in position) the connection to
Y10 is broken, the parking brake closes and pressure switch B5 switches the
travel direction to neutral.
How the parking brake switch
S17 works
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5 Working hydraulics: Working hydraulics lockout, bucket float position, lift kick-out, bucket return-to-dig, quick
change device, mode switch
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B15 Bucket return-to-dig inductive switch E5
B17 Lift kick-out inductive switch E5
B30 Quick-change device pressure switch B5
CN5 15-pin connector F5
CN6 15-pin connector G5
CN10 Red 15-pin connector
CN12 White 12-pin connector B5
D4 1 A diode G5
D5 1 A diode F5
D17 1 A diode F5
D18 1 A diode G5
D27 1 A diode D5
D52 3 A diode E5
D53 1 A diode E5
D54 6 A diode B5
D55 1 A diode E5
F3A 15 A lighting and switch illuminating fuse A5
F4B 7.5 A quick-change device fuse A5
F7C 7.5 A working attachment fuse A5
H29 Quick-change device symbol field C5
K7 Supply relay D+ D5
K17 Lift kick-out relay F5
K18 Bucket return-to-dig relay F5
K30 Quick-change device relay D5
S14 Bucket return-to-dig switch C5
S18 Float position switch D5
S19 Working hydraulics lock switch C5
S22 Lift kick-out switch C5
S25 Reserve switch E5
S26 Quick-change device switch E5
X17 4-pin connector E5
X42 3-pin connector G5
X55 2-pin connector H
Y09 Bucket return-to-dig solenoid H5
Y14 Working hydraulics lockout solenoid valve H5
Y17 Lift kick-out solenoid H5
Y18 Float position solenoid H5
Y28 Quick-change device solenoid valve H5
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How the working hydraulics lockout switch S19 works
Switch button position 1 (safety cut-off):
In position 1 (button function) connections 7 and 5 are connected.
When switch position 1 is selected the contact in the switch connects
connections 7 and 5, and the battery directly supplies voltage to the
solenoid valve Y14 (working hydraulics lockout).
Current flow: batteries G2, fuse F1C, switch S19, connection 7 to
connection 5 to solenoid valve Y14 .
As long as the button remains pressed in position 1 and there is pressure
in the pilot control hydro accumulator, the lift arms can be lowered,
whether the ignition is switched on or not.
Switch position 0 (operating position) with the diesel engine running:
(Terminal D+) voltage is present via relay K7 from fuse F7C at the switch
S19 connection 4 and via connection 6 at the solenoid valve Y14, the
valve opens and the pilot control unit is pressurised.
Current flow: fuse F7C relay K7, diode D54, switch S19 connection 4
switch S19 connection 6 to solenoid valve Y14.
Only when the ignition is on can the equipment not be lowered.
Switch position 2 (OFF position, on-road travel):
If switch S19 is actuated in position 2 (snap-in position) the connection to
the solenoid valve Y14 is interrupted. In position 2 contacts 4 and 2 are
connected.
The working hydraulics lockout symbol field lights up (control via
connections 4 and 2 in the switch S19).
Connections of the inductive switches B15 and B17
1 Power supply +
2 N/C switch output +signal
3 Earth connection -
4 N/O switch output +signal
Automatic bucket return-to-dig function
If the bucket return-to-dig switch S14 is switched on, current flows to the
inductive proximity switch B15 (N/O).
The proximity switch B15 is closed when activated.
(N/O normally open)
The relay K18 on the control unit A2 is activated and the solenoid Y9 on the
pilot control lever is energised.
If the pilot control lever is now fully moved to tilting in, the solenoid Y9 makes
contact and the lever is held in position by the solenoid.
The bucket is now tilted in until the proximity switch B15 switches off and the
circuit to the solenoid Y9 is broken.
The force of the spring returns the pilot control lever to the neutral position.
The bucket remains in the horizontal position.
Float position function
If the float position switch S18 is switched on, current flows to the solenoid
Y18 on the pilot control unit.
If the pilot control lever is now fully moved to lowering, the solenoid Y18
makes contact and the lever is held in position by the solenoid.
Electric switching of the
working hydraulics
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When the spool valve is fully activated the bottom piston end of the lifting
cylinder is connected to the rod side and the bucket position can adapt to
uneven ground.
Lift kick-out function (optional)
If the lift kick-out switch S22 is switched on, current flows to the inductive
proximity switch B17.
The proximity switch B17 is closed when not activated (N/C - normally
closed).
If the pilot control lever is now fully moved to lowering, the lever is held in
position by the solenoid Y17.
The lift arms move upwards until the proximity switch B17 switches off. The
The force of the spring returns the pilot control lever to the neutral position
and the lifting movement is switched off.
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6 Lighting: Steering column switch, direction indicator, horn, hazard warning system, lighting system
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B10 Horn A6
CN5 Green 15-pin connector D6
CN10 Red 15-pin connector A6
CN11 Purple 12-pin connector -
CN13 Red 12-pin connector B6
D11 6 A diode C6
D12 6 A diode C6
D13 6 A diode E6
D14 6 A diode E6
D21 6 A diode E6
D24 1 A diode A6
E3 Left driving headlight G6
E4 Right driving headlight G6
E6 Left tail light G6
E7 Right tail light G6
E14 Left/right number plate light G6
F1A 7.5 A right high beam fuse E6
F1C 10 A hazard warning system fuse, interior lights, optional rotating beacon A6
F2A 7.5 A high beam fuse, left E6
F2B 7.5 A fuse driving headlight, right E6
F2C 7.5 A fuse, driving light, left E6
F5A 3 A sidemarker light fuse, left E6
F6A 3 A sidemarker light fuse, right E6
F6C 15 A front windscreen wiper, horn A6
H15 Front left indicator G6
H16 Front right indicator G6
H17 Rear left indicator G6
H18 Rear right indicator G6
K1 Indicator sensor relay C6
K5 Windscreen wiper interval relay C6
K25 Right indicator relay E6
K26 Left indicator relay E6
M2 Front windscreen wiper motor G2
M4 Front windscreen washer pump G2
S3 Steering column switch B6
S4 Hazard warning system switch D6
S6 Parking light / driving light switch D6
X19 8-pin connector F6
X24 9-pin connector A6
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7 Wiper and washer system / air-conditioning: Front/rear windscreen washer/wiper system, heating, air-
conditioning
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B26 Temperature switch C7
B27 Air-conditioning pressure switch (optional)
D7-{}-
CN1 Green 9-pin connector B7
CN4 Yellow 12-pin connector A7
D3 1 A diode F7
D20 1 A diode F7
F3B 7.5 A rear windshield wiper fuse A7
F7A 25 A air-conditioning fuse (optional) A7
F8A 15 A heater blower fuse A7
K14 Air-conditioning coupling relay (optional) F7
K15 Air-conditioning fan relay (optional) F7
M3 Rear windshield wiper motor H7
M5 Heater blower motor H7
M9 Rear windshield washer pump H7
M12 Air-conditioning fan motor (optional) H7
S11 Blower motor rotary switch C7
S13 Rear wiper motor / washer pump switch C7
S21 Air-conditioning switch (optional) C7
X39 2x1-pin connector C7
Y22 Air-conditioning compressor magnetic coupling (optional) H7
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8 Lighting: Brake lights, cab light, flashing beacon, front & rear working floodlights, compressor seat, socket,
radio
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A3 Radio (optional) F8
B11 Loudspeaker (optional) G6
B12 Brake light pressure switch C8
CN9 White 9-pin connector B8
CN10 Red 15-pin connector E8
CN13 Red 12-pin connector A8
CN14 Purple 15-pin connector B8
E2 Cab light with switch H8
E10 Front left working floodlight H8
E11 Front right working floodlight H8
E12 Rear left working floodlight (optional) H8
E13 Rear right working floodlight (optional) H8
F1B 7.5 A brake light fuse A8
F3C 25 A Working floodlight fuse A8
F8B 10 A fuse socket, radio, seat compressor A8
H20 Left brake light H8
H21 Right brake light H8
H22 Flashing beacon (optional) H8
M7 Driver's seat compressor motor E8
S7 Front working floodlights switch C8
S8 Rear working floodlights switch C8
S9 Flashing beacon switch (optional) C8
W1 Radio aerial (optional) E8
X20 Socket D
X30 2x1-pin connector -
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9 Cooling emergency steering system: Control electronics A1, temperature sensors, cooling system
proportional valve, warning buzzer, emergency steering system, emergency steering pump
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A1 Control electronics B9
B3 Emergency steering pressure switch H9
B3A Emergency steering check pressure switch H9
B8 Hydraulic oil temperature sensor H9
B21 Coolant temperature sensor H9
B31 Warning buzzer H9
CN5 Green 15-pin connector E9
CN6 Yellow 15-pin connector E9
CN7 White 15-pin connector A9
F02 150 A emergency steering pump (MEGA fuse) G9
F7B 7,5 A Control electronics A1 A9
H24 Emergency steering symbol field D9
M8 Emergency steering pump motor H9
S10 Emergency steering button D9
ST1 15-pin connector B9
Y13 Cooling system proportional valve H9
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10.1.2 Circuit diagrams
(ID 9842090)
Valid for: L512 - 466 / from 8174; L514 - 467 / from 8174
Design
Control panel, right side
1 Cab ground point
A1 Control electronics
A2 Control board (fuses and
relays)
F04 50 A starter circuit fuse
F30 50 A starter circuit fuse KL 15
F31 15 A Ignition start switch fuse
K2a Engine start relay
K4 Preglow relay
K30 Quick change device relay
K31 Relay KL.15
ST1 15-pin connector
KL.15 Screw connection M5
KL.30 Screw connection M6
The operating voltage of the machine is 12 volts. The batteries (2 x 12 V)
are connected in parallel.
The two batteries are mounted in the left cab access.
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The following table is a complete list of the components of the electrical
system. The codes in the step column are to help find components in the
circuit diagrams
Abbreviations:
WH wiring harness
SV solenoid valve
LED light emitting diode
OH operating hours
Item Description Step Machine
view
A1 Control electronics 9, 10 2
A2 Control board 1 - 10 2
A3 Radio (optional) 8F
A5 LCD display for travel speed, operating hours, clock 3B
A13 Display unit 3, 4
B1 Travel gear speed sensor 2H
B3 Emergency steering pressure switch 10H 1, 3
B3a Emergency steering check pressure switch 10H 1, 3
B4 Air filter contamination vacuum switch 3H 1, 2
B5 Parking brake pressure switch 4D 3
B6 Hydraulic oil overheating thermo switch 4H
B7 Pressure switch for engine oil pressure 3H
B8 Hydraulic oil temperature sensor 9H 1
B9 Warning buzzer 2E
B10 Horn 6A 2
B11 Loudspeaker (optional) 6G
B12 Brake light pressure switch 8C
B15 Bucket return-to-dig inductive switch 5E
B16 Backing up alarm 4H
B17 Lift kick-out inductive switch 5E
B20 Coolant temperature thermo switch and sender unit 3H 2, 3
B20a Coolant temperature thermo switch (MV ignition pump) L524, L534 2H
B21 Coolant temperature sensor 9H 3
B26 Air-conditioning temperature switch (optional) 7C 3
B27 Air-conditioning pressure switch (optional) 7D
B30 Quick change device pressure switch (optional) 5B
B31 Warning buzzer 9H
CN1 Green connector A2, 9 pin 4, 6, 7
CN2 Green connector A2, 9 pin 4F
CN3 Green connector A2, 12 pin 1, 6
CN4 Yellow connector A2, 12 pin 6, 7, 8
CN5 Green connector A2, 15 pin 1, 2, 3, 4, 6
CN6 Yellow connector A2, 15 pin 1, 2, 4
CN7 White connector A2, 15 pin 5, 10
CN8 White connector A2, 4 pin 1, 2
CN9 Red connector A2, 15 pin 5, 8
CN10 Red connector A2, 15 pin 5, 6, 7
CN11 Purple connector A2, 12 pin 6, 7, 8
CN12 White connector A2, 12 pin 3, 4, 5, 6
CN13 Red connector A2, 12 pin 1, 4, 6, 8
CN14 Purple connector A2, 15 pin 6, 7, 8
D1 6 A diode 6C
D2 1 A diode 1D
D3 1 A diode 7F
D4 1 A diode 5G
D5 1 A diode 5F
Components of the electrical
system
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view
D6 1 A diode 4E
D7 1 A diode 1D
D8 1 A diode 4C
D9 1 A diode 4E
D10 1 A diode 1D
D11 6 A diode 6C
D12 6 A diode 6C
D13 6 A diode 6E
D14 6 A diode 6E
D15 1 A diode 1E
D16 1 A diode 2B
D17 1 A diode 5F
D18 1 A diode 5G
D19 1 A diode 4E
D20 1 A diode 7F
D21 6 A diode 6E
D22 1 A diode 4F
D23 1 A diode 4F
D24 1 A diode 6A
D25 1 A diode 4C
D26 1 A diode 4E
D27 1 A diode 5D
D28 1 A diode 4B
D30 1 A diode 4B
D50 6 A diode 2C
D51 1 A diode 2C
D52 3 A diode 5E
D53 1 A diode 5E
D55 1 A diode 5E
E2 Cab light with switch 8H
E3 Left driving headlight 6G 3
E4 Right driving headlight 6G 3
E6 Left tail light 6G 3
E7 Right tail light 6G 3
E10 Front left working floodlight 8H 3
E11 Front right working floodlight 8H 3
E12 Rear left working floodlight (optional) 8H
E13 Rear right working floodlight (optional) 8H
E14 Left/right number plate light 6G 3
F01 125 A main fuse (MEGA fuse) 1E 1
F02 200 A emergency steering pump (MEGA fuse) 10G 3
F03 125 A fuse, engine preglow (MEGA fuse) 2G 2, 3
F04 50 A starter 1C
F1A 7.5 A high beam fuse, left 6E
F1B 7.5 A brake light fuse 8A
F1C 10 A hazard warning system fuse, interior lights, rotating beacon 6A
F2A 7.5 A right high beam fuse 6E
F2B 7.5 A fuse, driving light, left 6E
F2C 7.5 A fuse driving headlight, right 6E
F3A 15 A lighting and switch illuminating fuse 5A
F3B 7.5 A rear windshield wiper and washing system fuse 7A
F3C 20 A Working floodlight fuse 8A
F4A 7.5 A cold release valve fuse, K7, A1 (supply via D+) 1A
F4B 7.5 A quick-change device fuse 5A
F5A 3 A sidemarker light fuse, right 6E
F5B 5 A display unit fuse, K24a (ignition +15) 2A
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view
F5C 15 A travel hydraulics fuse 4A
F6A 3 A sidemarker light fuse, left 6E
F6B 3 A Fuse buzzer, motor stop relay, preglow, KL.15, start release 2A
F6C 15 A front washing pump and windscreen wiper, horn 6A
F7A 25 A air-conditioning fuse (optional) 7A
F7B 7.5 A Control electronics A1, emergency steering button 10A
F7C 7.5 A working attachment fuse 5A
F8A 15 A heater blower,air-conditioning fuse (optional) 7A
F8B 10 A fuse socket, radio, seat compressor 8A
F8C 10 A engine stop fuse, (MV injection pump L524, L534) 2C
F30 50 A fuse terminal 15 (MEGA fuse) 1C
F31 15 A Ignition start switch fuse 1C
G1 Alternator with controller 1F 3
G2 Batteries 1G 1, 2
H2 Preglow symbol field 3B
H3 Forwards symbol field 3A
H4 Engine oil pressure symbol field 3A
H5 Working hydraulics lock symbol field 3B
H6 Charge control symbol field 3A
H7 Air filter contamination symbol field 3B
H8 Emergency steering symbol field 3B
H9 Reverse symbol field 3A
H10 Direction indicator system symbol field 3B
H11 Parking brake symbol field 3A
H12 High beam driving light symbol field 3B
H13 Engine overheating symbol field 3B
H15 Front left indicator 6G 3
H16 Front right indicator 6G 3
H17 Rear left indicator 6G 3
H18 Rear right indicator 6G 3
H19 Braking system accumulator pressure symbol field 3B
H20 Left brake light 8H 3
H21 Right brake light 8H 3
H22 Flashing beacon (optional) 8H
H23 Hydraulic oil overheating symbol field 3A
H24 Emergency steering symbol field 10D
H25 Travel range 1 symbol field 3B
H27 Safety belt symbol field 3B
H28 Special function symbol field 3B
H29 Quick-change device symbol field 5C
K1 Indicator sensor relay 6C
K2 Engine start relay 1C
K2a Engine start relay 1E
K3 Engine stop relay 2E
K4 Preglow and afterglow relay 2E
K5 Relay windscreen wiper wash interval 7C
K7 Supply relay D+ 5D
K8 Ignition on supply relay 2B
K14 Air-conditioning coupling relay (optional) 7F
K15 Air-conditioning fan relay (optional) 7F
K17 Lift kick-out relay 5F
K18 Bucket return-to-dig relay 5F
K22 Parking brake relay 4E
K22a Travel lockout relay 4C
K23 Forwards relay 4E
K23a Forwards relay 4E
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view
K24 Reverse relay 4E
K24a Reverse relay 4E
K25 Right indicator relay 6E
K26 Left indicator relay 6E
K27 Start release relay 1E
K28 Hydraulic oil overheating relay 4B
K29 Preglow power relay 2G 3
K30 Quick-change device relay 5D
K31 Relay terminal 15 1E
KL15 Terminal 15 threaded pin M5 1A
KL30 Terminal 30 threaded pin M6 1C
M1 Starter 1G 1
M2 Front windscreen wiper motor 7G
M3 Rear windshield wiper motor 7H
M4 Front windscreen washer pump 7G 1
M5 Heater blower motor 7H
M7 Driver's seat compressor motor (optional) 8H
M8 Emergency steering pump motor 10H 2, 3
M9 Rear windshield washer pump 7H 1
M12 Air-conditioning fan motor (optional) 7H
P3 Fuel supply segment field 3B
P6 Coolant temperature segment field 3B
R3 Preglow spark plug 2H 2, 3
R4 Tank encoder 3H 2
R5 Field resistor (alternator) 2C
S1 Ignition start switch 1B
S2 Travel direction control lever 4A
S3 Steering column switch 6B
S4 Hazard warning system switch 6D
S6 Parking light / driving light switch 6D
S7 Front working floodlights switch 8C
S8 Rear working floodlights (optional) switch 8C
S9 Flashing beacon switch (optional) 8C
S10 Emergency steering button 10D
S11 Blower motor rotary switch 7C
S12* Additional equipment button (optional) 4A
S13 Rear wiper motor / washer pump switch 7C
S14 Bucket return-to-dig switch 5C
S15 Battery main switch 1H 1, 2, 3
S17 Parking brake switch 4C
S18 Float position switch 5D
S19 Working hydraulics lock switch 5C
S21 Air-conditioning switch (optional) 7C
S22 Lift kick-out switch 5C
S26 Quick change device switch (optional) 5E
S100 Travel range button, neutral position 4B
S101 Mode button (clock, travel speed, operating hours) 3B
ST1 15-pin connector 10B
ST2 12-pin connector 9, 10
ST3 15-pin connector 9, 10
V1 Starter extinguishing diode 1H
W1 Radio aerial (optional) 8F
X1 9-pin connector 1, 2 2
X2 70-pin connector 1 - 10 2
X3 11-pin connector 3, 4
X10 15-pin MATE-N-LOK connector 3, 5, 7, 8
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view
X11 2-pin MATE-N-LOK connector 3, 5
X140 2x1-pin Fastin-Faston connector 8G
X16 6-pin connector 5G-H
X20 Socket 8D
X22 12-pin connector 6, 7, 8 1
X24 9-pin connector 6A
X25 9-pin connector 6C
X28 6-pin connector 7H
X37 6-pin connector 8F
X40 4-pin connector 7D-G
X53 9-pin connector 5E-F
X61 2-pin connector 6G
Y2 Forward travel direction solenoid valve 4H 1, 3
Y3 Reverse travel direction solenoid valve 4H 1, 3
Y4 Cold start solenoid valve 2H
Y5 Motor stop solenoid 2H
Y6 Travel range 1 solenoid valve 4H
Y9 Bucket return-to-dig solenoid 5H
Y10 Parking brake solenoid valve 4H 3
Y13 Cooling system proportional valve 9H 1
Y14 Working hydraulics lockout solenoid valve 5H 3
Y17 Lift kick-out solenoid 5H
Y18 Float position solenoid (optional) 5H
Y22 Air-conditioning compressor magnetic coupling (optional) 7H
Y26 Travel direction detection solenoid valve 4H
Y27 Cold start solenoid valve 1H 3
Y28 Solenoid valve Quick change device (optional) 5H
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MJFCIFSS
Machine view (1) left
Machine view (2) right
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Machine view (3) above
Circuit diagrams
The circuit diagrams are divided into steps from 1 to 10. The following is a
list of the steps and their main functions.
Overview:
1 Power supply: Battery, alternator, ignition starter switch, battery main
switch, starter
2 Engine control: Engine stop, preglow, cold start solenoid valve, output
speed sensor
3 Engine monitoring: Display unit A13, temperature switch, pressure
switch, fuel level sensor
4 Travel drive: Display unit A13, travel hydraulics solenoid valve, parking
brake solenoid valve, control levers S2 and S100
5 Working hydraulics: Switches, proximity switches, retaining solenoids
6 Lighting: Steering column switch, driving headlights, direction indicator
system, horn
7 Wiper system: Front windscreen wipers, rear windscreen wipers,
heating and air conditioning system
8 Lighting: Working floodlight, brake light, cab light, radio (optional)
9 Cooling system: Control electronics A1, temperature sensors,
proportional solenoid valve, fan drive
10 Emergency steering system: Control electronics A1, emergency
steering pressure switch, emergency steering pump, emergency steering
switch
The circuit diagram of the electrical system shows the functional procedures
for the entire machine, including optional attachments. All components and
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connectors are marked with a letter and number and shown with the
appropriate symbols so that they are clearly identifiable. The components
are also listed in the keys together with their names.
The circuit diagrams are divided into steps (vertically separated sections),
whereby one step may contain one or more functions. Power connections
between the steps are indicated: The same letter combination, step (1-18)
and coordinate (A-H) is given in the end.
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MJFCIFSS
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A2 Control board 1, 2, 3
A5 LCD display for travel speed, operating hours, clock 3B
A13 Display unit 3A-B
B1 Travel gear speed sensor 2H
B4 Air filter contamination vacuum switch 3H
B7 Pressure switch for engine oil pressure 3H
B9 Warning buzzer 2E
B20 Coolant temperature thermo switch and sender unit 3H
B20a Coolant temperature thermo switch / fuel quantity 2H
CN3 Green 12-pin connector 1E
CN5 Green 15-pin connector 1, 2, 3
CN6 Yellow 15-pin connector 1, 2
CN8 White 4-pin connector 1, 2
CN12 White 12-pin connector 3E
CN13 Red 12-pin connector 1C
D2 1 A diode 1D
D7 1 A diode 1D
D10 1 A diode 1D
D15 1 A diode 1E
D16 1 A diode 2B
D50 6 A diode 2C
D51 1 A diode 2C
F01 125 A main fuse (MEGA fuse) 1E
F04 50 A starter 1C
F30 50 A fuse terminal 15 (MEGA fuse) 1C
F03 125 A fuse, engine preglow (MEGA fuse) 2G
F4A 7.5 A cold release valve fuse supply via D+ 1A
F5B 5 A display unit fuse, K24a (ignition +15) 2A
F6B 3 A Fuse buzzer, motor stop relay, preglow, KL.15, start release 2A
F8C 10 A engine stop fuse, (MV injection pump L524, L534) 2C
F31 15 A Ignition start switch fuse 1C
G1 Alternator with controller 1F
G2 Batteries 1G
H2 Preglow symbol field 3B
H3 Forwards symbol field 3A
H4 Engine oil pressure symbol field 3A
H5 Working hydraulics lock symbol field 3B
H6 Charge control symbol field 3A
H7 Air filter contamination symbol field 3B
H8 Emergency steering symbol field 3B
H9 Reverse symbol field 3A
H10 Direction indicator system symbol field 3B
H11 Parking brake symbol field 3A
H12 High beam driving light symbol field 3B
H13 Engine overheating symbol field 3B
H19 Braking system accumulator pressure symbol field 3B
H23 Hydraulic oil overheating symbol field 3A
H27 Safety belt symbol field 3B
H28 Special function symbol field 3B
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K2 Engine start relay 1C
K2a Engine start relay 1E
K3 Engine stop relay 2E
K4 Preglow and afterglow relay 2E
K8 Ignition on supply relay 2B
K27 Start release relay 1E
K29 Preglow power relay 2G
K31 Relay terminal 15 1E
KL15 Terminal 15 threaded pin M5 1A
KL30 Terminal 30 threaded pin M6 1C
M1 Starter 1G
P3 Fuel supply segment field 3B
P6 Coolant temperature segment field 3B
R3 Preglow spark plug 2H
R4 Tank encoder 3H
R5 Field resistor (alternator) 2C
S15 Battery main switch 1H
S1 Ignition start switch 1B
S101 Mode button (clock, travel speed, operating hours) 3B
X2 70-pin connector 1, 2, 3
X10 15-pin MATE-N-LOK connector 3B
V1 Starter extinguishing diode 1H
Y5 Motor stop solenoid 2H
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4 Travel drive: Display unit A13, travel hydraulics solenoid valve, parking brake solenoid valve, control levers S2
and S100
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MJFCIFSS
A2 Control board 4
A13 Display unit 4A
B5 Parking brake pressure switch 4D
B6 Hydraulic oil overheating thermo switch 4H
B16 Backing up alarm 4H
CN1 Green 9-pin connector 4F
CN5 Green 15-pin connector 4C
CN6 Yellow 15-pin connector 4D-E
CN12 White 12-pin connector 4C-D
CN13 Red 12-pin connector 4A-D
D6 1 A diode 4E
D8 1 A diode 4C
D9 1 A diode 4E
D19 1 A diode 4E
D22 1 A diode 4F
D23 1 A diode 4F
D25 1 A diode 4C
D26 1 A diode 4E
D28 1 A diode 4B
D30 1 A diode 4B
F5C 15 A travel hydraulics fuse 4A
K22 Parking brake relay 4E
K22a Travel lockout relay 4C
K23 Forwards relay 4E
K23a Forwards relay 4E
K24 Reverse relay 4E
K24a Reverse relay 4E
K28 Hydraulic oil overheating relay 4B
S2 Travel direction control lever 4A
S12* Additional equipment button (optional) 4A
S17 Parking brake switch 4C
S100 Travel range button, neutral position 4B
X2 70-pin connector 4
X3 11-pin connector 4B
Y2 Forward travel direction solenoid valve 4H
Y3 Reverse travel direction solenoid valve 4H
Y6 Travel range 1 solenoid valve 4H
Y10 Parking brake solenoid valve 4H
Y26 Travel direction detection solenoid valve 4H
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MJFCIFSS
The travel hydraulics are controlled by means of the LH control lever, switch
S100, the display unit and relays.
Driving forwards
If forward travel is selected on the travel switch S2, a positive signal is sent
to the display unit connection X3 pin 3. The electronics in the display unit
send a negative signal from output X4 pin 1 via the safety relay K23a to the
travel direction relay K23 connection 85.
the relay K22a.
The relay K23 picks up and energises the forward travel solenoid valve Y2.
The two safety relays K23a and K24a are controlled by fuse F5B via relay
K8. When there is no power supply to the display unit, the control of both
travel directions is also interrupted.
Driving in reverse
If reverse travel is selected on the control lever S2, a positive signal is sent
the relay K22a.
The relay K24 picks up and energises the reverse travel direction solenoid
valve Y3 on the pump and the travel direction detection solenoid valve Y26
on the travel motor.
Switching between travel ranges 1 and 2
When the diesel engine is started, travel range 2 is always selected.
If travel range 1 is selected on the lever S100, a positive signal is sent to the
display unit connection X3 pin 8.
The electronics in the display unit send a positive signal from output X4 pin
19 via the travel range 1 solenoid valve Y6 on the travel motor.
When the travel range 1 solenoid valve Y6 is energised, the travel motor is
held at the maximum pivot angle.
The output X4 pin 19 of the display unit becomes de-energised again, as
does the travel range 1 solenoid valve Y6.
When the travel range 1 solenoid valve Y6 is not energised, the travel motor
can move from the maximum, to the minimum swivel angle.
If the hydraulic oil overheats, the system automatically switches to travel
range 1.
If the hydraulic oil reaches a temperature above 100 C, the temperature
switch B6 closes.
The temperature switch B6 switches the relay K28 and energises the travel
range 1 solenoid valve Y6.
hydraulics
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MJFCIFSS
The machine continues moving in travel range 1 until the hydraulic oil
temperature falls back below 100 C.
In this condition, the pilot lamps H25 and H26 for both travel ranges light up.
Directional change lockout
The directional change lockout is active at speeds above 13 km/h.
If the driver attempts to change direction at a speed above 13 km/h, the
pump is first switched to neutral.
The speed is reduced when the pump is in the neutral position.
When the speed is below 13 km/h, the travel direction is then changed.
Parking brake switch S17 with switch positions 2, 0, 1
Position 1 (OFF)
After the diesel engine is started, position 1 (OFF) must be briefly selected
in order to release the brake. This safety procedure prevents accidental
release of the brakes. When the ignition is switched on, voltage is present
via the fuse F5C at the switch S17 connection 7 and at the relay K22
connection 30.
If the switch S17 is moved to position 1 the contact in the switch closes
connections 7 and 5, the relay K22 picks up, the contact on K22 closes a
seal-in circuit and the connection to S17 connection 6.
After the button on switch S17 is released, it is in position 0, connections 4
and 6 are connected and the solenoid valve Y10 is energised.
At the same time, the pressure switch B5 closes and the relay K22a
deactivates the travel lockout, which means the travel direction can be
selected. The relay K22 remains energised by the seal-in circuit.
The brake can be released even when the engine is not running, provided
accumulator pressure is available.
Position 0
In position 0 contacts 4 and 6 are connected and the brake is actuated.
To open the brake again (parking brake OFF), the switch S17 must be
switched to position 0 again.
Position 2 (ON)
In position 2 (ON) contacts 4 and 6 are connected and the brake is closed.
If the switch S17 is actuated in position 2 (snap-in position) the connection to
Y10 is broken, the parking brake closes and pressure switch B5 switches the
travel direction to neutral.
How the parking brake switch
S17 works
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5 Working hydraulics: Switches, proximity switches, retaining solenoids
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A2 Control board 5
B15 Bucket return-to-dig inductive switch 5E
B17 Lift kick-out inductive switch 5E
B30 Quick-change device pressure switch 5B
CN7 White 15-pin connector 5
CN9 Red 15-pin connector 5
CN10 Red 15-pin connector 5
CN12 White 12-pin connector 5B
D4 1 A diode 5G
D5 1 A diode 5F
D17 1 A diode 5F
D18 1 A diode 5G
D27 1 A diode 5D
D52 3 A diode 5E
D53 1 A diode 5E
D55 1 A diode 5E
F3A 15 A lighting and switch illuminating fuse 5A
F4B 7.5 A quick-change device fuse 5A
F7C 7.5 A working attachment fuse 5A
H29 Quick-change device symbol field 5C
K7 Supply relay D+ 5D
K17 Lift kick-out relay 5F
K18 Bucket return-to-dig relay 5F
K30 Quick-change device relay 5D
S14 Bucket return-to-dig switch 5C
S18 Float position switch 5D
S19 Working hydraulics lock switch 5C
S22 Lift kick-out switch 5C
S26 Quick-change device switch 5E
X2 70-pin connector 5D-F
X10 15-pin connector 5A-F
X51 9-pin connector 5C-F
Y9 Bucket return-to-dig solenoid 5H
Y14 Working hydraulics lockout solenoid valve 5H
Y17 Lift kick-out solenoid 5H
Y18 Float position solenoid (optional) 5H
Y28 Quick change device solenoid valve (optional) 5H
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How the working hydraulics lockout switch S19 works
Switch button position 1 (safety cut-off):
In position 1 (button function) connections 7 and 5 are connected.
When switch position 1 is selected the contact in the switch connects
connections 7 and 5, and the battery directly supplies voltage to the
solenoid valve Y14 (working hydraulics lockout).
Current flow: batteries G2, fuse F1C, switch S19, connection 5 to
solenoid valve Y14.
As long as the button remains pressed in position 1 and there is pressure
in the pilot control hydro accumulator, the lift arms can be lowered,
whether the ignition is switched on or not.
Switch position 0 (operating position) with the diesel engine running:
(Terminal D+) voltage is present via relay K7 from fuse F7C at the switch
S19 connection 4 and via connection 6 at the solenoid valve Y14, the
valve opens and the pilot control unit is pressurised.
Current flow: fuse F7C relay K7, switch S19 connection 4 switch S19
connection 6, solenoid valve Y14.
Only when the ignition is on can the equipment not be lowered.
Switch position 2 (OFF position, on-road travel):
If switch S19 is actuated in position 2 (snap-in position) the connection to
the solenoid valve Y14 is interrupted. In position 2 contacts 4 and 2 are
connected.
The working hydraulics lockout symbol field lights up. (Control via
connections 4 and 2 in the switch S19).
Connections of the inductive switches B15 and B17
1 Power supply (+)
2 N/C switch (output +signal)
3 Test connection (-)
4 N/O switch (output +signal)
Automatic bucket return-to-dig function
If the bucket return-to-dig switch S14 is switched on, current flows to the
inductive proximity switch B15 (N/O).
The proximity switch B15 is closed when activated.
(N/O normally open switch)
If the pilot control lever is now fully moved to tilting in, the solenoid Y9 makes
contact and the lever is held in position by the solenoid.
The bucket is now tilted in until the proximity switch B15 switches off and the
The force of the spring returns the pilot control lever to the neutral position.
The bucket remains in the horizontal position.
Float position function
If the float position switch S18 is switched on, current flows to the solenoid
Y18 on the pilot control unit.
If the pilot control lever is now fully moved to lowering, the solenoid Y18
makes contact and the lever is held in position by the solenoid.
Electric switching of the
working hydraulics
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MJFCIFSS
When the spool valve is fully activated the bottom piston end of the lifting
cylinder is connected to the rod side and the bucket position can adapt to
uneven ground.
Lift kick-out function (optional)
If the lift kick-out switch S22 is switched on, current flows to the inductive
proximity switch B17.
The proximity switch B17 is closed when not activated. (NC = normally
closed).
If the pilot control lever is now fully moved to lowering, the lever is held in
position by the solenoid Y17.
The lift arms move upwards until the proximity switch B17 switches off. The
The force of the spring returns the pilot control lever to the neutral position
and the lifting movement is switched off.
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6 Lighting: Steering column switch, driving headlights, direction indicator system, horn
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MJFCIFSS
A2 Control board 6
B10 Horn 6A
CN3 Green 12-pin connector 6B-F
CN4 Yellow 12-pin connector 6A-F
CN5 Green 15-pin connector 6D
CN10 Red 15-pin connector 6A
CN11 Purple 12-pin connector 6A
CN12 White 12-pin connector 6E
CN13 Red 12-pin connector 6B
CN14 Purple 15-pin connector 6A-E
D1 6 A diode 6C
D11 6 A diode 6C
D12 6 A diode 6C
D13 6 A diode 6E
D14 6 A diode 6E
D21 6 A diode 6E
D24 1 A diode 6A
E3 Left driving headlight 6G
E4 Right driving headlight 6G
E6 Left tail light 6G
E7 Right tail light 6G
E14 Left/right number plate light 6G
F1A 7.5 A high beam fuse, left 6E
F1C 10 A hazard warning system fuse, interior lights, optional rotating beacon (optional) 6A
F2A 7.5 A right high beam fuse 6E
F2B 7.5 A fuse, driving light, left 6E
F2C 7.5 A fuse driving headlight, right 6E
F5A 3 A sidemarker light fuse, right 6E
F6A 3 A sidemarker light fuse, left 6E
F6C 15 A front washing pump and windscreen wiper, horn 6A
H15 Front left indicator 6G
H16 Front right indicator 6G
H17 Rear left indicator 6G
H18 Rear right indicator 6G
K1 Indicator sensor relay 6C
K25 Right indicator relay 6E
K26 Left indicator relay 6E
S3 Steering column switch 6B
S4 Hazard warning system switch 6D
S6 Parking light / driving light switch 6D
X24 9-pin connector 6A
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7 Wiper system: Front windscreen wipers, rear windscreen wipers, heating and air conditioning system
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A2 Control board 7
B26 Air-conditioning temperature switch (optional) 7C
B27 Air-conditioning pressure switch (optional) 7D
CN1 Green 9-pin connector 7B
CN4 Yellow 12-pin connector 7A
CN11 Purple 12-pin connector 7A-E
CN14 Purple 15-pin connector 7B-F
D3 1 A diode 7F
D20 1 A diode 7F
F3B 7.5 A rear windshield wiper and washing system fuse 7A
F7A 25 A air-conditioning fuse (optional) 7A
F8A 15 A heater blower,air-conditioning fuse (optional) 7A
K5 Relay windscreen wiper wash interval 7C
K14 Air-conditioning coupling relay (optional) 7F
K15 Air-conditioning fan relay (optional) 7F
M2 Front windscreen wiper motor 7G
M4 Front windscreen washer pump 7G
M3 Rear windshield wiper motor 7H
M5 Heater blower motor 7H
M9 Rear windshield washer pump 7H
M12 Air-conditioning fan motor (optional) 7H
S11 Blower motor rotary switch 7C
S13 Rear wiper motor / washer pump switch 7C
S21 Air-conditioning switch (optional) 7C
X2 70-pin connector 7E-G
X10 15-pin connector 7C-E
X40 4-pin connector 7D-G
Y22 Air-conditioning compressor magnetic coupling (optional) 7H
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8 Lighting: Working floodlight, brake light, cab light, radio (optional)
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MJFCIFSS
A2 Control board 8
A3 Radio (optional) 8F
B11 Loudspeaker (optional) 8G
B12 Brake light pressure switch 8C
CN4 Yellow 12-pin connector 8B
CN9 White 9-pin connector 8B
CN11 Purple 12-pin connector 8B
CN14 Purple 15-pin connector 8B
E2 Cab light with switch 8H
E10 Front left working floodlight 8H
E11 Front right working floodlight 8H
E12 Rear left working floodlight (optional) 8H
E13 Rear right working floodlight (optional) 8H
F1B 7.5 A brake light fuse 8A
F3C 20 A Working floodlight fuse 8A
F8B 10 A fuse socket, radio, seat compressor 8A
H20 Left brake light 8H
H21 Right brake light 8H
H22 Flashing beacon (optional) 8H
M7 Driver's seat compressor motor (optional) 8E
S7 Front working floodlights switch 8C
S8 Rear working floodlights (optional) switch 8C
S9 Flashing beacon switch (optional) 8C
W1 Radio aerial (optional) 8F
X20 Socket 8D
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9 Cooling system: Control electronics A1, temperature sensors, proportional solenoid valve, fan drive
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A1 Control electronics 9B
B8 Hydraulic oil temperature sensor 9H
B21 Coolant temperature sensor 9H
B31 Warning buzzer 9H
Y13 Cooling system proportional valve 9H
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10 Emergency steering system: Control electronics A1, emergency steering pressure switch, emergency
steering pump, emergency steering switch
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A1 Control electronics 10B
A2 Control board 10
B3 Emergency steering pressure switch 10H
B3A Emergency steering check pressure switch 10H
CN7 White 15-pin connector 10A
F02 200 A emergency steering pump (MEGA fuse) 10G
F7B 7.5 A control electronics A1, emergency steering button 10A
H24 Emergency steering symbol field 10D
M8 Emergency steering pump motor 10H
S10 Emergency steering button 10D
X51 9-pin connector 10
Wiring harness
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MJFCIFSS
10.2 Wiring harnesses
10.2.1 Side cover switch wiring harness
(ID 9657842)
Valid for: L512 - 466 / 0501 8173; L514 - 467 / 0501 - 8173
Design
Side cover switch wiring harness
D52 Quick-change device diode
D54 6 A working hydraulics diode
H24 Emergency steering check
signal lamp
H29 Quick-change device signal
lamp
S10 Emergency steering pump
button
S13 Rear wiper motor / washer
pump switch
S14 Bucket return-to-dig switch
S18 Float position switch
S19 Working hydraulics switch
S22 Lift kick-out switch
S26 Quick-change device switch
S101 Mode switch (clock, km/h,
operating hours)
X10 15-pin connector
X11 2-pin connector
X51 9-pin connector
X53 9-pin connector for quick-
change device diodes
X58 2-pin connector for working
hydraulics diode
Wiring harness
10. 2- 2 of 14 L512 - 466 / from 8174
L514 - 467 / from 8174
MJFCIFSS
10.2.2 Side cover switch wiring harness
(ID 9845018)
Design
Side cover wiring harness
H24 Emergency steering check
signal lamp
H29 Quick-change device signal
lamp
S10 Emergency steering pump
switch
S13 Rear wiper motor / washer
pump switch
S14 Bucket return-to-dig switch
S18 Float position switch
S19 Working hydraulics switch
S22 Lift kick-out switch
S26 Quick-change device switch
S101 Mode switch (clock, km/h,
operating hours)
X10 15-pin connector
X11 2-pin connector
X51 9-pin connector
X53 9-pin connector, diodes
Quick-change device
Wiring harness
L512 - 466 / 0501 - 8173 10. 2- 3 of 14
L514 - 467 / 0501 - 8173
MJFCIFSS
10.2.3 Cab wiring harness
(ID 9655276)
Valid for: L512 - 466 / 0501 - 8173; L514 - 467 / 0501 - 8173
Design
Cab wiring harness
1 Cab wiring harness
A2 Control board
CN1 9-pin connector
CN2 9-pin connector
CN6 15-pin connector
CN7 15-pin connector
CN8 4-pin connector
D56 Relay K6 extinguishing diode
K4 Preglow system relay
K6 Starter relay
X1 9-pin connector
X2 70-pin connector
X19 8-pin connector
X42 3-pin connector
X50 9-pin connector to dashboard
wiring
Wiring harness
10. 2- 4 of 14 L512 - 466 / 0501 - 8173
L514 - 467 / 0501 - 8173
MJFCIFSS
10.2.4 Dashboard wiring harness
(ID 9841475)
Valid for: L512 - 466 / 0501 - 8173; L514 - 467 / 0501 - 8173
Design
Dashboard wiring harness
1 Cab ground point
A2 Control unit
A13 Display unit
D50 6 Amp diode
D51 1 Amp diode
K5 Washer/wiper relay
K30 Quick-change device relay
R5 Alternator field resistor
S1 Ignition start switch
S2 Steering column switch
S4 Hazard light switch
S6 Driving light switch
S7 Front working floodlights switch
S8 Rear working floodlights switch
S17 Parking brake switch
S25 Optional switch
X3 11-pin display unit connector
front view
X4 21-pin display unit connector
front view
X10 15-pin right switch connector
X11 2-pin right switch connector
X16 6-pin right pilot control unit
magnet connector
X24 9-pin steering column switch
connector
connector
X28 6-pin wiper motor connector
magnet connector
X45 2-pin field resistor connector
X50 9-pin connector to cab wiring
harness
X51 9-pin connector to side cover
switch wiring harness
X60 9-pin connector to relays K23a
/ K24a
Wiring harness
L512 - 466 / 0501 - 8173 10. 2- 5 of 14
L514 - 467 / 0501 - 8173
MJFCIFSS
10.2.5 Heating wiring harness
(ID 9841181)
Valid for: L512 - 466 / 0501 - 8173; L514 - 467 / 0501 - 8173
Design
Heating wiring harness
1 Cab ground point
2 Permanent positive connection
A2 Control board
B26 Air-conditioning temperature
switch
CN12 Purple 12-pin connector
M4 Front windscreen washer
pump
M5 Heater blower motor
M9 Rear windshield washer pump
S11 3 speed blower motor rotary
switch
S21 Air-conditioning switch
X19 8-pin connector
X20 Socket
X21 2-pin compressor seat
connector
X22 12-pin connector to cab roof
2-pin connector M4
X31 2-pin connector M9
X36 4-pin heater blower connector
Wiring harness
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L514 - 467 / from 8174
MJFCIFSS
10.2.6 Cab wiring harness
(ID 9845017)
Note: The cab wiring FITTINGS and HEATING were integrated in the cab
wiring harness.
Design
Cab wiring harness
Wiring harness
L512 - 466 / from 8174 10. 2- 7 of 14
L514 - 467 / from 8174
MJFCIFSS
1 Cab wiring harness
2 Cab ground point
B10 Horn
B26 Air-conditioning temperature
switch
B31 Warning buzzer
CN1 Green 9-pin connector
CN2 Yellow 9-pin connector
CN7 White 15-pin connector
D51 1 Amp diode
F30 Fuse terminal 15 15 A
F31 Fuse Ignition start switch
fuse 15 A
GND Ground connection
K2a Start relay 70 A
K30 Quick-change device relay
K31 Relay ignition start switch
70 A
KL.15 Terminal 15
K4/30 To relay preglow relay
connection 30
K4/R To relay preglow relay
connection R
K5 Relay wiper washer interval
M2 Front windscreen wiper
motor
M4 Front windscreen washer
pump
M5 Heating blower motor
M7 Drivers seat compressor
M9 Rear windshield washer
pump
R4 Tank encoder
S1 Ignition start switch
S2 LIEBHERR control lever
button
S4 Hazard warning system
switch
S6 Parking light, driving light
switch
S7 Front working floodlights
switch
S8 Rear working floodlights
switch
S11 3 speed blower motor rotary
switch
S21 Air-conditioning switch
S100 Fast / slow switch
ST1 Control electronics plug A1
red 15-pin connector
white 12-pin connector
white 15-pin connector
V30 Permanent positive
connection
X1 Connector to 9-pin main WH
connector
X2 Connector to 70-pin main
WH connector
X3 11-pin
monitor connector
X4 21-pin
monitor connector
X4/18 Spare input
X10 Plug to wiring harness 15-pin
switch bar
switch bar
magnet connector
X20 Socket
X22 Connector to 15-pin cab WH
connector
connector
connector
switch bar
X60 Plug diode D51 2-pin
X68 Plug to WH engine preglow
1-pin
Plug pin assignment
9-pin Deutsch-DRC / socket (to central wiring harness)
R Terminal 30 of F01 125A
S Ground connection
T Starter terminal 50
U Free (blind plugs)
V Starter terminal 50
W Blind plugs
X Magnet engine stop, coolant
temperature thermo switch
Y Blind plugs
Z Blind plugs
70-pin Deutsch-DRC / socket (to central wiring harness)
1 Terminal 61(D+)
2 Terminal W (Diesel motor
speed signal)
3 Power supply solenoid valve
quick change device (Y28)
4 Transmission input speed
sensor (B1)
5 Preglow power relay (K29)
6 Vacuum switch for air filter
contamination (B4)
36 Bucket return-to-dig relay (K18)
37 Inductive switch lift kick-out
(B17)
38 Earth connection solenoid valve
quick change device (Y28)
39 Free (blind plugs)
40 Working hydraulics lockout
solenoid valve (Y14)
41 Right driving headlight (E4)
42 Left tail light (E6), left/right
X1 plug
X2 plug
Wiring harness
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MJFCIFSS
7 Free middle ballast
8 Sender unit coolant temperature
(B20)
(B20)
10 Pressure switch for engine oil
pressure (B7)
11 temperature sensor hydraulic
oil overheat (B6)
17 Pressure switch for engine oil
pressure (B12)
24 Back-up alarm (B16)
solenoid valve (Y3)
26 Travel direction detection
solenoid valve (Y26)
solenoid valve (Y2)
28 Power supply parking brake
pressure switch (B5)
29 Switching signal (B5) to travel
lockout relay (K22a)
(Y6)
(Y10)
33 Relay lift kick-out (K17)
34 Quick change device pressure
switch (B30)
35 Inductive switch for bucket
return-to-dig (B15)
number plate light (E14)
45 Right tail light (E7)
46 Air-conditioning fan motor (M12)
47 Air-conditioning fan motor (M12)
48 Air-conditioning coupling relay
(K14) and fan (K15)
49 Air-conditioning pressure switch
(B27)
50 Air-conditioning compressor
magnetic coupling (Y22)
51 Front left indicator (H15)
52 Rear left indicator (H17)
53 Rear right indicator (H18)
54 Front right indicator (H16)
55 Terminal 15 (reserve)
motor (M8)
supply (B21)
59 Analog input coolant
temperature sensor (B21)
60 Hydraulic oil temperature
sensor supply (B8)
61 Analog input hydraulic oil
temperature sensor (B8)
62 Proportional valve cooling
system (Y13)
switch (B3)
pressure switch input (B3a)
pressure switch supply (B3a)
MARK II / 11-pin. socket (to display unit)
(see 16.1.1 display unit)
MARK II / 21-pin. socket (to display unit)
(see 16.1.1 display unit)
X3 plug
X4 plug
Wiring harness
L512 - 466 / 0501 - 8173 10. 2- 9 of 14
L514 - 467 / 0501 - 8173
MJFCIFSS
10.2.7 Cab roof wiring harness
(ID 9619889)
Valid for: L512 - 466 / 0501 - 8173; L514 - 467 / 0501 - 8173
Design
Cab roof wiring harness
1 Cab roof ground point
2 Auxiliary loudspeaker
connection (optional)
A3 Radio
B11 Loudspeaker (optional)
E2 Cab light with switch
E10 Front left working floodlight
E11 Front right working floodlight
E12 Rear left working floodlight
(optional)
E13 Rear right working floodlight
(optional)
H22 Flashing beacon (optional)
M3 Rear wiper motor
X22 12-pin connector to heating
wiring harness
X32 4-pin rear wiper connector
X37 6-pin radio connector
X65 2-pin direction indicator
X66 2-pin direction indicator
Wiring harness
10. 2- 10 of 14 L512 - 466 / from 8174
L514 - 467 / from 8174
MJFCIFSS
10.2.8 Cab roof wiring harness
(ID 9845013)
Design
Cab roof wiring harness
1 Cab roof ground point
A3 Radio
B11 Loudspeaker (optional)
E2 Cab light with switch
E10 Front left working floodlight
E11 Front right working floodlight
E12 Rear left working floodlight
(optional)
E13 Rear right working floodlight
(optional)
H22 Flashing beacon (optional)
M3 Rear wiper motor
X22 12-pin connector to wiring
harness
X32 4-pin rear wiper connector
X37 6-pin radio connector
X65 2-pin connection (optional)
X66 2-pin connection (optional)
Wiring harness
L512 - 466 / 0501 - 8173 10. 2- 11 of 14
L514 - 467 / 0501 - 8173
MJFCIFSS
10.2.9 Central wiring harness
(ID 9655212)
Valid for: L512 - 466 / 0501 - 8173; L514 - 467 / 0501 - 8173
Design
Central wiring harness front section
AA Connection to central wiring
harness rear section
B10 Horn
B12 Brake light pressure switch
B15 Bucket return-to-dig inductive
switch
B17 Lift kick-out inductive switch
E3 Left driving headlight
E4 Right driving headlight
H15 Left indicator
H16 Right indicator
R4 Fuel supply gauge
Wiring harness
10. 2- 12 of 14 L512 - 466 / 0501 - 8173
L514 - 467 / 0501 - 8173
MJFCIFSS
Central wiring harness rear section
harness front section
1 Rear section ground point
2 Cab floor ground point
3 Applies as of ser. no. 0705
4 Applies from ser. no. 0501 to
0704
B1 Travel gear speed sensor
B3 Emergency steering pressure
switch
B3a Emergency steering check
pressure switch
B4 Air filter contamination vacuum
switch
B5 Parking brake pressure switch
B6 Hydraulic oil overheating
temperature switch
B7 Pressure switch for engine oil
pressure
B8 Hydraulic oil temperature
sensor
B16 Backing up alarm
B20 Coolant temperature switch
and sensor
B20a 50 C cold start temperature
switch
B21 Coolant temperature sensor
E6 Left rear light
E7 Right rear light
F01 125 A main fuse
F02 150 A emergency steering fuse
G1 Alternator
G2 Batteries
H17 Rear left indicator
H18 Rear right indicator
H20 Rear left brake light
H21 Rear right brake light
K29 Preglow power relay
M1 Starter
M8 Emergency steering pump
motor
Y2 Forwards solenoid valve
Y3 Reverse solenoid valve
Y4 Injection adjuster solenoid
valve
Y5 Motor stop solenoid valve
Y6 Travel range 1 solenoid valve
Y10 Parking brake solenoid valve
Y13 Fan motor proportional
solenoid valve
Y14 Pilot control solenoid valve
Y26 Travel direction detection
solenoid valve
Y27 Cold start solenoid valve
X1 9-pin connector
X2 70-pin connector
X27 2-pin number plate lamp
connector
X38 2-pin air-conditioning
compressor connector
X40 4-pin air-conditioning pressure
switch connector
Wiring harnesses
L512 - 466 / from 8174 10. 2- 13 of 14
L514 - 467 / from 8174
MJFCIFSS
10.2.10 Central wiring harness
(ID 9845019)
Design
Central wiring harness front section
1 AA Connection to central wiring
harness rear section
2 Pressure switch brake lights
B12
3 Inductive switch for bucket
return-to-dig B15
4 Inductive lift kick out switch B17
5 Left-hand driving headlight E3
6 Right-hand driving headlight E4
7 Left flashing light H15
8 Right flashing light H16
Wiring harnesses
10. 2- 14 of 14 L512 - 466 / from 8174
L514 - 467 / from 8174
MJFCIFSS
Central wiring harness rear section
1 Rear section ground point
2 Cab floor ground point
harness front section
B1 Travel gear speed sensor
B3 Emergency steering pressure
switch
B3a Emergency steering check
pressure switch
B4 Air filter contamination vacuum
switch
B5 Parking brake pressure switch
B6 Hydraulic oil overheating
temperature switch
B7 Pressure switch for engine oil
pressure
B8 Hydraulic oil temperature
sensor
B16 Backing up alarm
B20 Coolant temperature switch
and sensor
B20a 50 C cold start temperature
switch
B21 Coolant temperature sensor
E6 Left rear light
E7 Right rear light
E14 2-pin number plate lamp
connector
F01 125 A main fuse
F02 200 A emergency steering fuse
G1 Alternator
G2 Batteries
H17 Rear left indicator
H18 Rear right indicator
H20 Rear left brake light
H21 Rear right brake light
K29 Preglow power relay
M1 Starter
M8 Emergency steering pump
motor
Y2 Forwards solenoid valve
Y3 Reverse solenoid valve
Y4 Injection adjuster solenoid
valve
Y5 Motor stop solenoid valve
Y6 Travel range 1 solenoid valve
Y10 Parking brake solenoid valve
Y13 Fan motor proportional
solenoid valve
Y14 Pilot control solenoid valve
Y26 Travel direction detection
solenoid valve
Y27 Cold start solenoid valve
X1 9-pin connector
X2 70-pin connector
X40 4-pin air-conditioning pressure
switch connector
Y22 2-pin air-conditioning
compressor connector
Control electronics A1
L512 - 466 / from 0501 10. 3- 1 of 4
L514 - 467 / from 0501
MJFCIFSS
10.3 Control electronics A1
(ID 989210701)
The control electronics A1 are fitted in the front of the right control panel.
The control electronics A1 have the following main functions:
Fan control
Emergency steering pump control
Design
H1 Green mains supply unit LED
H2 Green mains control electronics
LED
H6 Red LED error output N20
H13 Red LED - coolant overheating
(B21)
H14 Green LED excess temperature
hydraulic oil (B8)
N20 Proportional valve fan
N24 Additional function 1
N25 Additional function 2
N26 Lift kick-out switch
N27 Emergency steering pump
Pot3 Maximum fan current
Pot4 Minimum fan current
Pot10 Zero reference sensor B8
Pot11 Amplification sensor B8
Pot12 Zero reference sensor B21
Pot13 Amplification sensor B21
ST1 15-pin male connector
ST2 Sockets connector 12-pin
ST3 Sockets connector 15-pin
S1.1 Coding switch with no function
S1.2 Coding switch with no function
10. 3- 2 of 4 L512 - 466 / from 0501
L514 - 467 / from 0501
MJFCIFSS
Plug pin assignment
Mate-N-Lok / 15-pin. male (to control electronics A1)
1 Supply 12 V (+)
2 Supply ground (-)
3 Battery charge indicator
terminal 61 (+)
4 Unassigned
5 Unassigned
6 Unassigned
7 Unassigned
8 Warning reserve 1 (-)
12 Unassigned
13 Unassigned
14 Additional function button 1 (+)
unassigned
15 Additional function button 2 (+)
unassigned
Mate-N-Lok / 12-pin. socket (to control electronics A1)
1 Input for emergency steering
button (+)
2 Input for emergency steering
pressure switch B3 (-)
3 Output for fan proportional valve
Y13
4 Input for pressure switch B3a,
check emergency steering (+)
5 Output for emergency steering
check indicator light (H24)
6 No function
output (+)
8 Output to warning buzzer B31
(+)
9 Unassigned
10 Additional function 1 switch
output (+) unassigned
11 Switch output N26 (+)
unassigned
12 Additional function 2 switch
output (+) unassigned
Mate-N-Lok / 15-pin. socket (to control electronics A1)
1 Unassigned
2 Unassigned
3 Unassigned
4 Unassigned
5 Unassigned
6 Unassigned
B21 supply
8 Unassigned
B21 analogue input
sensor B8 supply
11 Unassigned
sensor B8 analogue input
13 Unassigned
14 Screen
15 Diesel engine-engine speed
from terminal W generator
Fan control
The control electronics A1 regulate the fan speed.
The following components affect the fan speed:
11 Power supply A1 from fuse F7b
12 Hydraulic oil temperature sensor B8
13 Coolant temperature sensor B21
14 Proportional magnet Y13
The two temperature sensors for the hydraulic oil B8 and coolant B21
regulate the current to the proportaional magnet Y13 via the control
electronics A1.
When it is not energised, the proportional valve Y13 is closed and the fan
turns at the maximum engine speed.
ST1 plug
ST2 plug
ST3 plug
L512 - 466 / from 0501 10. 3- 3 of 4
L514 - 467 / from 0501
MJFCIFSS
When the proportional magnet is fully energised (1.2 A) the fan turns at
minimum speed.
The higher the temperature or the resistance of the sensors, the lower the
current at the proportional valve.
If one of the two sensors detects overheating, the warning buzzer B31
sounds.
Overheating coolant is indicated by the red LEDs H13 on the control
electronics.
Overheating hydraulic oil is indicated by the green LEDs H14 on the control
electronics.
Overheating or a fault on one of the two sensors B8 and B21 is
indicated only by the two LED's H13, H14 and the warning buzzer B31.
None of the indicator lamps on the display unit light up.
Emergency steering pump control
The control electronics A1 switch on the emergency steering pump if the
steering pump or the diesel engine fails.
The following components affect the emergency steering pump:
Power supply A1 from fuse F7b
Emergency steering pressure switch B3
Pressure switch B3a, check emergency steering
F02 fuse, 200 A
S10 manual actuation button
M8 emergency steering pump electric motor
Every time the machine is started, the system checks whether the
emergency steering pump is working.
The emergency steering check is automatically initiated if the diesel engine
is constantly running above 650 min
-1
.
The following tests are performed:
The indicator light H24 lights up.
The emergency steering pump M8 starts and pressure is built up in the
steering circuit.
If the pressure reaches 5 bar at the pressure switch B3a, the emergency
steering pump is switched off again.
If the indicator lamp H24 goes out, the emergency steering check has
been successfully completed.
If the diesel engine or the pump for the working hydraulics and steering
system fails during operation, the pressure in the steering system (LS 2) falls
below 5 bar and the negative signal from the pressure switch B3 to the
control electronics A1 is interrupted. The emergency steering pump must
turn itself on.
The control electronics A1 automatically switch on the emergency steering
pump for 50 seconds. At the same time, the indicator lamp H8 in the display
unit A13 lights up.
After the 50 seconds have passed, the emergency steering pump can be
switched on again using the button S10.
When overheating the emergency steering pump is switched off by the
integrated thermo switch.
Emergency steering check
Emergency steering pump
10. 3- 4 of 4 L512 - 466 / from 0501
L514 - 467 / from 0501
MJFCIFSS
LED display
The LEDs on the control electronics A1 display the following statuses:
LED H1 lights up for normal supply (fuse F7B)
LED H2 lights up if the voltage stabiliser is OK
LED H6 lights up for short circuits or interruption at the control output N20
(fan magnet Y13)
LED H9 lights up for short circuits or interruption at the control output N24
(attachment 1 has no function)
LED H10 lights up for short circuits or interruption at the control output
N25 (attachment 2 has no function)
N26 (lift kick-out) The LED lights up when the engine is running
because there is no consumer unit connected.
N27 emergency steering pump
LED H13 lights up for overheating or interruption at the coolant
temperature sensor B21
LED H14 lights up for overheating or interruption at the hydraulic oil
temperature sensor B8
Control board A2
L512 - 466 / from 0501 10. 4- 1 of 2
L514 - 467 / from 0501
MJFCIFSS
10.4 Control board A2
(ID 9657843)
The control board A2 is fitted in the back of the right control panel.
Design
The control board A2 contains relays, fuses, diodes, the electronic indicator
sensors and connectors.
Control board A2
Control board A2
10. 4- 2 of 2 L512 - 466 / from 0501
L514 - 467 / from 0501
MJFCIFSS
F1a 7.5 A high beam fuse, left
F2a 7.5 A high beam fuse, right
F3a 15 A lighting and switch
lighting fuse
F4a 7.5A cold start valve fuse
Y27, supply via D+
F5a 3 A sidemarker light fuse,
right
F6a 3 A left sidemarker lamp fuse
F7a 25 A air-conditioning fuse
(optional)
F8a 15 A heater blower fuse
F1b 7.5 A brake light fuse
F2b 7.5 A driving light fuse, left
F3b 7.5 A rear windshield wiper
fuse
F4b 7.5 A quick-change device
fuse
F5b 5 A monitor fuse (ignition
+15)
F6b 3 A start/monitor preglow
relay buzzer fuse
F7b 7.5 A additional electronics
A1, fan, emergency steering
fuse
F8b 10 A socket fuse (optional
radio and compressor seat)
F1c 10 A hazard warning system,
interior lighting, flashing
beacon fuse
F2c 7.5 A right full beam fuse
F3c 25 A working floodlight fuse
F4c 3 A monitor fuse (battery
+30)
F5c 15 A drive hydraulics fuse
(backing up alarm)
F6c 15 A front window wiper/
washing system and horn
fuse
F7c 7.5 A working attachment
fuse
F8c 10 A motor stop fuse
D1 6 A diode
D2 1 A diode
D3 1 A diode
D4 1 A diode
D5 1 A diode
D6 1 A diode
D7 1 A diode
D8 1 A diode
D9 1 A diode
D10 1 A diode
D11 3 A diode
D12 3 A diode
D13 3 A diode
D14 3 A diode
D15 1 A diode
D15 1 A diode
D16 1 A diode
D17 1 A diode
D18 1 A diode
D19 1 A diode
D20 1 A diode
D21 1 A diode
D22 1 A diode
D23 1 A diode
D23 1 A diode
D24 1 A diode
D25 1 A diode
D26 1 A diode
D27 1 A diode
D28 1 A diode
K1 Direction indicator relay
K2a Engine start relay (from ser.
no. 564 the relay is external)
K2 Engine start relay
K3 Motor stop relay
K7 Supply relay D+
K8 Ignition on supply relay (+15)
K14 Air-conditioning relay
K17 Lift kick-out relay
K18 Bucket return-to-dig relay
K22 Parking brake relay
K22a Parking brake pressure
switch relay
K23 Forwards relay
K25 Right indicator relay
K26 Left indicator relay
K27 Start release relay
K28 Hydr. oil overheating relay
15 V V15 ignition on connection
30 V Connection V30 battery +30
GND Ground connection
BZ Buzzer B9
Battery installation
L512 - 466 / from 0501 10. 5- 1 of 2
L514 - 467 / from 0501
MJFCIFSS
10.5 Battery installation
The power supply voltage of the electrical system is 12 Volts.
Design
Battery installation
1 Batteries
2 Main fuse
3 Battery main switch
The batteries 1 are mounted in the left cab access.
The two batteries are connected in parallel.
The battery main switch 3 is located in the back of the engine compartment.
10.5.1 Battery
(ID 6905231)
Technical data
Description Value Unit
Battery voltage 12 V
Battery capacity 88 Ah
Cold test current (at -18 C EN) 680 A
Number of batteries Two
L512-466/from 0501
L514-467/from 0501
0-)&,)66
11 Transfer gear
Chapter contents
11 Transfer gear 11.0 - 1
11.1 Transfer gear (D 7621960) 11.1 - 1
11.1.1 Speed sensor (D 6905583) 11.1 - 2
11.0 - 1 of 2
Transfer gear Service manual
L512-466/from 0501
L514-467/from 0501
0-)&,)66
11.1 Transfer gear
(ID 7621960)
The transfer gear is fitted in the rear axle and shares its oil supply with the
differential.
Layout
Sectional view of the transfer gear
1 Plug
2 Oil guide plate
3 Pulley
4 Speed sensor
5 Shaft seal ring
6 Upright pin
7 Washer
8 Hex nut
9 nput shaft
10 Shim
11 Tapered roller bearing
12 Spacer
13 Dust guard plate
14 Hydraulic motor
15 Housing
16 Spur gear
17 Snap ring
18 Deep groove ball bearing
19 Snap ring
20 Dust cover
21 Spur gear
22 Housing
Transfer gear
11.1 - 1 of 4
L512-466/from 0501
L514-467/from 0501
0-)&,)66
The transfer gear is a single-level, helical-toothed spur gear transmission.
t is not a shifting gear.
The hydraulic motor 14 is flange mounted directly on the distributor gear
and is connected to the input shaft via the spline shaft profile. This is
mounted on the opposite side with a deep groove ball bearing 18.
A helical toothed spur gear 16 is pressed on to and engages with the
output spur gear 21.
The distributor gear output is both the rear axle input 9 and the connecting
flange for the drive shaft to the front axle.
A speed sensor 4 is mounted on the output.
Basic function
The spur gear 16 on the input shaft is driven by the hydraulic motor 14.
This drives the helical toothed output spur gear 21 of the axle input shaft
9, which engages with the crown wheel of the differential.
The basic functions of the transfer gear are:
Adjusting the speed and the drive torque of the hydraulic motor to the
axle input shaft.
Distributing output to the front and rear axles.
TechnicaI data
Name VaIue Units
Type 1AVG185
Ratio 1.82
11.1.1 Speed sensor
(ID 6905583)
Layout
Speed sensor
The speed sensor 2 is screwed on to the output of the distributor gear and
fastened with a counter nut 3.
A high-resistance coil is surrounded by a permanent magnet and cast in a
housing. This is an inductive sensor.
To adjust A the sensor, check the screw opening and see whether a
segment of the pulley 1 is visible. Then screw in the speed sensor 2 by
hand until it touches the the pulley 1. Then unscrew the speed sensor by
a third to a half turn and fasten it with the counter nut 3 (see the technical
data).
Transfer gear
11.1 - 2 of 4
L512-466/from 0501
L514-467/from 0501
0-)&,)66
Basic function
A pulley intersects the magnetic field of the permanent magnet and
induces an alternating voltage in the coil.
The alternating voltage is converted into impulses in a logical element of
the electronics (display unit).
The number of impulses (frequency) is proportional to the speed of the
pulley and is used to evaluate the speed of the machine.
n addition to this, the output speed is used for monitoring and control-
ling the reversing process during operation:
When the speed is below 13 km/h, the reversing process is initiated
imediately
When the speed is above 13 km/h, the travel pump is first de-
energised. The travel pump turns towards the neutral position.
When the machine reaches a speed below 13 km/h, the new
direction of the travel pump is activated.
TechnicaI data
Name VaIue Units
Manufacturer VDO
Type nductive encoder
Output voltage (U eff.) 0.8 V
Distance to gearwheel ,A min.0.5 mm
max.0.75 mm
nternal resistance 1050
100
Ohm
Tapped bore M 18x1.5 mm
Counter nut tightening torque 50 Nm
Transfer gear
11.1 - 3 of 4
L512-466/from 0501
L514-467/from 0501
0-)&,)66
12 AxIes, tyres
Chapter contents
12 Axles, tyres 12.0 - 1
12.1 Front axle (D 5716736, 5716735) 12.1 - 1
12.1.1 Differential 12.1 - 3
12.1.2 Wheel hub 12.1 - 5
12.1.3 Wheel hub 12.1 - 6
12.2 Rear axle (D 5716862, 5716858) 12.2 - 1
12.2.1 Differential 12.2 - 3
12.2.2 Steering axle wheel hub 12.2 - 5
12.3 Cardan shafts (D 7621814) 12.3 - 1
12.3.1 Front cardan shaft 12.3 - 1
12.0 - 1 of 2
Axles, tyres Service manual
L512-466/from 0501
L514-467/from 0501
0-)&,)66
12.1 Front axIe
(ID 5716736, 5716735)
Layout
Valid for: L 512-/0501-, ID 5716736
1 Self-locking differential
2 Drive shaft flange
3 Axle casing
4 Wheel hub
The axle consists of the differential with tapered gear and the self-locking
differential 1 and the planetary final drive in the wheel hub 4. Wheel hubs
are mounted on the axle casing 3 on tapered roller bearings.
Valid for: L 514-/0501-, ID 5716735
1 Axle casing
2 Self-locking differential
3 Drive shaft flange
4 Wheel hub
The axle consists of the differential with tapered gear and the self-locking
differential 2 and the planetary final drive in the wheel hub 4. Wheel hubs
are mounted on the axle casing 1 on tapered roller bearings.
Front axle
12.1 - 1 of 6
L512-466/from 0501
L514-467/from 0501
0-)&,)66
Basic function
The basic functions of the axle are:
ncreasing and transmitting the drive torque
Transmitting the machine vertical force to the wheels
The gear output torque is transmitted via the drive shaft to the axle input
shaft. The torque is increased to the wheel torque by the ratio of the
tapered gear in the differential housing and that of the planetary drives in
the wheel hubs. The input turning speed is reduced to the wheel speed
accordingly.
The vertical operating load of the machine is transmitted from the rear
section via the screwed connection to the axle casing. The axle casing
transmits this load to the wheel hubs so that the machine is supported by
the wheels.
AxIe Iubrication
The axle has a common oil system. The oil chambers on the differential
and the wheel hubs are linked. Oil filler and drain plugs are respectively
attached to the wheel hubs and the differential housing.
Service brake and parking brake
The service brake and parking brake are on the axle input. See the
detailed description in the "Brake system chapter.
WheeI attachment
The wheels are fixed to the wheel flange of the wheel hubs by wheel nuts.
The wheels are centered by the spherical collar nuts.
TechnicaI data
Valid for: L 512-466/0501-, ID 5716736
Name VaIue Units
Type AP-R 735/P4
Locking value of the self-locking
differential
45 %
Wheel base 1700 mm
Differential ratio 2.67
Wheel hub ratio 6.00
Total gear ratio 16.02
Mass 232.0 kg
TechnicaI data
Valid for: L 514-467/0501-, ID 5716735
Name VaIue Units
Type AP-R 745
differential
45 %
Front axle
12.1 - 2 of 6
L512-466/from 0501
L514-467/from 0501
0-)&,)66
Name VaIue Units
Grooved nut tightening torque (hub) 1400
+200
Nm
Wheel base 1870 mm
Total gear ratio 16.62
Mass 322 kg
12.1.1 DifferentiaI
Layout
Sectional view of the differential
1 Axle casing
2 Half shaft
4 O-ring
5 Axle tapered gear
6 Differential housing
7 Crown wheel
8 Adapter sleeve
Front axle
12.1 - 3 of 6
L512-466/from 0501
L514-467/from 0501
0-)&,)66
10 Compensation axle
11 Compensation tapered gear
12 Thrust washer
13 nner disc
14 Outer disc
15 Shim
17 Cheese-head screw
18 Retaining ring
19 Axle input shaft
21 Spacer
23 Shaft seal ring
24 Deflector
25 Drive flange
26 Washer
27 Retaining plates
28 Hex nut
Speed baIance of the right and Ieft wheeIs
When turning a corner, the left and right wheels cover different distances.
The speeds of the two wheels are therefore also different. The correct
speed for each wheel is induced by the rolling condition.
The axle input shaft 19 defines the mean speed of the two power take-off
shafts 2 via the crown wheel 7. The crown wheel 7 drives the differential
housing 9 and hence four facing compensation tapered gears 11 of the
differential. These rest on the tooth faces of the adjacent axle tapered
gears 5 and thus drive the power take-off shafts 2. The compensation
tapered gears 11 have a balancing function and turn about their own axes
to compensate for various wheel torques. The speed reduction of one
wheel is compensated by the increased of the other wheel.
DifferentiaI speed Iocking function
On the left and right of the compensation tapered gears 11 there are
locking discs 13 and 14, which counteract the relative movement between
the axle tapered gears 5 and the differential housing 9 with a braking
torque in proportion to the drive torque. The braking torque has a locking
action on the side with the poor traction, thus generating the necessary
support for the side with the good traction.
The locking discs consist of outer discs 14 which are mounted in the
differential housing and of non-twisting inner discs 13 linked to the axle
tapered gears 5. The drive torque on the tooth faces of the compensation
gears 11 and axis tapered gears 5 in the differential housing 9 creates
tooth separating forces. These act as reactive forces on the axle tapered
gears 5, which in turn support the locking discs, thus creating a braking
torque.
The drive torque is now transferred via the crown wheel 7, the differential
housing 9 and the outer discs 14 with a certain torque (locking torque) to
the inner discs 9. The inner discs 13 transfer this torque to the axle
tapered gears 5, which are in turn connected via the teeth to the power
take-off shafts 2. The drive torque is now transferred with the Iocking
vaIue to the wheel with good traction.
The locking torque depends upon the load and is always proportional to
the input torque. The Iocking vaIue is the relationship between the torque
difference and the total torque of both wheels.
Front axle
12.1 - 4 of 6
L512-466/from 0501
L514-467/from 0501
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12.1.2 WheeI hub
Valid for: L512-466/0501-
Sectional view of the wheel hub
1 Planetary carrier
2 Ring gear
3 Plug
4 O-ring
5 Lamination support
6 Hex screw
7 Thrust washer
8 Snap ring
9 Sun gear
10 Thrust washer
11 Cylinder roller bearing
12 Planetary pinion
13 Wheel stud
14 O-ring
15 Hub
16 Shaft seal ring
17 Bell
18 Half shaft
19 Axle casing
22 Dowel
Front axle
12.1 - 5 of 6
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12.1.3 WheeI hub
Valid for: L514-467/0501-
1 Axle casing
2 O-ring
3 Hub carrier
5 Ring gear
6 Plug
7 Planetary carrier
8 Bell
9 Bearing bushing
10 Sun gear
11 Thrust washer
13 Planetary pinion
14 Snap ring
15 Grooved nut
16 Spacer
17 Shaft seal ring
18 Dust guard plate
Front axle
12.1 - 6 of 6
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12.2 Rear axIe
(ID 5716862, 5716858)
Layout
Valid for: L 512-466/0501-, ID 5716862
1 Speed sensor
2 Transfer gear
3 Oscillating axle mount
4 Differential
5 Axle casing
6 Axle kingpin bearing
7 Wheel hub
Valid for: L 514-467/0501-, ID 5716858
1 Axle casing
2 Transfer gear
3 Differential
6 Wheel hub
Rear axle
12.2 - 1 of 6
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Basic function
The basic functions of the axle are:
ncreasing and transmitting the drive torque
Transmitting the machine vertical force to the wheels
The transfer gear output torque is transmitted to the axle input shaft. The
torque is increased to the wheel torque by the ratio of the tapered gear in
the differential housing and that of the planetary drives in the wheel hubs.
The input speed is reduced to the wheel speed accordingly.
The vertical operating load of the machine is transmitted from the rear
section via the oscillating axle mount to the axle casing. The axle casing
transmits this load to the wheel hubs so that the machine is supported by
the wheels.
AxIe Iubrication
The oil chambers on the differential and in the transfer gear are linked.
Each wheel hub has its own oil system. Oil filling and drain screws are
fitted on the differential, the transfer gear and the wheel hubs.
TechnicaI data
Valid for: L 512-466/0501-, ID 5716862
Name VaIue Units
Type APL-R 735 /
1AVG185
differential
25 %
Grooved nut tightening torque (hub) 1400
+200
Nm
Angle of swing 6
Axle steering angle 30
Wheel base 1700 mm
Total gear ratio (with AVG) 32.9
Mass 380 kg
TechnicaI data
Valid for: L 514-467/0501-, ID 5716858
Name VaIue Units
Type APL-R 745 /
1AVG185
differential
25 %
Grooved nut tightening torque 1400
+200
Nm
Angle of swing 6
Rear axle
12.2 - 2 of 6
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Name VaIue Units
Axle steering angle 30
Wheel base 1870 mm
Total gear ratio (with AVG) 30.33
Mass 474 kg
12.2.1 DifferentiaI
Layout
Sectional view of the differential
1 Axle casing
2 Half shaft
3 Axle drive housing
5 Axle input shaft
6 Spacer
8 Compensating disc
9 nner disc
10 Outer disc
11 Axle tapered gear
12 Half shaft
14 Dowel
15 Adapter sleeve
16 Crown wheel
17 Compensation tapered gear
18 Plug
19 Axle tapered gear
22 Adjustment nut
23 Locking pin
Rear axle
12.2 - 3 of 6
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Speed baIance of the right and Ieft wheeIs
When turning a corner, the left and right wheels cover different distances.
The speeds of the two wheels are therefore also different. The correct
speed for each wheel is induced by the rolling condition.
The axle input shaft 5 defines the mean speed of the two power take-off
shafts 12 via the crown wheel 16. The crown wheel 16 drives the differen-
tial housing 20 and hence four facing compensation tapered gears 17 of
the differential. These rest on the tooth faces of the adjacent axle tapered
gears 19 and thus drive the power take-off shafts 12. The compensation
tapered gears 17 have a balancing function and turn about their own axes
to compensate for various wheel torques. The speed reduction of one
wheel is compensated by the increased of the other wheel.
DifferentiaI speed Iocking function
On the left and right of the compensation tapered gears 17 there are
locking discs 9 and 10, which counteract the relative movement between
the axle tapered gear 19 and the differential housing 20 with a braking
torque in proportion to the drive torque. The braking torque has a locking
action on the side with the poor traction, thus generating the necessary
support for the side with the good traction.
The locking discs consist of outer discs 10 which are mounted in the
differential housing and of non-twisting inner discs 9 linked to the axle
tapered gears 19. The drive torque on the tooth faces of the compensation
gears 17 and axis tapered gear 19 in the differential housing 20 creates
tooth separating forces. These act as reactive forces on the axle tapered
gears 19, which in turn support the locking discs 9 and 10, thus creating
a braking torque.
The drive torque is now transferred via the crown wheel 16, the differential
housing 20 and the outer discs 10 with a certain torque (locking torque) to
the inner discs 9. The inner discs 9 transfer this torque to the axle tapered
gears 19, which are in turn connected via the teeth to the power take-off
shafts 12. The drive torque is now transferred with the Iocking vaIue to
the wheel with good traction.
The locking torque depends upon the load and is always proportional to
the input torque. The Iocking vaIue is the relationship between the torque
difference and the total torque of both wheels.
Rear axle
12.2 - 4 of 6
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12.2.2 Steering axIe wheeI hub
Layout
1 Half shaft
2 Snap ring
3 Bearing bushing
4 Shaft seal ring
5 Bushing
6 Cover
8 Universal joint
9 Axle kingpin
10 Shim
11 Hub carrier
12 Shaft seal ring
14 Spacer
16 Snap ring
17 Thrust washer
18 Fixing ring
19 Snap ring
20 Sun gear
21 Thrust washer
22 Planetary pinion
24 Snap ring
25 Grooved nut
26 Hub
27 O-ring
28 Wheel stud
29 Sealing ring
30 O-ring
31 Roll pin
32 Axle kingpin
34 Track rod arm
35 Axle casing
WheeI attachment The wheels are fixed to the wheel flange of the wheel hubs by wheel nuts.
The wheels are centered by the spherical collar nuts.
Rear axle
12.2 - 5 of 6
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12.3 Cardan shafts
(ID 7621814)
12.3.1 Front cardan shaft
Layout
Front cardan shaft
1 Flange
2 Universal joint
3 Bearing
4 Flange
5 Hex nut
6 Universal joint
7 Yoke shaft
8 Universal joint
9 Flange
The cardan shaft consists of two sections. These are linked by the
intermediate flange.
Each section is equipped with a universal joint on the transfer gear output
and on the front axle input.
A centered universal joint and a telescopic yoke shaft to compensate the
length are mounted on the rear section.
An intermediate bearing supports the front section of the cardan shaft.
Function
The cardan shaft transmits the torque from the transfer gear to the front
axle. The cardan shaft is able to make an angle compensation between
the input and output due to the universal joints at both ends. The angle
compensation is necessary due to the articulated steering. The cardan
shaft and connector tube can be displaced axially to mesh together. This
makes length compensation possible. Length compensation is necessary
due to tolerances in assembly and slight displacements during operation.
Uniformity of torque transmission
With cardan shafts with single universal joints, the rotation of the connec-
tor tube between the two universal joints is not uniform. This is always the
case when the universal joint has to compensate for an angle. This
phenomenon is avoided by using a double universal joint cardan shaft.
The connector tube now turns evenly.
TechnicaI data
Name VaIue Units
Type GKN
Min. length 1880 mm
Cardan shafts
12.3 - 1 of 2
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Name VaIue Units
Max. length 1940 mm
Flange bolt tightening torque 76 Nm
Mass 20.5 kg
Cardan shafts
12.3 - 2 of 2
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13 VehicIe frame, baIIast weight
Chapter contents
13 Vehicle frame, ballast weight 13.0 - 1
13.1 Vehicle frame 13.1 - 1
13.2 Oscillating axle mount (D 9657935) 13.2 - 1
13.3 Articulation lock (D 9654879) 13.3 - 1
13.4 Ballast weight (D 9654274, 9654275) 13.4 - 1
13.0 - 1 of 2
Vehicle frame, ballast weight Service manual
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13.1 VehicIe frame
Layout
The machine frame consists of the front and rear sections. These are
linked by the articulation bearing.
Main components of the machine frame
1 Front section
2 Rear section
4 Articulation bearing
Basic function
The machine frame transmits the forces from the lift arm to the axles. The
frame bears all the key components of the machine such as the diesel
engine, driver's cab and transfer gear.
Vehicle frame
13.1 - 1 of 2
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13.2 OsciIIating axIe mount
(ID 9657935)
Layout
The oscillating axle mount is installed between the front and rear sections.
Articulation bearing
1 Front section
2 Swivel bearing
3 Support ring
4 Snap ring
5 Pin
6 Bushing
7 Pressure flange
8 M10x25 10.9 pressure flange
cheese-head screw
9 M10x65 10.9 bearing cover
cheese-head screw
10 Bearing cover
11 Sempozell seal
12 Shim
13 Rear section
Oscillating axle mount
13.2 - 1 of 2
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1 M27x200 10.9 hex screw
2 Stretching bushing
3 Bar
4 Metal-elastic block
5 Locking pin
6 Bearing block
7 Rear section
The oscillating axle mount links the front and rear section.
t allows:
Steering of the machine by turning the machine frame to the left or
right.
Balancing of the machine by turning the front section towards the rear
section around the logitudinal axis of the vehicle.
TechnicaI data
Name VaIue Units
M10x25 10.9 cheese-head screw
tightening torque
60 Nm
M10x65 10.9 cheese-head screw
tightening torque
60 Nm
M27x200 10.9 hex screw tightening
torque
920 Nm
13.2 - 2 of 2
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13.3 ArticuIation Iock
(ID 9654879)
Layout
Articulation lock
1 Safety bar
2 Pin
3 Spring clip
Basic function
The articulation lock blocks the articulation joint of the machine. This
means the steering of the machine is locked, for example during trans-
portation.
Articulation lock
13.3 - 1 of 2
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13.4 BaIIast weight
(ID 9654274, 9654275)
Layout
The ballast weight is fastened to the rear section with three screws.
Location of ballast weight
1 Ballast weight
2 Screws
3 Rear section
TechnicaI data
Valid for: L512-466/0501-, ID 9654274
Name VaIue Units
Mass 510 kg
Material CG 10
screws
560 Nm
TechnicaI data
Valid for: L514-467/0501-, ID 9654275
Name VaIue Units
Mass 710 kg
Material CG 10
screws
560 Nm
Ballast weight
13.4 - 1 of 2
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14 CentraI Iubrication system
Chapter contents
14 Central lubrication system 14.0 - 1
14.1 Central lubrication (D 9654877) 14.1 - 1
14.0 - 1 of 2
Central lubrication system Service manual
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14.1 CentraI Iubrication
(ID 9654877)
Layout
The central lubrication consists of a central lubricating rail. This is welded
to the left side of the machine in the articulation area on the rear section.
Lubricating rail on the rear section
1 Rear oscillating axle mount
2 Front oscillating axle mount
3 Bottom steering cylinder
Basic function
The two central lubricating rail is designed to reach lubrication points
which are otherwise inaccessible.
Central lubrication
14.1 - 1 of 2
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15 Covering, cab access
Chapter contents
15 Covering, cab access 15.0 - 1
15.1 Covering (D 9658616) 15.1 - 1
15.2 Cab access (D 9657817) 15.2 - 1
15.0 - 1 of 2
Covering, cab access Service manual
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15.1 Covering
(ID 9658616)
Layout
Covering sections
1 Cover
2 Front mud guard, left and right
hatch
Cover
1 Cover 2 Front section
The cover 1 is fixed to the front of the front section 2 with four screws.
Covering
15.1 - 1 of 4
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Front mud guard
1 Front mud guard 2 Front section
The two front mud guards 1 are each fixed by 2 screws to the front
section 2.
Engine cover
2 Rear frame
3 Gas-filled spring
4 Clamping lever
The engine compartment hood 1 is fixed with 4 screws to the rear frame
2. After unlocking the two clamping levers 4, the engine compartment
hood can be opened up with the aid of the two gas-filled springs 3.
Covering
15.1 - 2 of 4
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Rear section
hatch
2 Rear frame
The rear hatch 1 is fixed with 4 screws to the rear frame 2.
Covering
15.1 - 3 of 4
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15.2 Cab access
(ID 9657817)
The brackets welded to the cab and the inside of the cab door help the
driver to get in and out of the vehicle.
Layout
Driver's cab access
1 Cab access and exit aid
2 Battery compartment
3 Cab access
The cab access 3 is fixed to the left side of the rear section with three
screws. The lowest step is linked to the cab access by two rubber
supports.
The battery compartment 2 is located between the steps.
Cab access
15.2 - 1 of 2
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16 Cab, heating, air-conditioning
system
Chapter contents
16 Cab, heating, air-conditioning system 16.0 - 1
16.0.1 Cab, heating, air-conditioning system 16.0 - 1
16.1 Control panel (D 9840789) 16.1 - 1
16.1.1 Display unit (D 6905915) 16.1 - 2
16.1.2 Switches on the instrument panel (D 9657841) 16.1 - 12
16.1.3 Switches on the side cover (D 9657842) 16.1 - 14
16.1.4 LH control lever (D 5716548) 16.1 - 15
16.2 Heating, ventilation (D 9619559) 16.2 - 1
16.2.1 Blower (D 6905460) 16.2 - 2
16.2.2 Heat exchanger (D 7621899) 16.2 - 3
16.2.3 Water valve (D 7621902) 16.2 - 4
16.2.4 Air filter (D 7621907) 16.2 - 4
16.3 Air-conditioning system (D 9840144) 16.3 - 1
16.4 Windscreen wiper and washer system (D 9657837) 16.4 - 1
16.0 - 1 of 2
Cab, heating, air-conditioning system Service manual
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16.0.1 Cab, heating, air-conditioning system
Layout
The cab is a safety cab and has been tested and certified according to
ROPS/FOPS regulations. t is mounted on cushioned bearings on the rear
section.
The cab is equipped with heating and ventilation systems.
Access to the cab is from the left-hand side of the machine via the cab
access and the left-hand door.
n emergencies, it is possible to exit through the door on the right-hand
side.
Driver's cab, outside view
1 Front windshield wiper
2 Front windscreen
3 Right cab door
4 Seat with safety belt
5 Access to electronics, fuses
and relays
6 Right working floodlight
7 Access to cabin fresh air filter
8 Rear windshield wiper
9 Rear windshield
10 Left working headlight
11 Heating and blower control unit
12 Left exterior mirror
13 Shelf and stowage space
14 Access to windshield washer
tank
15 Door lock
16 Left cab door
17 Door lock
18 Outlet nozzles
19 Access aid
20 Adjustable steering column
21 Outlet nozzles
16.0 - 1 of 6
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Driver's cab seen from right
1 Working floodlights
2 Exterior mirror
3 LH control lever
4 Door lock
5 Door lock
6 Access to cab air filter
7 Star grip screw
8 Clamp
9 Air flap lever
16.0 - 2 of 6
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Inside view of the driver's cab
1 Radio loudspeaker
2 Sun visor
3 nterior mirror
4 Radio (optional)
5 nterior illumination with switch
6 Brake/inching pedal
7 Steering column switch
8 Adjustable steering column
with steering wheel
9 Monitor
10 Steering column adjustment
lever
11 Starter switch
12 Gas pedal
13 Ashtray
14 LEBHERR control lever
15 Control lever mounting for op-
tional working functions
16 Door handle (right-hand door)
17 Adjustable arm rest
18 Switches on the side cover
(control console)
19 Driver's seat
20 Fuse box
21 Box with control electronics
and relays
22 Ventilation vent adjustment
lever
23 Round glove compartment
24 Heater controls
25 Ventilation controls
26 Heating/ventilation/air-condi-
tioning outlet nozzles (6 total)
27 Cigarette lighter socket
28 Glove compartment with cover
16.0 - 3 of 6
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Cab windows ESG (single-pane safety glass) is used as standard in LEBHERR wheel
loader cabs.
Specially hardened glass (approx. 50 x 60 cm) is used in the field of
vision.
The glass cannot be machined at a later point (i.e. it cannot be drilled or
cut etc.).
The glass panes consist of a middle section and two side sections, held in
the window frame by a mounting rubber. The mounting rubber serves as a
frame between the panes and the cab interior.
The front windscreen mounting rubber is a single component. t begins
and ends athe the top left corner below the working floodlight panel. The
rear windscreen mounting rubber consists of four separate sections.
Fitting gIass panes
When fitting the rear windscreen pay special attention that the mounting
rubber is cut to a mitre joint at the four corners.
This means that the mounting rubber must be accurately cut to the right
length to make sure it is tight.
The mounting rubber by the roof gutter 1 must also be of an exact length
and cut to a mitre. There may be no gaps or leaks in this area.
Silicon sealant must also be used around the mitre joints.
When installing a glass pane it is advisable to fix the top section of the
mounting rubber to the cab frame using a small amount of superglue.
First put in the left and right side sections and fit them into the mounting
rubber using a rubber mallet, then hold them loosely on the clips using the
fastening elements.
Then place the middle section in the bottom mounting rubber and align it
so that the distance (at least 2 - 3 mm) to the side sections is even. Small
wooden wedges make it easier to align the panes and attach the fasten-
ings. Do not allow movements of the cabin to cause the panes to touch.
16.0 - 4 of 6
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After checking the position of the panes again, apply silicon seal to a
length of 15 cm around the corners of the cab frame (outside only).
This is necessary because the mounting rubber can be slack at this point,
which may cause leaks.
Then tighten the fastening screws to the correct torque and remove the
wooden wedges.
Finally use an installation tool to insert the beading. Cut it to the right
length just before you finish inserting it.
AppIying siIicon seaIant
To apply the transparent silicon sealant, use a manually operated or
compressed-air sealant gun.
Before applying sealant to the panes, clean the edges with acetone or
thinners.
To avoid smearing the glass while applying sealant, attach masking tape
immediately to the left and right of the mounting rubber (inside and
outside).
Then smooth the mounting rubber outside using a template and inside
using your thumb and remove the masking tape.
mportant: Do not touch the silicon sealant until it has dried (around 5
hours depending on the temperature).
16.0 - 5 of 6
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16.1 ControI paneI
(ID 9840789)
mportant control and display elements are arranged in the control panel.
Their locations are determined by ergonomic factors.
Ergonomic design means that all aspects of comfort and safety at the
workplace are taken into account.
This means, for example, that steering and operation can be made as
comfortable as possible by adjusting the steering column and the driver's
seat.
Layout
Control panel
1 Steering column switch
2 Display unit
3 Switches on the instrument
panel
4 Starter switch
5 LEBHERR control lever
6 Location for additional operat-
ing lever
7 Control electronics
8 Switches on the side cover
9 Fuse and relay box
10 Ventilation vent adjustment
lever
11 Heating control element
12 Ventilation control element
13 Air conditioning control
element (optional)
AdjustabIe steering coIumn with
steering wheeI and steering
coIumn switch
The display unit, headlight and floodlight switches, and switches for the
parking brake and hazard warning system are integrated in the steering
console.
The ignition starter switch is positioned on the right side of the steering
console.
Right side cover (controI paneI) The LEBHERR control lever is mounted on the right in the side cover. An
optional additional control lever can be installed to the right of that.
The other control elements in the side cover are: Switches and indicator
lamps for the attachment, emergency steering, windscreen wipers and
washers and the mode switch.
The control electronics A1 are located under the side cover. The top
section of the side cover can be detached.
Control panel
16.1 - 1 of 18
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Rear part of the controI paneI The rear part of the side cover contains the control unit A2 with the fuses
and relays, as well as the lever for adjusting the air flap.
The pin assignment of the connectors on the control board is described in
section 10 of the "Electrical system.
The control elements for the heating, ventilation and optional air-condition-
ing are arranged in the rear part of the side cover. (See the "Heating,
ventilation chapter)
16.1.1 DispIay unit
(ID 6905915)
The display unit is integrated in the steering console and is part of the
control panel.
The display unit informs the driver of the operating state of the machine
and provides warnings for various malfunctions.
Some malfunctions are also indicated with an audible warning sound.
Layout
Display unit
(black)
field (black)
3 Charge control symbol field
colour (red)
field (red)
5 Forward travel direction sym-
bol field (green)
6 Reverse travel direction sym-
bol field (green)
7 Hydraulic oil overheating
symbol field (red)
(red)
9 LC display for travel speed,
service hours and time (yellow)
10 Travel range - - symbol field
(green)
11 Travel range - - symbol field
(green)
12 Engine overheating symbol
field (red)
13 Special function symbol field
(red)
14 Safety belt symbol field (yel-
low)
Control panel
16.1 - 2 of 18
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15 Working hydraulics lockout
symbol field (red)
(yellow)
field (red)
18 High beam symbol field (blue)
19 Brake system accumulator
pressure symbol field (red)
20 Direction indicator symbol field
(green)
field (yellow)
The display unit contains segment and symbol fields as well as an LC
display for the various warning or display functions.
Display unit, rear view
1 X-4 connector 2 X-3 connector 3 Opening for dip switches
The dip switches have the following functions:
Dip switches 1 and 2 switch the frequency according to the device and
the gear wheel used (travel speed)
Dip switch 3 switches between mph and km/h
Dip switch 4 selects either the speed or the clock as the default display
after the ignition is turned on.
Dip switches 5 and 6 are unassigned and must be switched to the
"OFF position
Control panel
16.1 - 3 of 18
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X3 connector pin CoIour Function DispIay
1 red-yellow Speed sensor B1 frequency signal input A5
2 green-red (+) gnition ON monitor supply
3 brown/black (+) Forwards signal S2 input H3
4 blue/yellow (-) Hydraulic oil temperature B6 input H23
5 yellow (+) Monitor backlighting input
6
orange/whi-
te
(+) Parking brake input H11
7 red (+) Battery charge D+ input H6
8 white/black (-) Engine oil pressure B7 input H4
9 brown-black (+) Reverse signal S2 input H9
10
green-yello-
w
(-) Analogue input, coolant temperature B20 P6
11 purple (-) Analogue input, tank sensor R4 P3
Pin assignment of X3 connector to display unit
X4 connector pin CoIour Function DispIay
1 brown-black (-) Forward travel direction output H3
2 brown-white (-) Reverse travel direction output H9
3 green (+) High beam input H12
4 green-black (+) Emergency steering pump input H8
5 green-blue (+) Working hydraulics lockout input H5
6 brown-black (-) Clock setting input S101
7 blue/white (-) Buzzer output B9
8 white/green (+) Switch to travel range - - input S2
9 white/red Not assigned H19
10 yellow-gree-
n
(-) Engine temperature input B20
H13
11 green/white (+) Switch to travel range - - input S2
12 red (+) Monitor supply (battery cl. 30)
13 black (-) Monitor supply (ground)
14 red/black (+) Direction indicator lamp H10
15 brown/white (+) Preglow display input H2
16 orange/bla-
ck
(+) Air filter contamination display input
H7
17 brown-gree-
n
(-) LC display input from S101
18 sky-green Not assigned
19 white-green (+) Travel range - - output (Y6) H25
20 Not assigned
21 Not assigned
Pin assignment of X4 connector to display unit
The main functions of the display unit are:
1 Displaying operating conditions
2 Warning function
3 Lamp check
4 Travel direction control
5 Travel range control
Control panel
16.1 - 4 of 18
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Lamp check during the starting procedure
During the lamp check the following symbol and segment fields on the
display unit are checked by the control electronics.
At the same time, the acoustic warning sound (buzzer) is tested. (2 x
buzzes)
The following symbols and segments are displayed during the lamp check
(when the starter key is in the " position):
Indicator unit lamp check
(charge control)
field
3 Hydraulic oil overheating sym-
bol field
5 Driving speed LED
6 Operating hours LED
7 Time LED
9 Travel range - I - symbol field
field
12 Braking system accumulator
pressure symbol field
field
field
FueI suppIy indicator
This display element is an LCD bar display and indicates the remaining
fuel supply.
The float in the submersed sensor in the fuel tank transmits a resistance
signal to the display unit.
On the bar below, the reserve fuel level is marked in red.
f the fuel supply sensor fails, the middle bars 4 and 5 flash (see also the
"Fuel system chapter).
Control panel
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CooIant temperature dispIay function
This display element is an LCD bar display and indicates the coolant
temperature.
The coolant temperature display sensor (B20a) transmits a resistance
signal to the display unit. The absolute values can be found in the table
below.
f the display sensor (B20a) fails, bars 4 and 5 flash, accompanied by a
warning sound from the side cover (control electronics).
Bar shown Input signaI from B20
(Ohm)
Temperature (C)
1 287 - 193 40 - 50
2 193 - 134 50 - 60
3 134 - 95 60 - 70
4 95 - 69 70 - 80
5 69 - 51 80 - 90
6 51 - 29 90 - 100
7 flashes 29 - 25 100 - 110
8 flashes with warn-
ing sound
25 - 21 115 - 120
Coolant temperature bar display
DispIaying speed, operating hours or time
This display element 1 is a switchable digital LC display.
The LEDs 2, 3, 4 directly below indicate the current display mode.
Press the MODE switch to select travel speed 2, operating hours 3 or
clock 4. This also enables the clock to be set.
DispIay mode DispIay: DigitaI (LCD) Input signaI
Lamp test All fields active nternal
Speed (km/h) Digital (LCD) mpulse (output sen-
sor)
Operating hours Digital (LCD) Alternator (D+)
Real time Digital (LCD) nternal
Triple LCD digital display
When the battery main switch is switched off or if the power supply is
interrupted, the clock must be reset.
A coding switch (on the back of the display unit) can be used to switch
between km/h and mph.
f the speed sensor fails "OPEN appears in the display
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DispIaying the battery charge controI
This display lights up if the alternator fails, for example if the V-ribbed belt
tears.
Operating state DispIay: Iamp Input signaI
Lamp test Lights up nternal
gnition ON Lights up
(-) Negative from (D+)
via X3 pin 7
Engine running Goes out
(-) Positive from (D+)
via X3 pin 7
Malfunction: no battery
charge
Lights up
(-) Negative from (D+)
via X3 pin 7
DispIaying and reporting the engine oiI pressure
The warning function of the symbol field is supported by an acoustic
signal.
Operating state DispIay: Iamp, buzz-
er
Input signaI
gnition ON Lights up
(-) Negative from B7
via X3 pin 8
Engine running Goes out None
Malfunction: oil pres-
sure too low
Lights up with buzzer
via X3 pin 8
DispIaying forward / reverse traveI direction
f the optional backing up alarm is fitted, this is activated when the vehicle
is driving in reverse.
er
Input signaI
Lamp test Buzz nternal (monitor)
gnition ON (cannot be
selected since brake is
closed)
Buzz, because it can-
not be selected
nternal (monitor)
Engine running (cannot
be selected since brake
is closed)
Buzz, because it can-
not be selected
nternal (switch S2 not
detected)
Motor running, brake
open, selection possible
Displays the selected
travel direction
(-) Positive from S2 via
X3 pins 3, 9
See also the "LEBHERR control lever section.
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DispIaying/reporting hydrauIic oiI overheating
This display lights up if the hydraulic oil overheats (100 C or above). The
machine switches to slow travel (travel range - -) and the travel range -
- and - - indicators light up simultaneously.
The hydraulic overheating indicator is accompanied by a warning sound.
gnition ON None None (B6 open)
Engine running None None (B6 open)
Malfunction: hydraulic
overheating
via X3 pin 4
DispIaying parking brake activation
The symbol field lights up when: (parking brake closed).
The starter key is in position ".
The parking brake is activated
The brake accumulator pressure is too low (the brake cannot be
released).
er
Input signaI
gnition ON, brake
closed
Lights up
(+) Positive from K22a
via X3 pin 6
Brake OPEN Goes out None (K22a open)
Malfunction: Brake ac-
cumulator pressure too
low
(+) Positive from K22a
via X3 pin 6
TraveI range dispIay
er
Input signaI
Lamp test
Travel ranges - - and
- - light up simulta-
neously
nternal
gnition ON
Travel range - - lights
up
nternal
gnition ON, range se-
lected
The selected travel
range lights up
X4 pins 8, 11
Engine running, range
selected
The selected travel
range lights up
X4 pins 8, 11
Malfunction: e.g. hy-
draulic oil overheating
Travel ranges - - and
- - light up simulta-
neously with buzzer
nternal, triggered by
temperature switch B6
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DispIaying or reporting engine overheating
This display lights up if the coolant temperature reaches 108 C or above.
An audible warning signal sounds at the same time.
f the coolant temperature for the ventilator controls (B21) fails, the buzzer
(B9) of the control electronics A1 (in the side cover) emits a tone (5x
beeps, 3 seconds pause etc.).
er
Input signaI
Lamp test None None
gnition ON None None (B20 open)
Engine running None None (B20 open)
Malfunction: Engine
overheating
via X 4 pin 10
SpeciaI function
Display not assigned. The symbol field colour is red. Reserved for special
function.
er
Input signaI
Lamp test None None
gnition ON None None
Engine running None None
Malfunction: Special
function
(+) Positive from X 4
pin 18
Instruction to use the safety beIt
When the ignition is switched on, this indicator flashes until the engine is
started. After the starting procedure the display flashes a further 15
seconds and then goes out.
er
Input signaI
Lamp test None None
gnition ON Flashes nternal
Engine running Flashes 15 seconds nternal
DispIaying working hydrauIics Iockout activation
This display indicates that the working hydraulics lockout has been ac-
tivated.
The working hydraulics lockout can only be activated when the diesel
engine is running.
Lamp test None None
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gnition ON, switch ON
None (switch not re-
cognised)
None
Engine running, switch
ON
Lights up
(+) Positive from S19
via X 4 pin 5
PregIow monitoring
f the outside temperature is 0 C or below, the display lights up when the
ignition key is in position " until the starting temperature is reached. The
afterglow function ceases after 30 seconds.
At the end of the preglow and afterglow period and when the diesel engine
is started, the symbol field goes out.
gnition ON
Lights up at tempera-
tures below 0C
(+) Positive via X4 pin
15 (from K4)
Starting procedure
(temperature below 0)
Lights up until the
starter switch is acti-
vated.
(+) Positive from K4
via X4 pin 15
DispIaying / reporting emergency steering
f the diesel engine shuts down or if the working pump breaks down when
the vehicle is moving, the emergency steering pump is automatically
activated for 50 seconds.
To repeat start the emergency steering pump press and hold down the
emergency steering button. This will reactivate the emergency steering
pump (switches off if the emergency steering pump overheats).
Emergency steering check display: The emergency steering pump is
checked during each start procedure. The display is also on the switch
side cover.
f the emergency steering pump check is unsuccessful, the display remains
on until the ignition is switched off.
gnition ON
Lights up until the
emergency steering
button is pressed.
(+) Positive from emer-
gency steering pump
via X4 pin 4
Engine start (emergen-
cy steering pump
check)
Lights up briefly
gency steering pump
via X4 pin 4
Malfunction: Steering
failure (emergency
steering pump running)
Flashes 50 seconds
gency steering pump
via X4 pin 4
Emergency steering
button ON (repeat start
of emergency steering
pump)
Lights up until the
emergency steering
button is pressed.
gency steering pump
via X4 pin 4
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High beam dispIay
The signal for the high beam display is received at fuse F1A via the high
beam power supply.
Lamp test None None
Switch ON (high beam) Lights up
(+) Positive via X4 pin
3
DispIaying / reporting the braking system accumuIator
pressure
This display not active.
Engine running None None
Direction indicator dispIay
The lamp (H10) is directly activated with a positive signal from the direc-
tion indicator relay (K1).
Lamp test None None
Switch ON Flashes
(+) Positive from K1
via X4 pin 14
Air fiIter contamination dispIay
This display lights up when the air filter is heavily contaminated. The air
filter must be serviced.
The vacuum switch (B4) on the suction tube between the diesel engine
and the air filter sends a negative signal (ground) to the display unit when
the vacuum is excessive (i.e. the air filter is very dirty).
Malfunction: Air filter
dirty
Flashes
(-) Negative (ground)
from B4 via X3 pin 16
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16.1.2 Switches on the instrument paneI
(ID 9657841)
The switches which are essential for operation and safety are integrated in
the steering console.
This are an ON/OFF switches for lamps and the hazard warning system,
as well as a sprung switch with OFF, ON and 0 positions for the parking
brake.
Layout
Switches on the instrument panel
1 Hazard warning system switch
2 Dummy plug
3 Parking light/driving light
switch
4 Front working floodlights
switch
5 Rear working floodlghts switch
(optional)
6 Parking brake switch
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Plugs on the steering console switches
K5 Windshield wiper interval relay
S6 Parking light/driving light
switch
1 Reserve
S4 Hazard warning system switch
2 Reserve
S7 Front working floodlights
switch
The hazard warning system 1, front working floodlight 4 and rear working
floodlight 5 switches can only be operated after the battery main switch
has been switched on.
To activate the driving light on the parking light/driving light switch 3, both
the battery main switch and the ignition switch must be on.
Engaging and reIeasing the parking brake
Parking brake switch 6
Field colour - red
For engaging or releasing the parking brake.
When the engine is started the parking brake is automaticaIIy en-
gaged.
When the switch is pressed the parking brake is engaged or released.
Button function "OFF position:
When the switch is pushed to the "OFF position, the parking brake is
released.
When a travel direction is selected and the switch is pushed to the
"OFF position, the direction of motion is changed to neutral.
Central position 0:
Travel directions and ranges can be selected in this position.
Button function "ON position:
After switching to the "ON position, the parking brake is engaged.
When a travel direction is selected and the switch is pushed to the "ON
position, the direction of motion is changed to neutral.
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16.1.3 Switches on the side cover
(ID 9657842)
The layout and function of the switches is described in this section. The
description of operation can be found in the appropriate sections in the
"Operation, handling" section of the operator's manual.
Layout
Switches on the side cover
1 Lifting limit switch
2 Float position switch
3 Bucket return-to-dig switch
4 Hydraulic quick-change device
switch (optional)
5 Emergency steering button
6 Emergency steering check in-
dicator lamp
indicator lamp (optional)
8 Working hydraulics lock switch
9 MODE button
10 Rear windshield wiper and
washer switch
Plug designations on the switches in the side cover (control console)
S22 Lifting limit switch
S18 Float position
S14 Bucket return-to-dig
S26 Quick-change device
S10 Emergency steering
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H24 Emergency steering check in-
dicator lamp
H29 Hydraulic quick-change device
indicator lamp
S19 Working hydraulics lock
S101 "MODE
S13 Windscreen wiper and washer
system
16.1.4 LH controI Iever
(ID 5716548)
Layout
LH control lever
1 Travel range switch
2 Travel direction switch
F Forward
R Reverse
The LH control lever consists of the control elements for shifting the travel
range, the travel direction and operating the working attachment.
The handle of the LH control lever is linked mechanically to the pilot
control device directly underneath it.
Retaining magnets for the bucket return-to-dig, float position and lifting
limit switch functions are integrated in the pilot control unit.
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Handle with switching mechanisms and electronics
1 Button switch
2 Cap
3 Handle section
4 Wiring harness relief
5 Microswitch
6 Latching mechanism
7 Counter nut
8 Additional actuator sprocket
9 Wiring harness
10 Latching notch
The handle consists of two sections 3. Each section is fastened to the
handle base with a chesse head screw. The cap 2 provides additional
support for the handle.
Part of the linkage consists of a turning mechanism with latching, limit stop
and reset functions, which is held to the lower (fixed) part of the switch rod
with a positioning screw.
Two microswitches 5 with additional actuators (sprocket 8) are attached to
the disc of the switch rod. ts wiring harness 9 is soldered to the micro-
switches.
A sub-strand of the wiring harness 9 leads to the switch button 1 in the
middle of the handle. This is connected with tab connectors.
During repairs please note:
Do not alter the factory settings of the latching mechanism 6 and the
position of the microswitches 5.
f the microswitches or wiring harness must be replaced, set the
position of the microswitches according to the table for the forward and
subsequent movement of the additional actuator.
The cable relief mechanism ensures that the cable harness does not
strain the microswitches during any movement of the lever.
Setting the microswitches
Max.forward movement 2.7 mm
Min. subsequent movement 1.0 mm
The forward movement is the distance the additional actuator (sprocket)
of the microswitch travels between its neutral position and switching point.
The subsequent movement is the distance the additional actuator of the
microswitch travels after it has clicked into the switch point before it
reaches the stop point of the latching mechanism.
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The LH control lever has a joystick function, where a linkage transfers the
movements of the handle to the pilot control unit.
Part of the linkage is a switching mechanism which activates one or the
other microswitch by turning the handle to the left or right against a return
spring.
Turning to the left activates the right microswitch (switching to the second
travel range).
Turning to the right activates the left microswitch (switching to the second
travel range, or to neutral if held for 2 seconds).
When the driver lets go of the handle, the return springs return it to the
central position, where it is held by a latching mechanism.
The spring loaded button switch 1 returns to the central position as soon
as a travel direction is selected.
Please see the "Operation chapter operating manual for more information.
Control panel
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16.2 Heating, ventiIation
(ID 9619559)
The driver's cab is equipped with a warm water heating system.
The heating circuit is included in the cooling circuit of the diesel engine.
Layout
Heating circuit
1 Diesel engine
2 Warm water supply
3 Water valve
4 Heat exchanger
5 Blower
6 Return flow line
The warm water supply 2 is located on the thermostat housing of the
diesel engine and is directed through flexible hoses to the heat exchanger
4 in the cabin.
The warm water supply line contains the water valve 3, which is activated
via a mechanical control line. This means the heating power can be
continuously regulated.
The return flow 6 of the heating circuit ends in the lower coolant line.
The heating device with the radial blower and heat exchanger 4 is moun-
ted under the driver's seat.
A flap in the intake channel of the blower enables it to be switched
continuously and to mix fresh air and cab air (fresh air/circulation flap).
The control elements are arranged behind the driver's seat (knobs, switch-
es and heating slider switch). The lever for the fresh air/circulation flap is
located on the right beside the switch side cover.
A serviceable fresh air/circulation filter is located between the fresh air/cir-
culation flap and the heater/ventilator. This is fixed with a retaining clip and
pressed against the sealing surface.
Heating, ventilation
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Heater/ventiIation basic function
Part of the heat energy in the diesel engine's cooling system passes
through the warm water supply 2, the water valve 3 and the heat
exchanger 4 in order to heat the driver's cab.
The blower 5 provides fresh air or cab air to the heat exchanger 4 and
removes heat energy from the coolant, thus heating the cab air.
Switching enables either fresh air from outside or cab air to be passed
though the heat exchanger, where it is heated and then circulated.
f the flap is closed (circulation mode), only cab air is passed through the
heat exchanger. This gives a better heating output.
The circulating water is already available for the heating circuit while the
engine is warming up (the thermostat in the diesel engine's cooling circuit
does not afffect the heating circuit).
The coolant flows back through the return flow line 6 to the coolant circuit
of the diesel engine in order to absorb more heat energy for the heating
circuit.
The pressure of the supply line and the suction of the return line circulate
the coolant in the heating circuit.
The temperature control slider switch 1 opens and closes the water valve
3 by means of a Bowden cable.
Setting the temperature: range b (blue) = cooler, range a (red) = warmer.
This means the heating power can be continuously regulated according to
the driver's needs. The blue range is cold, the red range is warm.
When the water valve 3 is closed, the blower works as a cab ventilator.
TechnicaI data
Name VaIue Units
Heating output 4800 Watts
16.2.1 BIower
(ID 6905460)
The blower is part of the heating / ventilation unit.
Layout
The blower is a 3-stage radial blower and is used for the ventilation,
heating and (optional) air-conditioning of the driver's cab.
t is located under the driver's seat cover plate and is mounted between
the fresh air/circulation filter element and the heat exchanger.
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Basic function
The blower sucks air (axial inlet) 4 through the fresh air / circulation
channel and after the radial outlet 5 supplies air to the heat exchanger. f
an air-conditioning system is fitted, the evaporator is first supplied with air
from the blower.
The strength of the air flow is regulated by changing the blower speed.
This can be regulated using a rotary knob. n the "0 position the blower is
switched off. n the "3 position the air flow is at the maximum level.
TechnicaI data
Name VaIue Units
Air flow 630 m/h
Blower speeds 3
Voltage 12 V
Current input (max) free blowing 10.5 A
Power consumption (max) free
blowing
125 Watts
16.2.2 Heat exchanger
(ID 7621899)
The heat exchanger is the actual heating element in the heating/ventilation
unit.
Layout
The heat exchanger 2 consists of large, thin closely layered plates 1.
These are welded to a winding copper pipe 5 through which the heated
coolant flows.
This design provides a large effective surface for the efficient exchange of
heat required with the cab air. t also means the heat exchanger 2
requires very little space.
Basic function of the heat exchanger
Part of the heat energy created in the cooling system of the diesel engine
is directed via the water valve to the heat exchanger 2.
Heated coolant flows through the copper pipe 5, warming it up.
The heated copper pipe 5 transfers heat to the plates 1 soldered on to it.
The plates 1 in the heat exchanger 2 transfer the heat energy (convection)
to the cab air flowing through it. This heat up the cab air.
The cooled coolant is pumped through the return flow line 4 back to the
cooling circuit of the diesel engine.
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16.2.3 Water vaIve
(ID 7621902)
The water valve is part of the heater / ventilation unit.
t can be accessed by removing the seat cover. The water valve 5 is
located to the left of the blower.
Layout
The water valve 5 is designed as a rotary slide valve. ts individual
components are made of plastic.
Flexible hoses 3 in the warm water supply line are connected to the water
valve and fastened with hose clips 4.
The rotary slide of the water valve is connected via a Bowden cable 2 to
the temperature control slider 1 lever and can be continously adjusted.
The water valve and blower are for switching on, switching off and
regulating the heating output.
The temperature control slider switch 1 opens and closes the rotary slide
of the water valve by means of a Bowden cable 2.
This controls or stops the flow of water to the heat exchanger. When the
water valve is closed, the heating / ventilation unit ventilates the cab.
16.2.4 Air fiIter
(ID 7621907)
The air filter is fitted in the fresh air/circulation intake shaft and is acces-
sible for servicing from outside the cab on the rear right side.
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Layout
The air filter consists of a tin plate metal frame 3, which contains and
supports the paper element 1.
On the metal frame there is a self-adhesive rubber strip 2 which seals the
air filter to the filter holder.
A support grid is attached to the opposite (front) side.
A retaining clip fastens and presses the air filter to the filter holder. Make
sure the filter is correctly fitted! The arrow 4 must point towards the
blower.
The job of the air filter is to filter out dust and other particles from the
fresh air or circulated air before it enters the blower.
The air filter is classified as a coarse filter for particles larger than 10 m.
TechnicaI data
Name VaIue Units
Filter type P 5209
Filter class EU3
Filtration 10
Filter surface (effective) 1.8 m
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16.3 Air-conditioning system
(ID 9840144)
The air-conditioning system is optional equipment.
Layout
Components of the air-conditioning system
2 ntake side (return flow)
3 Pressure side (forward flow)
4 Blower (3-speed)
5 Expansion valve
6 Evaporator
7 Heat exchanger (heater)
8 Filter / dryer
9 Sight glass
10 Pressure switch
11 Condenser
Air-conditioning system
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Basic refrigeration function
Cooling circuit diagram
2 Magnetic coupling
3 Condenser
4 Fan
5 Pressure switch
6 Dryer collector unit
7 Sight glass
8 Temperature switch
9 Temperature sensor
10 Condensed water pan
11 Evaporator
12 Blower
13 Expansion valve
a High pressure liquid refrigerant
b High pressure liquid/gas
refrigerant
c Low pressure liquid/gas
refrigerant
d Low pressure gas refrigerant
The refrigerant is drawn up by the air-conditioning compressor 1 as a gas
and raised to a higher energy level (pressure and heat energy).
The resulting heat is dissipated in the condenser 3. The energy level is
thus reduced.
The refrigerant condenses. ts energy level is further lowered by this
change of state.
The refrigerant which still contains bubbles reaches the dryer collector unit
6, where it is filtered and dried and then reaches the expansion valve 13
on the evaporator via the ascending pipe.
The liquid, compressed refrigerant is sprayed via the expansion valve 13
into the depressurised evaporator 11.
n the process, the refrigerant is able to expand. As it expands, the
refrigerant loses pressure energy and cools the evaporator considerably.
The evaporator 11 impinged upon by the warm cab air surrenders its heat
energy to the coolant. This heat exchange cools the cab air and warms
the refrigerant.
The warmed refrigerant vaporises, changing to its gaseous state. This
change in state results in a further loss of energy from the (warm)
evaporator which, in turn, leads to a further drop in temperature.
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Temperature controI
The temperature is regulated by the cyclical activation and deactivation of
the magnetic coupling 2 of the air-conditioning compressor during opera-
tion or when the warm heating air is added as, for example during re-heat
operation.
The frequency of activation/de-activation is controlled by the preset tem-
perature switch 8 in the evaporator (see the technical data).
Additional temperature regulation takes place at the expansion valve.
Pressure and temperature are captured at the evaporator output as the
injection quantity is metered precisely.
These monitoring elements prevent the evaporator from icing up.
Re-heat mode
When the windows are misted over, the cab air must be dried. This is
achieved by simultaneously operating the air-conditioning and heating
systems.
The heated cab air is able to absorb more moisture. The moisture in the
air passing over the cool evaporator is precipitated in the form of con-
densed water.
Re-heat operation is also recommended to achieve a pleasant climate in
the cab.
TechnicaI data
Name VaIue Units
Cooling output 4.8 kW
Compressor oil (type) ZXL 100 PG
Compressor oil filling quantity 180 cm
Operating voltage 12 V
Current consumption (max.) 20 A
Low pressure switch OFF 2.0
0.5
bar
Low pressure switch ON 3.5
0.5
bar
High pressure switch OFF 25.0
2.0
bar
High pressure switch ON 18.0
1.5
bar
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16.4 Windscreen wiper and washer system
(ID 9657837)
Layout
Windscreen wiper and washer system
1 Star grip screw
2 Cover
3 Washer fluid container
4 Front windscreen washer
pump
5 Rear windscreen washer pump
6 Check valve
7 Washer fluid hose
8 Outlet nozzle
9 Front windscreen washer
motor
10 Rear windscreen washer
motor
The machine is equipped with an electric windshield wiper and washer
system for the front and rear windows.
Essentially it consists of the windshield wipers with nozzles, the wiper
motor with gears, the reservoir for the washer fluid and the controls.
The windshield wiper and washer systen for the front and rear windows
use a common washing agent container.
Check valves are built into the washing agent pipes to the outlet nozzles.
The switches for the wiper and washer system for the front windscreen are
on the steering column switch.
The switches for the wiper and washer system for the rear windscreen are
on the right-hand side cover. A sprung key function controls the washing
agent pump.
Front and rear windshieId
washer system
The two washer fluid pumps are fixed to the bottom of the common
washer fluid reservoir. This is fitted in the rear left of the cabin and can be
accessed from outside.
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Access to the washer fluid reservoir and pump
When the slider switch on the steering column switch or the button switch
in the right side cover is pressed, the selected washer pump is energised
for as long as the button remains held down.
The washer pumps pump the washer fluid from the common washer fluid
reservoir through hoses to the outlet nozzles on the selected windscreen
wiper.
Check valves in the washer fluid hoses prevent the fluid from flowing back
into the reservoir when the button switch is released. This ensures that the
washer fluid is supplied immediately to the outlet nozzle for the next wash.
Loosen the star grip screw to remove and tip out the cover along with the
washer fluid reservoir. This enables you top top up the washer fluD
Antifreeze must be added in good time before the onset of winter.
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17 Lift arm, quick-change device
Chapter contents
17 Lift arm, quick-change device 17.0 - 1
17.1 Z-bar lift arm 17.1 - 1
17.1.1 Z-bar lift arm (D 9657865) 17.1 - 3
17.1.2 Z-bar lift arm (D 9657855) 17.1 - 4
17.1.3 Bucket bearing 17.1 - 5
17.2 P-bar lift arm 17.2 - 1
17.2.1 P-bar lift arm (D 9658060) 17.2 - 3
17.2.2 P-bar lift arm (D 9658040) 17.2 - 4
17.3 Quick-change device 17.3 - 1
17.3.1 Hydraulic quick-change device for Z-lift arm (D
9657866) 17.3 - 2
17.3.2 Hydraulic quick-change device for P-lift arm (D
9658050) 17.3 - 3
17.0 - 1 of 2
Lift arm, quick-change device Service manual
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17.1 Z-bar Iift arm
Layout
Main components of the Z-bar lift arm
1 Connecting link
2 Z-bar linkage
3 Stop surfaces for the Z-bar
linkage
4 Automatic bucket return-to-dig
5 Tilt cylinder
6 Bucket arm
7 Lift cylinder
8 Bucket stops
9 Bucket bearing
Z-bar kinematics
The lift arm is attached to the front section of the machine.
The lift arm has a Z-kinematic design. That is to say, the tilt cylinder,
reversing lever and connecting link form a "Z shape. The "Z shape can
be seen from the right-hand side.
n the case of the lift arm with Z-bar kinematics, no parallel movement is
possible.
The Z-bar lift arms can be equipped with a hydraulic quick-change device
(optional).
Two lift cylinders and a tilt cylinder are attached to the lift arm.
The lift arm is bolted to the front section via the bucket arm bearings and
via the cylinder bearings on the cylinder bottom-end.
The bearing points on the lift arm are sealed and protected against wear
caused by dirt and corrosion.
The lift cylinders are mounted at the piston rod-end on the bucket arm and
at the cylinder bottom-end on the front section.
The tilt cylinder is mounted at the piston rod-end on the Z-bar linkage and
at the cylinder bottom-end on the front section.
The automatic bucket return-to-dig device is mounted on the tilt cylinder.
Z-bar lift arm
17.1 - 1 of 6
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Basic function
The lift arm bears and moves the attached equipment or implement.
Movements of the bucket arm
Bucket arm movement
The bucket arm is raised or lowered by extending or retracting the lift
cylinders.
You can find details on this in the "Working hydraulics chapter.
Movements of the working
attachment
Bucket movement
The bucket is tilted in or out by extension and retraction of the tilt cylinder.
Z-bar lift arm
17.1 - 2 of 6
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17.1.1 Z-bar Iift arm
(ID 9657865)
TechnicaI data
Distance between bore holes
Name VaIue Units
L Length 2250 mm
Weight of complete lift arm (without
cylinders)
640 kg
Weight of bucket arm 425 kg
Weight of Z-bar linkage 130 kg
Weight of complete connecting link 39 kg
Z-bar lift arm
17.1 - 3 of 6
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17.1.2 Z-bar Iift arm
(ID 9657855)
TechnicaI data
Name VaIue Units
L Length 2350 mm
cylinders)
650 kg
Weight of Z-bar linkage 130 kg
Weight of complete connecting link 39 kg
Z-bar lift arm
17.1 - 4 of 6
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17.1.3 Bucket bearing
Layout
Main components of the bucket bearing
1 Bucket arm
2 Grease fitting
3 Bucket bearing plate
4 Bearing pin retainer
5 Bearing pin
6 Radial sealing ring
7 Bearing bushing
The bearings at the bucket steering points are equipped with radial sealing
rings 6.
Also, the bearings on the bucket arm 1 to the front section, as well as for
the lifting cylinders and on the connecting link are equipped with radial
sealing rings.
For each bearing bore hole, a lubrication duct leads from the grease fitting
2 to the lubricating groove of the bearing bushing 7.
Bearing seaIing
The bearing sealing protects the bearing from the penetration of dirt, water
and corrosive media.
Penetration by dirt results in wear or in corrosion of the bearing pin, the
bearing areas, the bearing borehole or the bearing ring.
The bearings are destroyed by wear and corrosion.
Wear and corrosion result in the play between the bearing borehole and
the bearing pin being increased. This means that in spite of lubrication of
the sliding bearing, the bearing wears down more quickly.
Z-bar lift arm
17.1 - 5 of 6
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17.2 P-bar Iift arm
Layout
Main components of the P-bar lift arm
2 Front linkage
3 Front connecting link
4 Bucket arm
5 Tilt cylinder
6 Automatic bucket return-to-dig
7 Rear linkage
8 Rear connecting link
9 Lift cylinder
10 Bucket stops
P-bar kinematics
The lift arm is attached to the front section of the machine.
The P-lift arms have a parallel kinematic design. This means that the tilt
cylinder 5, rear linkage 7 and front linkage 2, front connecting link 3 and
bucket arm 4 are arranged in the form of a parallelogram.
The parallel kinematics enable the load to be kept parallel to the ground,
e.g. with a forklift, over the entire lifting range.
The P-lift arms are equipped with a hydraulic quick-change device. The
hydraulic quick-change device is fitted as standard equipment.
Two lift cylinders 9 and two tilt cylinders 5 are fitted to the lift arms.
The lift arms are bolted to the front section of the machine via the bucket
arm bearings and the cylinder bearings at the cylinder base, and via the
connecting links 8.
The bearing points on the lift arm are sealed and protected against wear
caused by dirt and corrosion.
The lift cylinders 9 are mounted at the piston rod-end on the bucket arm 4
and at the cylinder bottom end on the front section.
The lift cylinders 5 are mounted at the piston rod-end on the front linkage
2 and at the cylinder bottom end on the rear linkage 7.
The automatic bucket return-to-dig device 6 is mounted on the left tilt
cylinder.
P-bar lift arm
17.2 - 1 of 4
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Basic function
The lift arm bears and moves the attached equipment or implement.
Movements of the bucket arm
Bucket arm movement
The bucket arm is raised or lowered by extending or retracting the lift
cylinders.
Movements of the working
attachment
Bucket movement
The bucket is tilted in or out by extension and retraction of the tilt
cylinders.
P-bar lift arm
17.2 - 2 of 4
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17.2.1 P-bar Iift arm
(ID 9658060)
TechnicaI data
Name VaIue Units
L Length 2300 mm
cylinders)
685 kg
Weight of right rear linkage 22 kg
Weight of left rear linkage 22 kg
Weight of left and right connecting
links
48 kg
Weight of right front linkage 24 kg
Weight of left front linkage 24 kg
Weight of 4 front connecting links 52 kg
P-bar lift arm
17.2 - 3 of 4
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17.2.2 P-bar Iift arm
(ID 9658040)
TechnicaI data
Name VaIue Units
L Length 2400 mm
cylinders)
700 kg
Weight of right rear linkage 22 kg
Weight of left rear linkage 22 kg
Weight of left and right connecting
links
48 kg
Weight of right front linkage 25 kg
Weight of left front linkage 25 kg
Weight of 4 front connecting links 52 kg
P-bar lift arm
17.2 - 4 of 4
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17.3 Quick-change device
The quick-change device can be attached to the lift arm of the machine.
t is designed to facilitate the fast changing of various attachments on the
lift arm.
Design of the quick-change device:
Combined electro-hydraulic design
Electric activation and deactivation by means of a switch
Hydraulic actuation using the LH control lever
For a more detailed description on operation, see the "Operator's manual.
Layout
Main components of the quick-change device:
2 Grease fitting
3 Left locking pin
4 Hydraulic lines
5 Hydraulic cylinder
6 Right locking pin
7 Covering
The quick-change device is also fitted with brackets for holding the work-
ing attachment.
The hydraulic lines 4 lead to the hydraulic cylinder 5 via bulkhead coupl-
ings.
The hydraulic cylinder and the locking pins are fitted in a support profile
and protected against dirt and damage by a covering 7.
Quick-change device
17.3 - 1 of 4
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The hydraulic quick-change device is activated/deactivated with the hy-
draulic quick-change device switch on the side cover (control panel).
The quick-change device is activated using the LH control lever.
The hydraulic cylinder of the quick-change device is supplied with hydrau-
lic oil via hydraulic lines from the working hydraulics pump directly via a
solenoid valve to the quick-change device.
When pressure is applied to the bottom side of the cylinder piston, the
locking pins are extended.
When pressure is applied to the rod side of the cylinder piston, the locking
pins are retracted.
17.3.1 HydrauIic quick-change device for Z-Iift arm
(ID 9657866)
This equipment is optional.
TechnicaI data
Main dimensions
Name VaIue Units
B Width 1170 mm
H Height 830 mm
T Depth 350 mm
Weight 200 kg
Quick-change device
17.3 - 2 of 4
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17.3.2 HydrauIic quick-change device for P-Iift arm
(ID 9658050)
TechnicaI data
Main dimensions
Name VaIue Units
B Width 1170 mm
H Height 830 mm
T Depth 280 mm
Weight 170 kg
Quick-change device
17.3 - 3 of 4
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18 Attachments, accessories
Chapter contents
18 Attachments, accessories 18.0 - 1
18.1 Bucket 18.1 - 1
18.1.1 Bucket (D 9657896) 18.1 - 2
18.1.2 Bucket (D 9608528) 18.1 - 3
18.1.3 Bucket (D 9657894) 18.1 - 4
18.1.4 Bucket (D 9657898) 18.1 - 5
18.2 Forklift 18.2 - 1
18.2.1 Forklift (optional) (D 9607741) 18.2 - 2
18.3 4-in-1 bucket 18.3 - 1
18.3.1 4-in-1 bucket (optional) (D 9607757) 18.3 - 2
18.3.2 4-in-1 bucket (optional) (D 9607758) 18.3 - 3
18.4 Side dump bucket 18.4 - 1
18.4.1 Side dump bucket (optional) (D 9608605) 18.4 - 2
18.4.2 Side dump bucket (optional) (D 9608985) 18.4 - 3
18.5 High dump bucket 18.5 - 1
18.5.1 High dump bucket (optional) (D 9608916) 18.5 - 3
18.0 - 1 of 2
Attachments, accessories Service manual
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18.1 Bucket
The bucket is one of a variety of attachments which can be mounted on
the lift arm.
The bucket is attached directly to the lift arm as a standard feature.
f the optional quick-change device is provided, the bucket is attached to
this.
The following description refers to the bucket with teeth.
Layout
The bottom cutting edge comes in various versions, depending on the
operating conditions.
Design variants include:
Welded tooth holder with plugged on tooth tips.
4-section, reversible cutting blade.
Bucket with teeth
1 Tooth tip
2 Tooth holder
3 Bottom cutting edge
4 Locking pin
The tooth tip 1 is plugged onto the tooth holder 2 and secured with a
traverse locking pin 4.
The tooth holder 2 is welded to the bottom cutting edge 3.
Bucket
18.1 - 1 of 6
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18.1.1 Bucket
(ID 9657896)
TechnicaI data
Main dimensions
Name VaIue Units
B1 - Loading dimension 2148 mm
H - Height 980 mm
L - Length with teeth 1040 mm
L1 - Length without teeth 970 mm
Weight 475 kg
Toothing UN-Z-2000 7 units
Bucket
18.1 - 2 of 6
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18.1.2 Bucket
(ID 9608528)
TechnicaI data
Main dimensions
Name VaIue Units
H - Height 980 mm
Weight 545 kg
Toothing UN-Z-2000 7 units
Bucket
18.1 - 3 of 6
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18.1.3 Bucket
(ID 9657894)
TechnicaI data
Main dimensions
Name VaIue Units
H - Height 980 mm
Weight 580 kg
Toothing UN-Z-2000 7 Units
Bucket
18.1 - 4 of 6
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18.1.4 Bucket
(ID 9657898)
TechnicaI data
Main dimensions
Name VaIue Units
H - Height 1055 mm
Weight 620 kg
Toothing UN-Z-2000 7 Units
Bucket
18.1 - 5 of 6
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18.2 ForkIift
The forklift is one of a variety of attachments which can be mounted on
the lift arm.
The forklift is either attached directly to the lift arms or via the quick-
change device.
The following description refers to the forklift with adjustable prongs.
Layout
The forklift consists of the fork carrier and adjustable fork prongs.
Main components of the forklift
1 Fork carrier 2 Fork prongs
The fork prongs 2 are attached to the fork carrier 1 and are secured
against slipping with the fork lock on the upper fork hook.
Forklift
18.2 - 1 of 2
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18.2.1 ForkIift (optionaI)
(ID 9607741)
TechnicaI data
Main dimensions
Name VaIue Units
Fork carrier prong size FEM
Prong length 1200 mm
L Length (fork carrier + prongs) 1572 mm
K Fork carrier width 1778 mm
H Height (fork carrier + prongs) 974 mm
Weight (fork carrier + prongs) 453 kg
Forklift
18.2 - 2 of 2
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18.3 4-in-1 bucket
The 4-in-1 bucket is one of several attachments which can be mounted to
the lifting arm.
The 4-in-1 bucket is attached to the lift arm via the quick-change device as
standard.
t can be used for pushing, as well as excavating and loading scrap,
gripping awkward objects, for greater dumping heights, as an excavating
bucket, and for depositing earth when opened as well as for grading.
The following description refers to the 4-in-1 bucket with teeth.
Layout
Welded tooth holder with plugged on tooth tips.
Main components of the 4-in-1 bucket
1 Back of the bucket
2 Bucket flap
4 Tooth (or cutting blade)
5 Hydraulic hose connection
6 Quick-release couplings
The tooth tip is plugged onto the tooth holder and secured with a traverse
locking pin.
The tooth holder is welded to the bottom cutting edge.
The 4-in-1 bucket is activated using an additional control lever.
The bucket flap 2 is opened and closed by the hydraulic cylinders 3.
The hydraulic cylinder 3 is supplied with hydraulic oil via hydraulic lines
from the working hydraulics pump via the control block and the quick-
release couplings 6.
When pressure is applied to the rod side of the cylinder piston, the bucket
flap 2 is opened.
bucket flap 2 is closed.
4-in-1 bucket
18.3 - 1 of 4
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18.3.1 4-in-1 bucket (optionaI)
(ID 9607757)
TechnicaI data
Main dimensions
Name VaIue Units
H - Height 1020 mm
Weight 695 kg
Toothing - UN-Z-2000 7 Units
280 bar
4-in-1 bucket
18.3 - 2 of 4
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18.3.2 4-in-1 bucket (optionaI)
(ID 9607758)
TechnicaI data
Main dimensions
Name VaIue Units
H - Height 1020 mm
Weight 750 kg
Toothing - UN-Z-2000 7 Units
280 bar
4-in-1 bucket
18.3 - 3 of 4
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18.4 Side dump bucket
The side dump bucket is one of a variety of attachments which can be
mounted on the lift arm.
The side dump bucket is attached to the lift arm via the quick-change
device as standard.
The side dump bucket allows hydraulically controlled lateral tipping (to the
right) in addition to the normal forward tipping function.
This lateral tipping capability makes the bucket is particularly suited for
tight working areas.
t can be used for bulk materials (such as soil sand), pushing, excavating
and loading bulk materials and grading.
The following description refers to the side dump bucket with a bottom
cutting edge without teeth.
Layout
Main components of the side dump bucket
1 Bucket body
2 Type plate
3 Bucket bearing
4 Connection lines
6 Bucket frame
7 Lock
Bottom cutting edge without teeth
The side dump bucket is controlled using an additional control lever.
The bucket body 1 is tipped in and out laterally by the hydraulic cylinder 5.
The hydraulic cylinder 5 is supplied with hydraulic oil via hydraulic lines
release couplings, as well as the connection lines 4.
bucket body 1 is tipped out to the side.
bucket body 1 is tipped in to the side.
Side dump bucket
18.4 - 1 of 4
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18.4.1 Side dump bucket (optionaI)
(ID 9608605)
TechnicaI data
Main dimensions
Name VaIue Units
H - Height 900 mm
L Length 1150 mm
Weight 800 kg
Tilt out angle to the right 95 degrees
280 bar
Side dump bucket
18.4 - 2 of 4
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18.4.2 Side dump bucket (optionaI)
(ID 9608985)
TechnicaI data
Main dimensions
Name VaIue Units
H - Height 980 mm
L Length 1230 mm
Weight 900 kg
Tilt out angle to the right 95 degrees
280 bar
Side dump bucket
18.4 - 3 of 4
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18.5 High dump bucket
The high dump bucket is one of a variety of attachments which can be
mounted on the lift arm.
The high dump bucket is attached to the lift arm via the quick-change
device as standard.
The high dump bucket is equipped with its own hydraulic circuit for the
high dumping function.
This high dumping function means that the buckets are especially suitable
for work requiring a great dump height, such as loading high-sided wag-
ons.
MateriaI may onIy be tipped out using the hydrauIic circuit of the
high dump bucket.
t can be used for light materials such as wood shavings, sawdust and
cereals.
The following description refers to the high dump bucket with a bottom
cutting edge without teeth.
Layout
Main components of the high dump bucket
1 Bucket carrier
3 Connection lines
4 Grease fitting
5 Bucket body
Bottom cutting edge without teeth
High dump bucket
18.5 - 1 of 0
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The high dump bucket is controlled using an additional control lever.
The bucket body 5 is tipped in and out by the hydraulic cylinders 2.
The hydraulic cylinders 2 are supplied with hydraulic oil via hydraulic lines
release couplings, as well as the connection lines 3.
bucket body 5 is tipped out.
bucket body 5 is tipped in.
High dump bucket
18.5 - 2 of 0
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18.5.1 High dump bucket (optionaI)
(ID 9608916)
TechnicaI data
Main dimensions
Name VaIue Units
B Bucket width 2490 mm
B1 Loading dimension 2420 mm
H Height 1435 mm
L Length with cutting blade 1540 mm
Bucket capacity as per SO 7546 2.5 m
Weight 1300 kg
250 bar
High dump bucket
18.5 - 3 of 0

Wheel Loader Liebherr L 512-L 514 Stereo - Service Manual

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Service Manual

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