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GUfLrRIryg - Liebherr Hydraulic Excavators R 914 C R 924 C Service Manual

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100% found this document useful (1 vote)

3K views876 pages

GUfLrRIryg - Liebherr Hydraulic Excavators R 914 C R 924 C Service Manual

Uploaded by

Евгений

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Service Manual

1 General information

2 Tools

3 Technical data / Maintenance guidelines

4 Engine / Motor

5 Coupling / Splitterbox

6 Hydraulic system

7 Hydraulic components

8 Electrical system

9 Swing gear

10 Swing ring

11 Travel gear

12 Track components

16 Options

17 Cab / Heater / Air conditioning system

18 Central lubrication

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Service Manual

Introduction
This manual contains technical data, design and functional descriptions, as well as service and set
up instructions. The documents include numbers of drawings, functional diagrams, as well as detailed
views of units and assemblies of LIEBHERR hydraulic excavators.
This manual has been created in order to assist the customer support services, but does of course
replace neither proper technical training and qualification of the user nor participation in LIEBHERR
operator training courses.
General basic technical information is not included in this manual. For operating instructions and
information on spare parts, please refer to the separate documentation.
For maintenance and reparation of the machine, follow conscientiously the safety instructions and
warnings.

Symbols used in this manual

In this manual the description of tasks and procedures that are associated with specific dangers are
accompanied by safety instructions mentioning the danger related to described work. The safety
instructions are graded according to the severity of the risk, and are identified with the symbols
«Danger» and «Caution», which have the following significances:
These terms are identified by symbols in the operating instructions and :

Danger!
Warning referring to a danger where there is a high probability of death or serious injury to
operators, unless the prescribed safety measures are taken.

Caution!
Warning relating to dangers that might lead to injury or machine damages, unless the prescribed
safety measures are taken.

The symbol «Note» is destined to attract the attention of the persons having to intervene on the
machine upon observations and comments concerning the procedure to be followed for operating as
well for maintenance or repair works.

Note!
Comments and advices which will, if adhered to, help you to keep your excavator operating, to
insure longlife to your machine and to facilitate certain procedures.

Signification of specific punctuation marks in descriptions

This mark indicates «a requirement that must be fulfilled», before going on with the procedure
below.
This mark identifies «an injunction to perform the mentioned action».
This mark indicates «the normally expected result of a carried out action».

About the contain of this Service Manual

This manual may not be replicated or made available to third parties without the explicit written
consent of LIEBHERR, who retains all rights in this documents.
All rights reserved - Printed in France.

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Service Manual

This manual shall be amended without prior notice to reflect new technical developments and
machine series. LIEBHERR reserves the right to make minor technical amendments to the machines
that might not be reflected in the accompanying documentation.
This manual might be complemented by additional service information sheets issued by LIEBHERR.
This manual has been compiled and published by the Technical Documentation Department of
LIEBHERR-FRANCE SAS 68005 Colmar cedex.
We hope that the information in this documentation, aimed at improving the service of LIEBHERR
excavators, is useful to you.

Structuration of our Service Manuals

In order to make it easy for users to find a specific sheet or information on a certain group, and to file
amended and additional pages, each page is identified as follows:
.

Example
7. = Main Group «Hydraulic com-
Main Group ponents»
12. = Sub Group «Variable Flow
Sub Group Hydraulic Pump - Type LPVD»
14. = Page «Adjustment for
Number of the Page in Sub Group Variable Flow Hydraulic Pump
LPVD»

7. 12. 14
The main groups are listed in the table of contents at the beginning of the book.
The subgroups are listed on a subgroup index, on the first page of each main group section. This
subgroup index also includes the indication of machines modells, types and serial number to which
the subgroup is relevant.

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Service Information

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Tab. 1-1 Lubricating oil specifications

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Fig. 1-1 Temperature-based selection of the SAE class

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Tab. 1-2 Fresh water quality

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Tab. 1-3 Fresh water quality with use of DCA 4*

Tab. 1-4 Permissible mixing ratio (for all seasons)

Fig. 1-2 Temperature-based mixing ratio of water + corrosion inhibitor / antifreeze

agent

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Tab. 1-5 Permissible corrosion inhibitors/antifreeze agent containing silicate from
Liebherr

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Fig. 1-3 Liebherr hydraulic oil, viscosity grade selection based on temperature

Tab. 1-6 Classification of products, engine oils for use as hydraulic oils

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Fig. 1-4 Engine oil for use as hydraulic oil, viscosity grade selection based on
temperature*

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Tab. 1-7

Tab. 1-8 Oil change intervals

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Tab. 1-9

Tab. 1-10 Symbols: Oil sampling depending on operating conditions

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Tab. 1-11

Tab. 1-12 Oil sampling depending on operating conditions

Tab. 1-13

Tab. 1-14 Symbols: Filter change depending on operating conditions

Tab. 1-15

Tab. 1-16 Filter change depending on operating conditions

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Tab. 1-17

Tab. 1-18 Filter change depending on operating conditions

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Tab. 1-19 Lubricating oil specifications

Fig. 1-5 Temperature-based selection of the SAE class

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Fig. 1-6 Operating temperature for Liebherr greases

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Fig. 1 Mate-N-LOK-Stecker und DT-Stecker

Fig. 2 Juniortimer Stecker und JPC-Stecker

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Fig. 1 Messvorrichtung / Measuring tool / Appareil de mesure

Tab. 1 Hub bei grösse / Stroke for size / Course pour la taille

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Fig. 2 Technische Zeichnung / Technical drawing / dessin technique

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Tab. 1 Chart for mounting wrenches (with bores)

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Tab. 2 Chart for mounting wrenches (forked type)

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Tab. 3 Chart for piston nut mounting wrenches

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Tab. 4 Mounting and spreader sleeve chart

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Tab. 5 Piston mounting sleeves

Tab. 6 Piston rod mounting sleeves

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Fig. 1 Wrench socket for slotted nut

Tab. 1 Identification numbers of the wrench sockets

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Fig. 2 Definition of dimensions of the sockets

Fig. 3 All the dimensions are indicated in mm

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Fig. 1 Dimensions of the compression devices

Tab. 1 Compression devices / Identification numbers and dimensions in mm

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Tab. 1 Compression devices / Identification numbers and dimensions in mm

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Fig. 1 Definition of the dimensions of the mounting tool

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Tab. 1 Slipring seals installation tools / Ordering numbers and dimensions in mm

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Service Manual

Group 3: Technical Data /

Maintenance guidelines

Technical data.........................................................................................................................3.10
R 914 C Litronic from serial number 19527

Technical data.........................................................................................................................3.12
R 924 C Litronic from serial number 19846

Control and maintenance chart.............................................................................................3.50

R 914 C Litronic from serial number 19527
R 924 C Litronic from serial number 19846

Lubrication chart ....................................................................................................................3.70

R 914 C from serial number 19527
R 924 C from serial number 19846

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Service Manual Technical data

Group 3: Technical Data /

Maintenance guidelines

3.10: Technical data

R 914 C Litronic from serial number 19527
Types 1062 HDSL 2400 / 1063 HDSL 2250 / 1064 HDSL 2000 / 1065 HDS 2000

1065 HDS 1064 HDSL 1063 HDSL 1062 HDSL

General
2000 2000 2250 2400
Operating weight kg 23730 - 25935
Length without attachment mm 4905 5050
Width mm 2505-2750 2505-2750 2816-3000 2966-3150
Height without attachment mm 3090 3070
Tail radius mm 2790
Ground clearance mm 475 470
Digging force kN 85 - 121
Breakout force kN 142 - 165
Total drawbar max. (at reduced speed and kN 260 264
max. pressure)

1065 HDS 1064 HDSL 1063 HDSL 1062 HDSL

Engine
2000 2000 2250 2400
Type D 934 S A6
Rating at nominal speed per DIN ISO 9249 kW 115 (157 hp)
Nominal speed rpm 1800
Max. torque Nm 760±10 at 1500 RPM
Oil quantity (fulling quantity on oil change l see subgroup 3.70
with filter)
Oil quality / -viscosity and oil change intervall see subgroups 1.50 and 3.50
Fuel tank capacity l 380
Further information see subgroup 4.12

1065 HDS 1064 HDSL 1063 HDSL 1062 HDSL

Hydraulic system
2000 2000 2250 2400
Hydraulic pump type DPVP 108
Design swash plate - axial pump piston
Max. power of the working pumps kW 94
Max. volume cm3 2 x 107,7
Max. flow (Qmax) l/min 2 x 208
Flow at regulation end l/min 150
Min. flow (at Qmin stop) 2 x 12

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1065 HDS 1064 HDSL 1063 HDSL 1062 HDSL

Hydraulic system
2000 2000 2250 2400

Oil quantity (fulling quantity on oil change l see subgroup 3.70

with filter)
Oil quality / -viscosity and oil change intervall see subgroups 1.50 and 3.50
Control valve block type VT5 VW 25/18
5 way rotary connection type DDF 525
Boom cylinder (monoblock) mm 130/85
Ø piston / rod
Boom cylinder (adjustable equipment) mm 160/95
Ø piston / rod
Stick cylinder (standard equipment) mm 140/95
Ø piston / rod
Stick cylinder (laterally adjustable equip- mm 90/50
ment)
Ø piston / rod
Bucket cylinder mm 125/85 - 120/80
Ø piston / rod
Hydraulic pump / servo control type gear pump
Max. flow / servo control l/min 40
Hydraulic pump / fan drive (cooling) type gear pump
Max. flow / fan drive (cooling) l/min 52
Servo circuit / work equipment / swing gear type VG - 5 - 4
transmission
Servo circuit / travel gear transmission type VG - 7 - 1
Further information see group 6
,

1065 HDS 1064 HDSL 1063 HDSL 1062 HDSL

Electrical system
2000 2000 2250 2400
Voltage V 24
Battery capacity Ah / V 2x 135 / 2x 12 (switched in series)
Alternator voltage / max current V/A 28 / 80
Starter power V / kW 24 / 6,6

1065 HDS 1064 HDSL 1063 HDSL 1062 HDSL

Swing gear
2000 2000 2250 2400
Swing gear type SAT 275 / 237
Swing ring type KUD 64 VJ 003-001
Swing motor type HMF 75-02P
Swing speed max. rpm 9,2
Gear oil quantity l see subgroup 3.70
Oil quality / -viscosity and oil change intervals see subgroups 1.50 and 3.50
Swing brake type disc brake (negative)
Further information see group 9

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1065 HDS 1064 HDSL 1063 HDSL 1062 HDSL

Travel gear
2000 2000 2250 2400
Travel gear type FAT 350 P022
Normal speed / high speed km/h 3,2 / 5,3 3,1 / 5,2
Travel motor type FMV 075
Gear oil quantity l 2x2,8
Oil quality / -viscosity and oil change intervals see subgroups 1.50 and 3.50
Travel brake type disc brake (negative)
Further information see group 11

1065 HDS 1064 HDSL 1063 HDSL 1062 HDSL

Track
2000 2000 2250 2400
Track type D6CV B60
Track roller type / D6 KL18c / D6 KL18c /
qutity 2x7 2x8
Carrier roller type / B60 /
qutity 2x2
Track pad width mm 500 / 600 / 700 / 750
Ground pressure kg/cm2 between 0,40 and 0,67
Further information see group 12

1065 HDS 1064 HDSL 1063 HDSL 1062 HDSL

Centralized lubrication
2000 2000 2250 2400
Grease quantity per working hour cm3 18
Grease quantity in the container kg 4/8
Further information see group 18

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Service Manual Technical data

3.12: Technical data

R 924 C Litronic from serial number 19846
Types1066 HDSL 2400 / 1067 HDSL 2250 / 1068 HDSL 2000 / 1069 EW 3400 / 1136 VH-HD /
1174 VH

1066 1067 1068 1069

1136 1174
General HDSL HDSL HDSL EW
VH-HD VH
2400 2250 2000 3400
Operating weight kg 26170 - 28340
Length without attachment mm 5250
Width mm 2966- 2816- 2566- 3966- 2000-2500
3150 3000 2750 4150
Height without attachment mm 3070
Tail radius mm 2940
Ground clearance mm 470
Digging force kN 97 - 139
Breakout force kN 146 - 179
Total drawbar max. (at reduced kN 264
speed and max. pressure)

1066 1067 1068 1069

1136 1174
Engine HDSL HDSL HDSL EW
VH-HD VH
2400 2250 2000 3400
Type D 934 S A6
Rating at nominal speed per DIN ISO kW 130 (177 ch)
9249
Nominal speed rpm 1800
Max. torque Nm 820±10 at 1500 rpm
Oil quantity (fulling quantity on oil l see subgroup 3.70
change with filter)
Oil quality / -viscosity and oil change intervall see subgroups 1.50 and 3.50
Fuel tank capacity l 380
Further information see subgroup 4.12

1066 1067 1068 1069

1136 1174
Hydraulic system HDSL HDSL HDSL EW
VH-HD VH
2400 2250 2000 3400
Hydraulic pump type DPVP 108
Design swash plate - axial pump piston
Max. power of the working pumps kW 109
Max. volume cm3 2 x 107,7
Max. flow (Qmax) l/min 2 x 208
Flow at regulation end l/min 173
Min. flow (at Qmin stop) l/min 2 x 12

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1066 1067 1068 1069

1136 1174
Hydraulic system HDSL HDSL HDSL EW
VH-HD VH
2400 2250 2000 3400
Oil quantity (fulling quantity on oil l see subgroup 3.70
change with filter)
Oil quality / -viscosity and oil change intervall see subgroups 1.50 and 3.50
Control valve block type VT5 VW 25/18
5 way rotary connection type DDF 525
Boom cylinder (monoblock) mm 140/90
Ø piston / rod
Boom cylinder (adjustable equip- mm 160/95
ment)
Ø piston / rod
Stick cylinder at monoblock mm 150/105
Ø piston / rod
Stick cylinder at industrial boom mm 125/85
Ø piston / rod
Stick cylinder at adjustable equip- mm 120/80 - 130/85
ment
Ø piston / rod
Bucket cylinder mm 120/80 - 130/85
Ø piston / rod
Adjustment cylinder at boom adjust- mm 130 / 85
ment
Ø piston / rod
Hydraulic pump / servo control type gear pump
Max. flow / servo control l/min 40
Hydraulic pump / fan drive (cooling) type gear pump
Max. flow / fan drive (cooling) l/min 52
Servo circuit / work equipment / swing type VG - 5 - 4/4 Z11
gear transmission
Servo circuit / travel gear transmis- type VG - 7 - 2
sion
Further information see group 6
,

1066 1067 1068 1069

1136 1174
Electrical system HDSL HDSL HDSL EW
VH-HD VH
2400 2250 2000 3400
Voltage V 24
Battery capacity Ah / V 2x 135 / 2x 12 (branchées en série)
Alternator voltage / max current V/A 28 / 80
Starter power V / kW 24 / 6,6

1066 1067 1068 1069

1136 1174
Swing gear HDSL HDSL HDSL EW
VH-HD VH
2400 2250 2000 3400
Swing gear type SAT 275 / 238

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1066 1067 1068 1069

1136 1174
Swing gear HDSL HDSL HDSL EW
VH-HD VH
2400 2250 2000 3400
Swing ring type KUD 64 VJ 003-001
Swing motor type HMF 75-02P
Swing speed max. rpm 8,1
Gear oil quantity l see subgroup 3.70
Oil quality / -viscosity and oil change intervals see subgroups 1.50 and 3.50
Swing brake type disc brake (negative)
Further information see group 9

1066 1067 1068 1069

1136 1174
Travel gear HDSL HDSL HDSL EW
VH-HD VH
2400 2250 2000 3400
Travel gear type FAT 350 P003 FAT FAT 350 P003
400
P063
Normal speed / high speed km/h 3,2 / 5,4
Travel motor type FMV 075 FMV FMV 075
100
Gear oil quantity l see subgroup 3.70
Oil quality / -viscosity and oil change intervals see subgroups 1.50 and 3.50
Travel brake type disc brake (negative)
Further information see group 11

1066 1067 1068 1069

1136 1174
Track HDSL HDSL HDSL EW
VH-HD VH
2400 2250 2000 3400
Track type B60
Track roller type / D6 / B60 / D6 /
qutity 2x9 2x9 2x9
Carrier roller type / B60 /
qutity 2x2
Track pad width mm 500 / 600 / 700 / 750
Ground pressure kg/cm2 between 0,44 and 0,67
Further information see group 12

1066 1067 1068 1069

1136 1174
Centralized lubrication HDSL HDSL HDSL EW
VH-HD VH
2400 2250 2000 3400
Grease quantity per working hour cm3 18
Grease quantity in the container kg 4/8
Further information voir groupe 18

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Service Manual Control and maintenance chart

3.50: Control and maintenance chart

R 914 C Litronic from serial number 19527
R 924 C Litronic from serial number 19846

Maintenance /
WORK TO BE CARRIED OUT
inspection at
R 914 C / R 924 C
operating hours

By maintenance personnel By authorized specialist personnel Note

(machine owner)
First and only interval
Repeat interval First and only interval
Special interval every 250 hours Repeat interval

DIESEL ENGINE AND SPLITTERBOX

Check oil level in engine

Check oil pressure and coolant temperature during operation

Check air filter on maintenance display

Check and drain water separator on fuel filter (or when the corresponding
symbol appears on the display)

If mounted, drain regularly the water in the water separator of the particles filter
system

Check coolant level

Drain off water and sediment at fuel tank

Empty dust discharge valve on air filter (shorten or extend interval as required)

Check oil level in splitterbox

Check and clean cooler and ventilator

Check condition of belt for A/C compressor and alternator installation

Replace lubricating oil filter cartridge (at least 1 x yearly)

Replace engine oil (at least 1 x yearly) 1)

Replace splitterbox oil

Check oil, cooling and fuel system for leaks and condition

Check anti-corrosion fluid / antifreeze in coolant, if necessary rectify the

mixture concentration

Check electronic control unit mounting

Check sensor and cable connections for sound condition

If mounted, carry out the maintenance of the diesel particulate filter LIEBHERR

If mounted, carry out the maintenance of the diesel particulate filter Engelhard

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Control and maintenance chart Service Manual

Maintenance /
WORK TO BE CARRIED OUT
inspection at
R 914 C / R 924 C
operating hours

By maintenance personnel By authorized specialist personnel Note

(machine owner)
First and only interval
Repeat interval First and only interval
Special interval every 250 hours Repeat interval

Check intake and emission system for leaks and condition (first time at 500 op.
hours)

Check the exhaust return shut-off flap

Check / adjust valve clearance

Check engine console, oil sump and splitterbox mounts

Replace fuel fine filter cartridge (or if powerloss) 2)

Replace fuel preliminary filter cartridge (or if powerloss) 2)

Replace oil separator fliter

Check heat flange (before start of winter)

Replace air filter main element (according to maintenance display / at least
annually)

Replace air filter safety element (every third change of main element / at least Never
annually) clean!

Check air hoses between air filter and engine (at filter maintenance)

Replace coolant (every 2 years or every 3000 hours) (only for authorized
specialist personnel)

Replace OS coolant (every 4 years or every 6000 hours) (only for authorized
specialist personnel)

Check vibration damper for distortion (every 3000 op. hours)

HYDRAULIC SYSTEM

Check oil level in hydraulic tank

Clean magnetic bar in return-line filter (daily during first 300 op. hours)

Replace filter unit on control oil unit

Check unit mounts

Check and clean hydraulic oil cooler and ventilator 2)

Drain off water in hydraulic tank

(when using environmentally acceptable fluids, max. 0.1 % water proportion
permissible, insert partial flow filter, take oil sample)

If mounted check return filter for hydraulic hammer for cleanliness, replace
element if necessary

Replace filter unit in return-line filter (first time at 500 op. hours) 2)

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Maintenance /
WORK TO BE CARRIED OUT
inspection at
R 914 C / R 924 C
operating hours

By maintenance personnel By authorized specialist personnel Note

(machine owner)
First and only interval
Repeat interval First and only interval
Special interval every 250 hours Repeat interval

Clean or replace filter unit of leak oil filter (first time at 500 op. hours) 2)
Replacement necessary after max. 3 cleanings

Check the degree of contamination of the bypass oil filter (optional equipment);
if required, change the filter cartridge.

Check hydraulic system for leaks and function

Check / adjust servo, primary and secondary pressures

If required, change the oil in the hydraulic system (to be carried out by
specialist technical personnel; add oil through filter). For oil grades and change
intervals, see fuels and lubricants, "Hydraulic oil".

Bleed hydraulic pumps (when replacing oil)

Replace ventilation and vent filters on hydraulic tank 2)

ELECTRICAL SYSTEM

Check indicator lights and display devices

Check lighting

Check acid concentration and level on batteries

Check cable terminals and pole ends on batteries

Check the central vent tubes of the batteries for proper installation and
damage.

Spray slip rings on swing connection (if present) with Cramolin contact spray

Check function of entire system and units

SWING GEAR TRANSMISSION

Check oil level and tightness

Replace oil (first time at 500 op. hours)

Check function and operation of slewing gear brake

Check swing gear transmission and hydraulic motor mounts

BALL SWING RING

Check mounting screws for correct positioning

Check pinion gear mesh

TRAVEL GEAR

Check oil level and tightness

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Control and maintenance chart Service Manual

Maintenance /
WORK TO BE CARRIED OUT
inspection at
R 914 C / R 924 C
operating hours

By maintenance personnel By authorized specialist personnel Note

(machine owner)
First and only interval
Repeat interval First and only interval
Special interval every 250 hours Repeat interval

Check travel gear transmission and hydraulic motor mounts

Replace oil (at least every 2 years). Replace oil every 1000 op. hours with dust
intensive application or a travelling proportion greater than 20%.

TRACKS

Visual check on track tension, retension if necessary

Clean track (when work is finished)

Check mounts on track pads and sprockets

Clean and grease sliding surfaces of tensioning device

Check for leaks on idlers, carrier rollers and track rollers

CAB + HEATING

Check / refill washing fluid in windscreen washer system container

Check heating function (before start of winter)

Check heating system for leaks

Check door and window hinges and locks

Check water inlet valve for function and dirt, clean if necessary

AIR-CONDITIONING SYSTEM

Switch on air-conditioning system regularly (at least 1 x every 14 days)

Check capacitor for contamination, blow out if required

Clean recirculated / fresh air filter, replace if required, shorten maintenance

interval for heavy dust use

Check mounting screws and compressor drive belt

Check dryer-collector unit (moisture, fill and condition), replace if required

Check evaporator unit, clean if required

Check electrical lines for abrasions and plug connections for correct
positioning

Check overpressure switch for function

Check refrigerating capacity after opening or repair, or as required

Replace dryer-collector unit annually, check coolant circuit for leaks and
replace refrigerant and refrigerant oil

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Service Manual Control and maintenance chart

Maintenance /
WORK TO BE CARRIED OUT
inspection at
R 914 C / R 924 C
operating hours

By maintenance personnel By authorized specialist personnel Note

(machine owner)
First and only interval
Repeat interval First and only interval
Special interval every 250 hours Repeat interval

Have function of ventilation flaps and defrost thermostat checked annually by

a refrigeration engineer

UNDERCARRIAGE + UPPERCARRIAGE + ATTACHMENT

Grease bearing points via centralised lubrication system (using button into the
cab for semi automatic systems or no handling for fully automatic systems).

Grease bearing points by hand if they are not connected to the centralised
lubrication system (if required on bucket, specials undercarriages and
attachments).

Visually check wear condition of teeth

Check parts for cracks

Check ballast weight and tanks mounts

Check line and screw connections for correct positioning

Check trim panel hinges, quick-release fasteners and gas pressure springs of
hatches. Lubricate or change the components if necessary.

Check the lowering speed of the attachment ~4 sec.

Indicate appropriate use of attachment

Have device lubricated according to lubrication chart by device operator and

indicate any operating errors.

HYDRAULIC QUICK-CHANGE ADAPTER

Check function of visual and acoustic warning devices

Visually check drawn out position of locking pins

Check condition of hydraulic hoses and of cable kit

Lubricate locking pins

Clean sieve filter in bolt connections of hydraulic hoses

MECHANICAL QUICK-CHANGE ADAPTER

Visually check drawn out position of locking pins

Lubricate locking pins

Tab. 1 Control and maintenance chart

1 Engine oil change intervals can be shortened dependent on temperature, fuel and oil quality.
2 Shorten the maintenance interval depending on conditions of use (eg. heavy dust use, barrel refuelling).

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Service Manual Lubrication chart

3.70: Lubrication chart

R 914 C from serial number 19527
R 924 C from serial number 19846

Fig. 1 Lubrication chart

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Lubrication chart Service Manual

Symbol Description

For oil change intervals and recommended lubri-

cants, observe the relevant instructions in Group 1 :
General Information.

Medium filling point

Slewing gear mechanism

Travel gear mechanism

Pump distributor gear

Gearbox or axle, check oil level

Diesel engine, check oil level

Hydraulic tank, check oil level

Lubrication point

Lubricate machine

Perform semi-automatic lubrication cycle

Tab. 1 Key to lubrication chart

Designation Symbol Volume [litre]*

Diesel engine 29

Hydraulic system 445 / 284

(system capacity / oil change volume)

Slewing gear mechanism 6,6

Travel gear mechanism 2x3

Pump distributor gear 1,9

Tab. 2 Lubricant quantities

* = guide values

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Group 4: Engine / Motor

Technical data for LIEBHERR Engine Type: D 934 S A6 ....................................................4.10

R 914 C from serial number 19 527
R 924 C from serial number 19 846

Installation and check list for Diesel particle filter..............................................................4.26

1 Installation certificate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.26.1
2 Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.26.2

Liebherr Diesel particle filter (accessory kit).......................................................................4.27

1 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.27.1
2 Design of the accessory kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.27.2
2.1 Particle filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.27.2
2.2 Backpressure monitoring system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.27.3
2.3 Monitoring elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.27.3
3 Function of the Diesel particle filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.27.5
3.1 Particle filtering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.27.5
4 Monitoring and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.27.5
4.1 Indicating and control unit A175 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.27.5
4.2 Reading data from data logger / data logger software update . . . . . . . . . . . . . . . . . . . . . . . . . 4.27.9
4.3 Regeneration of the built-in particle filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.27.9
4.4 Cleaning particle filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.27.9
5 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.27.10
5.1 Maintenance of the particle filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.27.10
5.2 Maintenance of filter (condensate trap) 100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.27.12
6 Retrofitting of particle filter accessory kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.27.13
6.1 Important instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.27.13
6.2 Preconditions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.27.13
6.3 Installation of the particle filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.27.14
6.4 Testing of data logger / limit test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.27.14

Datalogger...............................................................................................................................4.40
1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.40.1
1.1 System requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.40.1
1.2 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.40.2
1.3 Login . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.40.3
1.4 Datalogger LHDL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.40.4
2 Datalogger / General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.40.5
3 Datalogger / installation test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.40.6
4 Datalogger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.40.8
4.1 Error memory. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.40.8
4.2 Pressure exceedings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.40.8
5 Datalogger / "Settings" menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.40.18
6 Datalogger / "Service" menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.40.23
7 Datalogger / "Softwareupdate" menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.40.24
8 Error statuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.40.29

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Service Manual Technical data for LIEBHERR Engine Type: D 934 S

Group 4: Engine / Motor

4.10: Technical data for LIEBHERR Engine Type: D 934 S

A6
R 914 C from serial number 19 527
R 924 C from serial number 19 846

Models / from serial nulbers

Power and torques

R 914 C-Li / 19 527 R 924 C-Li / 19 846

Power rating per DIN / ISO 9249 kW (HP) 115 (157) 130 (177)
Maximal torque (for engine RPM) N.m (U/ 735 (1500) 820 (1500)
min)

General data R 914 C-Li / 19 527 R 924 C-Li / 19 846

Constructive type 4 cylinders Inline-Engine, turbocharged
Working principle 4 stroke - direct fuel injection
Bore mm 122
Stroke mm 136

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Technical data for LIEBHERR Engine Type: D 934 S Service Manual

General data R 914 C-Li / 19 527 R 924 C-Li / 19 846

Displacement l 6,36
Firing order 1-3-4-2
Compression ratio 17,0 : 1
Compression pressure at starting RPM bar 20 - 34
Weight of engine (dry) kg 840
Direction of rotation (when facing flywheel) left (counterclockwise)
Flywheel housing SAE 2
Cooling system Coolant circulation

RPM range R 914 C-Li / 19 527 R 924 C-Li / 19 846

Nominal engine speed min-1 1800
High idle speed min-1 1910 ±30
Low idle speed min-1 900 ±30
Nb of teeth of toothed flywheel ring (for RPM sensor) 147
119 (120-1)

Adjustment values R 914 C-Li / 19 527 R 924 C-Li / 19 846

Intake valves clearance - cold mm 0,30
Exhaust valves clearance - cold mm 0,40
Begin of delivery (injection timing) °cranksh electronical regulated
Adjustment of RPM range electronical regulated

Capacities (indicative values) R 914 C-Li / 19 527 R 924 C-Li / 19 846

Lube oil pan capacity l 29,0
Coolant capacity (oil cooler included) l 32

Operating values R 914 C-Li / 19 527 R 924 C-Li / 19 846

Coolant temperature °C 79 up to max. 100
Thermostat range - begin of opening °C / °C 79 / 92
MInimal pressure in cooling system bar 0,6
Lube oil temperature °C maxi. 115
Minimum oil pressure °C à 800 min-1 1,5 bar (oil temperature 90 °C)
à 400 min-1 2,5 bar (oil temperature 90 °C)
à 1800 min-1 4,6 - 6,2 bar (oil temperature
90°C)
Heat rejection to coolant kW 64 70
Flow of coolant pump l / min 300
3
Intake air flow m / min 9,1 9,7
Exhaust gas flow m3 / min 19,7 22,1
Maxi. allowed engine inclination to right or left 45 °
Maxi. allowed engine inclination to front or rear 45 °

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Service Manual Technical data for LIEBHERR Engine Type: D 934 S

Note!
You will find all other information and values necessary for adjustments, maintenance and repair
works in the «Workshop manual - Diesel engine D 934 S A6».

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Service Manual Installation and check list for Diesel particle filter
Installation certificate

4.26: Installation and check list for Diesel particle filter

Necessary condition for the waranty:

– The Installation and check list must be completed, signed, and returned.
– The prescribed maintenance intervals of the assembly must be adhered to (refer to "Mainte-
nance" in subgroup 4.27).
– The Diesel engine must be operated with an approved Diesel fuel conforming to the fuel speci-
fications according to DIN EN 590, ASTM D 975 D1 and D2 without dye (heating oil).

1 Installation certificate
Vehicle / Diesel engine
Machine:
(Type)
Vehicle identification number:
PIN e.g. WLHZ 10400 ZK 325051 (17 digits)
Diesel engine model:
(B: Model, see below)
Diesel engine serial No.:
(A: Engine number, see below)
Diesel engine operating hours:
(on display)

Particle filter
Ident. no. (C) Serial no. (D):
Kit no.:
Input element 10
Center element 30 / filter
Data logger

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Installation and check list for Diesel particle filter Service Manual
Checks

2 Checks

Test point Actual View

Checks
Specified value value Comment

1. Checking of the engine (prior to installation of filter)

1.1 Air filter * clean ...............

1.2 Exhaust gas turbocharger * airtight ...............

1.3 Oil feed line to the Diesel engine Liebherr -Motoroil ...............
10 W 40 low ash

1.4 Gasoil for Diesel engine Gasoil respon-

ding to:
DIN EN 590
ASTM D 975 D1
ASTM D 975 D2

1.5 Diesel engine injection * and no blue fumes ...............

combustion OK

* only to be checked if built in subsequently

2. Testing of the warning system

While the Diesel engine is off, dis- Check-LED A Disconnecting point V for the test-
connect the backpressure line L Display D ing limit values.
from connecting point V of the
data logger A133.
Connect the hand pump (tool list
group 2.01) using the auxiliary
hose to connecting point V and
pressurise the system with the
hand pump to the limit value.

Caution!
Do not pressurise pressure sen-
sors with more than 0.8 bar!

Ignore error message "Wire

break terminal W" and confirm
with OK.

To determinate the position of data logger A133, see the spare parts catalog gived with the particle filter.

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Service Manual Installation and check list for Diesel particle filter
Checks

Test point Actual View

Checks
Specified value value Comment

2.1 Lead pressure Indicating and control unit A175

Check red LED A ("Druck/pres- Except R944C

sure") lights up on display A175 Tunnel: ...............
approximately 60 seconds after P > 160 mbar
pressure P build-up. P < 180 mbar

R944C Tunnel
only:
P > 180 mbar
P < 200 mbar

2.2 Main pressure / limit load

Check red LED A ("Druck/pres- Except R944C

sure") lights up on display A175 Tunnel: ...............
and buzzer signal starts simulta- P > 180 mbar
neously approximately 60 sec-
onds after pressure P build-up R944C Tunnel
only:
After test is completed, discon- P > 200 mbar
nect the hand pump and recon-
nect the backpressure line L to
data logger.

2.3 Temperature sensor check

Check cables from the plug con- Plug X1315B

nection/data logger A133 to the shoud be con-
temperature sensors B306/B346. nected to sensor
...............
Correct installation if necessary. B306 (filter input).

Plug X1316B
should be con-
nected to sensor
B346 (filter out-
put).

2.4 Engine RPM indicator check

Run the engine at maximum RPM < 100 rpm

(1950 rpm).
Check the difference between en- ...............
gine RPM indicated by A175 dis-
play and engine RPM indicated
by machine’s display does not ex-
ceed 100 rpm.

3. Testing of the recording function

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Installation and check list for Diesel particle filter Service Manual
Checks

Test point Actual View

Checks
Specified value value Comment

3.1 Menu switchover

After the engine is started, the ok? yes / no

display of A175 must switch with-
out error message from the ...............
"Ready for operation" menu to
the "Measurement (pressure,
speed or temperature)" menu.

3.2 Display of actual backpressure in the filter

Apply a load on the Diesel engine

by fully pressurising the hydraulic
system for 5 minutes (full load
simulation) until recommended
conditions are reached:
– Full load engine rpm: 1800 tr/
min ;
– Engine coolant at normal ope-
rating temperature.

When recommended conditions Except R944C ...............

are reached, check backpressure Tunnel:
P indicated on A175 display does P < 120 mbar
not exceed the maximum value.
R944C Tunnel
only:
P < 140 mbar

4. Leakage test

4.1 Exhaust gas system airtightness

Yes / No
Check for traces of soot at con-
nections A in the exhaust gas
system.
If there are clear signs of leakage,
check the system for loose con- ...............
nections. Visual inspection

Check for traces of soot in the

end pipe B. ...............
If there are traces of soot in the
end pipe B, check the filter and
replace it if necessary.

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Service Manual Installation and check list for Diesel particle filter
Checks

Danger!
There is a risk of injury from burns when working on the hot and / or running engine.
When checking the engine, always wear protective gloves and suitable protective clothing.
Always inform operating personnel of the potential risks and the danger area associated with the
inspection work.
When working around the engine, always make sure the engine cannot be started.

Type: Serial No.: Operating hours:

Date: Mechanic: Client:

Date: Checked for completeness by the Service Center:

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Installation and check list for Diesel particle filter Service Manual
Checks

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Service Manual Liebherr Diesel particle filter (accessory kit)
Function

4.27: Liebherr Diesel particle filter (accessory kit)

1 Function
The Diesel particle filter can be installed in Liebherr hydraulic excavators as an exhaust gas cleaning
system for the Diesel engine.
The particle filterparticle filter accessory kit consists of the following main components:
– Particle filter 10
– Condensate trap with sintered metal filter 100
– Data logger A133
– Indicating and control unit A175

Fig. 1 Main components of the particle filter accessory kit

10 Particle filter 100 Condensate trap / filter

A133 Data logger A175 Indicating / control unit

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Liebherr Diesel particle filter (accessory kit) Service Manual
Design of the accessory kit

Note!
Component location may differ depending on the machine. Refer to spare part list provided with par-
ticle filter to locate components.

2 Design of the accessory kit

2.1 Particle filter

The particle filter is installed in the exhaust line of the Diesel engine at the location of the silencer
(except for R944C Tunnel).
The particle filter is made of stainless steel, fully insulated and noise optimised. It consists of the fol-
lowing main components:
– Input module 15 adjusted to suit the model, with radial / axial input (depending on machine type).
– Output module 20 adjusted to suit the model, with radial / axial output (depending on machine
type).
– Filter module 30 with integrated particle filter.
– Centring rings 50 / 60 with seal rings 65.
– Connecting clamps 70.

Fig. 2 Particle filter design

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Service Manual Liebherr Diesel particle filter (accessory kit)
Design of the accessory kit

15 Input module 20 Output module

30 Filter module 31 Silencer / muffler
32 Filter module (filled) for cleaning 33 Tranport cover
34 Form (supplied with filter) 50 Centring ring, output
60 Centring ring, input 65 Seal rings
66 Spray adhesive 70 Connecting clamp

2.2 Backpressure monitoring system

The backpressure monitoring system includes a backpressure line from the particle filter to the data
logger. As this line is exposed to great temperature differences during operation (especially during
the cold season), a condensate that might contain soot particles collects in the line.
These particles are held back by the filter 100 and must be removed at prescribed intervals.
Regularly drain off condensate (see “Maintenance of filter (condensate trap) 100” on page 12).

Fig. 3 Condensate trap for exhaust backpressure to the monitoring element

100 Filter, complete 103 Sintered metal filter with holder

201 Tank with seal ring (with drain valve) 204 Tank with seal ring (without drain valve)

2.3 Monitoring elements

To monitor the state of the particle filter, a number of parameter values are recorded and stored by
the data logger A133. The data logger A133 forwards the recorded values to the indicating and con-
trol unit A175 where they are shown on the display. If a limit value is exceeded, the machine operator
is notified with a visual and acoustic warning signal.
The following parameter values are recorded and displayed:
– Temperatures at the input and output of the particle filter 10, measured by temperature sensors
B306 / B346.
– Exhaust gas backpressure at the input of the particle filter 10, measured by the pressure line with
sintered metal filter 100.
– Diesel engine speed, measured through terminal W on the alternator.
The measured values can be transferred to a PC/laptop for further processing (see 4.2 on page9).
Depending on the state and operating hours of the engine, the particle filter will sooner or later be
contaminated with particles formed in the channels and burnt-off particles from the oil ash.

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Liebherr Diesel particle filter (accessory kit) Service Manual
Design of the accessory kit

To check the contamination of the particle filter, the system measures the backpressure in front of
the filter. The greater the contamination, the higher the backpressure. From a certain limit value (de-
termined by machine model), the red warning LED A (Druck/Pressure) at the indicating and control
unit A175 lights on. It indicates to the machine operator that the filter’s absorption capacity has been
reached.
The particle filter is regenerated by increasing the exhaust gas temperature. This can be done by the
machine operator. At a temperature of 250°C or higher in the filter, the collected soot particles are
incinerated. Subsequently, the machine can be operated in normal mode until the red warning LED
lights on or until next scheduled maintenance (see “Regeneration of the built-in particle filter” on
page 9).
If the above measure does not result in a reduced exhaust backpressure, check the system and clean
the filter module if necessary (see 5.1.4).
When the red warning LED A is on and the buzzer sounds (indicating a system error or a limit load
of the filter module), check the system and clean the filter module if necessary (see “Cleaning particle
filter” on page 9).

Fig. 4 Monitoring elements

10 Particle filter 100 Sintered metal filter

A133 Data logger A175 Indicating and control unit
B306 Temperatur sensor - input B346 Temperatur sensor - output

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Service Manual Liebherr Diesel particle filter (accessory kit)
Function of the Diesel particle filter

X1313 Interface to data logger X1315 Plug connection

X1316 Plug connection

3 Function of the Diesel particle filter

3.1 Particle filtering

The exhaust gas cleaning system reduces the Diesel particle load (PM) and the concentration of gas-
eous pollutants (CO and HC). The particles are held back in the monolith where they accumulate.
The particles are removed from the exhaust gas when it is fed through the porous channnel walls of
the monolith. The inlet channels are sealed at the other end. This means that the exhaust gas must
escape through the coated channel walls. The large number of channels results in an extremely large
filter surface and thus a high retention capacity for soot particles.

Fig. 5 Principle of the particle filter

1 Raw gas entering the filter 2 Channel wall

3 Channel seal 4 Cleaned exhaust gas exiting the filter

4 Monitoring and operation

4.1 Indicating and control unit A175

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Liebherr Diesel particle filter (accessory kit) Service Manual
Monitoring and operation

Fig. 6 Indicating and control unit

A175 Indicating and control unit A Red warning LED ("Druck/pressure")

B Yellow error LED ("System Error") C Green operating mode LED ("Power")
D Display E Confirmation button ("OK")
F Menu button (DOWN) G Menu button (UP)

4.1.1 Display at indicating and control unit A175

After starting the ignition, the following messages are displayed on the screen: "LIEBHERR Particle
Filter" and "Data Logger Ready". After the Diesel engine has been started, the display shows the last
used menu.
The system includes seven menus. Depending on the selected menu, the display shows different
operating data (see Tab. 1).
To change menu, press the UP and DOWN buttons.
Press and hold the button UP or DOWN for approximately 2 seconds.
The display changes to the next menu.

No. Menu Navigation

1 Temperature 2:
Pressure:

2 Temperature 1:
Pressure:

3 Pressure
¦¦¦¦¦¦¦¦¦¦¦¦¦¦¦¦¦¦¦¦¦

4 Temperature 1:
Temperature 2:

5 Speed:
Pressure:

6 Temperature 2:
Pressure:

7 Temperature 1:
Pressure:

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Service Manual Liebherr Diesel particle filter (accessory kit)
Monitoring and operation

No. Menu Navigation

1 - 7 = menus
Description of menu texts:
Temperature 1 = temperature of exhaust gas entering particle filter (engine side)
Temperature 2 = temperature of exhaust gas exiting particle filter (exhaust side)
Pressure = exhaust backpressure
Speed = engine speed
¦¦¦¦¦¦¦¦¦¦¦¦¦¦¦¦¦ = bar display indicating exhaust backpressure

Tab. 1 Display during normal operation, available menus

Country-specific settings
The language of the display texts can be selected by the operator. The temperature is indicated in
degrees Celsius or degrees Fahrenheit (see Fig. 7).
Simultaneously press and hold the buttons UP and DOWN for approximately 4 seconds.
The "Sprache" (language) menu is displayed.
Press the button UP or DOWN until the desired language is shown.
Press the button OK.
The "Temperature" menu is displayed.
Press the button UP or DOWN to select the desired unit for temperatures (C or F).
Press the button OK.
The normal operation screen is displayed.

Fig. 7 Display, country-specific settings

1 - 7 = menus

4.1.2 Indication at the display and indicator lights, troubleshooting

The indicating and control unit monitors the particle filter function and indicates if there are any mal-
functions or if the operating conditions are not suitable for the filter. It also indicates whether the par-
ticle filter must be inspected (routine inspection). Some of the texts are accompanied by a buzzer or
LED signal. The text remains displayed until the cause of the problem is eliminated.
The operator can switch off the buzzer signal manually.

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Liebherr Diesel particle filter (accessory kit) Service Manual
Monitoring and operation

Press and hold the button OK for approximately 1 second.

The buzzer is switched off.
The fault/warning message remains displayed.

Display message/indicator LED Description Remedy

Inspection due - The operating hour counter has rea- Carry out service/clean filter.
ched the value of the next service ti- After completion of the service, preset the
me. subsequent interval in the "Service" menu, in
group "Data logger".

Thermocouple 1 (or 2) defective yellow (B) Temperature sensor defective or Press the OK button to deactivate warning
malfunctioning. buzzer sound.
Check temperature sensors B306/B346, re-
connect or replace.

ERROR idle run / temp. yellow (B) Prolonged operation at insufficiently Press the OK button to deactivate warning
high exhaust gas temperature/at idle buzzer sound.
speed. There is a risk that the ex- Increase machine / motor load (full-load ope-
haust gas backpressure might incre- ration).
ase above the set limit. Operate machine at a higher speed.

Lead pressure reached red (A) The particle filter is blocked. The Regenerate particle filter: operate machine at
backpressure is above the limit value full load until the pressure begins to drop.
and is likely to rise further. If there is no pressure drop: shut down ma-
Risk of damage to the Diesel engine. chine, dismantle filter and have it cleaned.

Main charging pressure reached red (B) (flas- The particle filter is very dirty and the Switch off the machine.
This signal is accompanied by a war- hing) exhaust backpressure is too high. Clean the filter (see 5.1.4).
ning buzzer sound. Risk of damage to the Diesel engine.

Filter defective or pressure line All LEDs Particle filter defective, pressure line Switch off the machine.
blocked flashing blocked or leak in pressure line and Check particle filter and pressure line/ex-
This signal is accompanied by a war- exhaust gas system. haust gas system. If necessary, check pres-
ning buzzer sound. sure sensor with hand pump from service
case.
Replace filter module or eliminate blockage/
leak in pressure line/exhaust gas system.

Pressure offset yellow The system can only measure the Press the OK button to deactivate warning
exhaust gas pressure (no engine buzzer sound.
speed and charge voltage values). Check data logger settings.
Check whether speed monitoring is activa-
ted.
Check ignition voltage threshold.

ERROR pressure & charge voltage yellow No measurements for exhaust gas Press the OK button to deactivate warning
pressure and charge voltage. buzzer sound.
Check backpressure from the particle filter to
the data logger. Check data logger settings. If
required, check the pressure sensor using
the hand pump from the service case.

ERROR charge voltage yellow No measurement for charge voltage. Check ignition voltage threshold.

ERROR voltage threshold yellow The system can only measure the Press the OK button to deactivate warning
charge voltage (no exhaust gas pres- buzzer sound.
sure and engine speed values). Check backpressure line from particle filter to
data logger. Check electrical connections
from the generator (terminal W).

Defect/wire break at Terminal W yellow No measurement of engine speed. Press the OK button to deactivate warning
Incorrect engine/generator transmis- buzzer sound.
sion ratio. Check electrical connections of the generator
(terminal W). Restore default settings.

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Monitoring and operation

4.2 Reading data from data logger / data logger software update
The measured values stored in the data logger can be transferred to a PC or laptop. To read the data,
export the data with the "Datalogger LHDL" program to a PC or laptop. To update the data logger
software, complete a software update.
To transfer the data, use a communication cable (ID no. 9067426).
For a description of the firmware/software of the data logger A133 and its operation, see group 4.40.

4.3 Regeneration of the built-in particle filter

The particle filter works best if the exhaust gas temperature is above 250°C for at least 50% of the
operating time. Under these conditions, it regenerates itself.
If the minimum exhaust gas temperature cannot be reached during the machine operating time, the
permissible exhaust gas backpressure / lead pressure will be reached at some point (warning LED A
at the control unit A175 is on). If this is the case, the filter 30 must be regenerated. During the regen-
eration process, the deposits in the particle filter are pyro-cleaned at a high exhaust gas temperature.
Operate the attachment (possibly with load) so that the hydraulic unit is fully pressurised and the Die-
sel engine is operating at maximum load.
If the exhaust gas backpressure fails to drop, switch off the Diesel engine, wait for approximately 30
minutes and repeat the above regeneration procedure. If this does not lead to the desired result, allow
the system to cool down, dismantle the filter module 30 and return it for cleaning to an authorised
workshop (customer service / supplier). For details, refer to Service Information 04-32-06/10.

Caution!
If the exhaust gas backpressure fails to drop during the regeneration process and actually increas-
es, the filter module 30 is heavily contaminated. Repeated unsucessful regeneration attempts can
cause damage to the particle filter and the Diesel engine.
Immediately abort regeneration if the exhaust gas backpressure exceeds 250 mbar.
Allow the particle filter to cool down, dismantle it and clean the filter (see 4.4).

4.4 Cleaning particle filter

If
- the particle filter has been operated for the maximum maintenance interval time (2000 operating
hours)
- the main lead pressure is reached (exhaust gas backpressure does not drop any further)
- the exhaust gas backpressure during regeneration in the machine reaches over 250 mbar
the filter module 30 must be immediately removed from the machine and sent to an authorised LIE-
BHERR service workshop for cleaning. During cleaning, the particles in the filter cartridges are incin-
erated and the ash residue is subsequently removed from the filter.
For this, the filter module 30 must be dismantled as described (see 5.1.2). After the filter module 30
has been dismantled, it must be sealed immediately on both sides with transport covers 33 (see Fig.
2) (matching filter size = 7.5’’ - 15’’). The filter module 30 must be carefully packed for protection from
impacts. The filter module 30 must be accompanied by a cover letter. For details, see Service Infor-
mation 04-32-06/10.

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Liebherr Diesel particle filter (accessory kit) Service Manual
Maintenance

5 Maintenance

Note!
The particle filter may only be used in conjunction with Diesel engines filled with Liebherr Motoroil
10W40 low ash engine oil.
If other oil products are used, the particle filter might quickly become clogged up with oil ash (making
shorter cleaning intervals - every 1000 operating hours - necessary).
The Diesel engine must be operated with an approved Diesel fuel conforming to the fuel specifica-
tions according to DIN EN 590, ASTM D 975 D1 and D2 without dye (heating oil).

5.1 Maintenance of the particle filter

As a rule, the filter element 30 must be cleaned at least every 2000 operating hours. In this case,
the preliminary filter in the input module 15 must also be cleaned.

Caution!
Do not touch the particle filter when it is hot, as this can cause serious injury from burns.
Do not inhale the ash residue in the filter as it can cause damage to the respiratory system.
Fine particles can cause damage to the eyes.
Let the filter cool down.
Always wear protective gloves.
When cleaning the filter, always wear face mask and protective goggles.

5.1.1 Checking connecting clamps

The connecting clamps 70 hold together the 3 main elements of the particle filter. If the clamps 70
are released, the exhaust gas system is no longer air-tight, so that the filter cannot work properly and
the indicated values and statuses are inaccurate.
To ensure tightness, the screws of the clamps 70 must be retightened every 500 operating hours
with the correct tightening torque (12 N.m.).

5.1.2 Dismantling of filter and input module for cleaning

After the filter 10 has cooled down, release the clamps 70.
Slide the clamps 70 onto the filter module 30.
Lift the filter module 30 with the clamps 70 from the machine.
Remove the centring ring 50 and 60 from the filter module 30.
Release the clamp (exhaust gas hose) and disconnect the line.
Disconnect the backpressure line at the input module 15.
Release the fastening clamps.
Lift the input module 15 from the uppercarriage.
Immediately seal the filter module 30 on both sides with transport covers 33 (see Fig. 2).

5.1.3 Cleaning of the preliminary filter after the maintenance interval has lapsed
When the prescribed maintenance interval (2000 operating hours) is reached, the preliminary filter at
the input element 15 must be cleaned as follows:
Position the input module in front of a funnel with adjusted diameter and vacuum cleaner hose or
similar piece of equipment.
Switch on the vacuum cleaner and blow out the preliminary filter with oil-free compressed air.
Turn the filter in axial direction and blow it out from the other side.

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Maintenance

After proper cleaning, re-insert the input module 15 (see 5.1.5).

5.1.4 Cleaning of the particle filter after the maintenance interval has lapsed or in the event
of a malfunction

Caution!
When the prescribed maintenance interval (2000 operating hours) or the limit load is reached (warn-
ing LED A on the control unit A175 is on and the buzzer sounds), clean the filter 30.
If the machine is operated when the particle filter load limit is reached the engine could be damaged
and the guarantee of the manufacturer becomes void.
Allow the filter to cool down, dismantle it and sent if for cleaning to an authorised service work-
shop (see 4.4).

If using replacement modules 30.1 when changing/cleaning filter module 30, always observe the
local conditions and the applicable instructions, e.g. VERT specifications for particle filter systems
in BAFU / SUVA filter list.
When using a replacement module 30.1, secure it with the centring rings 50 / 60 , seal rings and
the clamps 70 to the input and output module 15 / 20 (see “Installation of the input module and the
filter module after cleaning” on page 11).

5.1.5 Installation of the input module and the filter module after cleaning
Before installing the filter module 30, remove transport covers 33.
Place the input module 15 in the uppercarriage.
Secure the input module 15 with the fastening clamp after having aligned it in its position.
Connect the backpressure line to the input module 15.
Connect the exhaust gas hose to the input module 15 and tighten the clamp.

Note!
The different lengths of the centring rings 50 / 60 in the input and output modules 15 / 20 ensure
that the filter 30 / replacement module 30.1 is installed correctly (in the correct flow direction).
For air-tight installation, mount new sealing rings 65 to the centring rings 50 / 60.

Remove the old sealing rings 65 from the centring rings 50 / 60 and clean the centring rings 50 /
60 to remove all sealant and adhesive residue.
Attach new seal rings 65 with sealant-compatible adhesive on both sides of the centring rings 50
/ 60.
Insert the centring rings 50 / 60 at the correct side of the filter module 30 / replacement module
30.1.
Insert the filter module 30 or the replacement module 30.1 with the clamps 70 and the inserted
centring rings 50 / 60 between the input and the output module 15 / 20 and align in axial and radial
direction.

Caution!
Repeated tightening of the profile clamps and associated squeezing of the seal rings results in the
compaction of the rings and thus leakage at the filter connections. Therefore use seal rings only on-
ce.

Slide the clamps 70 over the gap between the input / filter / output modules.
Realign the filter modules to the required radial angle.

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Liebherr Diesel particle filter (accessory kit) Service Manual
Maintenance

Tighten the screws of the profile clamps 70 only when the components are properly aligned and
connected in their final position. Tightening torque: 12 Nm.

5.2 Maintenance of filter (condensate trap) 100

5.2.1 Draining condensate

The condensate within container 201 must be drained regularly.
Turn the drain screw 203 90° counter-clockwise (direction A) (see Fig. 8) to drain off the conden-
sate into a suitable container.

Caution!
The backpressure monitoring system can only work correctly if the system is completely tight and
the filter 100 is sealed.
The drain valve must therefore be closed properly.
To close the drain valve, turn the drain screw 203 by 90° clockwise (direction Z) (see Fig. 8).

In case the container (204) doesn’t have a drain valve, remove it for draining.

5.2.2 Checking / replacing filter 100

The sintered metal filter 103 must be checked every 500 operating hours, and cleaned if necessary.
Replace the sintered metal filter 103 every 1000 operating hours.
Turn the drain screw 203 by 90° counter-clockwise (direction A) to drain off the condensate into a
suitable container.
Remove the container 201.
Remove the cap nut 105.
Pull off the filter parts 101 - 104 and clean or replace the sintered metal filter cartridge 103.
Reassemble the filter parts 101 - 104 in the correct sequence (see Fig. 8) and position and tighten
the cap nut 105.
Mount the container 201 with the seal ring 202.
To close the drain valve, turn the drain screw 203 90° clockwise (direction Z).

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Retrofitting of particle filter accessory kit

Fig. 8 Design of the condensate trap

100 Filter complete 101 Centrifuge

102 Shield 103 Sintered metal filter element
104 Shielding plate 105 Cap nut
201 Container 202 Seal ring
203 Release valve
A Drain valve open Z Drain valve closed

6 Retrofitting of particle filter accessory kit

6.1 Important instructions

Note!
Please note that all work on the exhaust gas system must be carried out by technicians authorised
by LIEBHERR.

6.2 Preconditions

The Diesel engine must be filled with Liebherr Motoroil 10 W 40 low ash engine oil.

The Diesel engine must be operated with an approved Diesel fuel conforming to the fuel specifi-
cations according to DIN EN 590, ASTM D 975 D1 and D2 without dye (heating oil).

R 914 C / R 924 C 4.27.13

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Retrofitting of particle filter accessory kit

6.3 Installation of the particle filter

Note!
The particle filter replaces the standard silencer and is installed in its place (except for R944C Tun-
nel).
The backpressure monitoring system can only work properly, if the backpressure line from the par-
ticle filter 10 and the filter 100 to the data logger A133 is completely air-tight.
Before installing the particle filter check the Diesel engine according to the installation and check
list.

Remove the installed silencer.

Install the particle filter 10 with the provided fastening elements in the uppercarriage. For detailed
instructions, see enclosed installation drawing and assembly part list.
Secure the exhaust gas lines and the end pipe at the input / output module.
Install the data logger A133 in the proper location.
Install the indicating and control unit A175 in the proper location.
Install the condensate trap 100 in the proper location.
Install the backpressure line from the particle filter 10 and the filter 100 to the data logger A133,
maintaining an inclination angle of 2° (rising).
Install all electrical connections according to the supplied installation drawings.
Start the Diesel engine and slowly increase the load (allow the engine to warm up).
All values/responses are listed in the enclosed installation and test list. Complete the list and re-
turn it to Liebherr Hydraulikbagger Gmbhl , Service Center, Liebherrstr. D - 88457 Kirchdorf / Iller,
Germany.

6.4 Testing of data logger / limit test

Caution!
Excessive test pressures can damage the pressure sensors of the data logger A133.
Pressurise the data logger A133 with maximum 0.8 bar, using a hand pump.

Push in the snap ring (blue) at position V of the data logger A133 and remove the backpressure
line L.
Attach the hand pump (see tool list 2.01) using an auxiliary hose (transparent hose included in kit)
to point V on the data logger A133. Ensure that the connection is air-tight.
Pressurise the data logger A133 with the hand pump to the prescribed limit pilot pressure and the
limit main charging pressure (see instructions in installation and check list) and check the re-
sponse of the control system.
The indicator (red LED or red LED and audible signal) responds approximately 1 minute after
the pressure is built up.
If the controls respond properly, disconnect the hand pump and reconnect the backpressure line
L to point V of the data logger A133. Ensure that the connection is air-tight.

4.27.14 R 914 C / R 924 C

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Retrofitting of particle filter accessory kit

Fig. 9 Separating point for tightness test

L Backpressure line V Separating point

R 914 C / R 924 C 4.27.15

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Service Manual Datalogger
General

4.40: Datalogger

1 General
To operate the Liebherr diesel particle filter, a number of important data and settings (software) are
required to monitor and control its function. The function-relevant data is recorded and saved in the
datalogger A133.
The data (temperature 1 before the filter, temperature 2 after the filter, exhaust gas backpressure and
diesel engine speed) is thereby saved during travel operation, i.e. each time the diesel engine is start-
ed. Whether the machine is in travel mode or not is indicated to the system by the speed signal from
terminal W at the alternator, by an increase in the charge voltage or by an exhaust gas backpressure
of more than 5 mbar (no detection by means of exhaust gas backpressure from firmware version 6.2).
The stored data can be called up at a later stage and downloaded from the integrated memory to an-
alyse the control and operation of the built-in diesel particle filter. The datalogger can be updated with
new software, if this should become necessary.

1.1 System requirements

1.1.1 Hardware
The following equipment/auxiliary material is required:
– Laptop / PC
– Communication cable ID no. 9067426

1.1.2 Operating systems

The software can be run with the following operating systems:
– Windows 2000 Professional
– Windows XP (Home + Professional)
– Operation with other operating systems has not be tested.

1.1.3 Interfaces / screen resolution / memory requirements

The PC/laptop should
– be equipped with a serial interface
– have a screen resolution of minimum 800x600 with minimum 256 colours
– have minimum 10MB free hard disk space
.

Note!
If the PC/laptop does not feature a serial port, you can use an USB adapter connected to a USB
port.

1.1.4 Directories
The following directories are created automatically by the software:
– C:\Program files\Liebherr\LHDL in the main directory for the program files
– C:\Program files\Liebherr\LHDL\Firmware in the software update directory for the flash files
– C:\Program files\Liebherr\LHDL\Parameter\LHB in the parameter directory for the parameter
files
The acronym LHDL used in the directory names stands for LIEBHERR DATALOGGER.
All necessary data are stored in the above subdirectories.
LHDL does not require any entries in the system registry and can be operated without any special
access rights.

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Datalogger Service Manual
General

The LHDL directory, the subdirectories and files must not be write-protected.
LIEBHERR reserves the right to make minor technical changes to the machines that might not be
reflected in the accompanying documentation. Screenshots, etc. are therefore to be seen as typical
examples, as the version details shown might deviate from those of your software.

Fig. 1 Datalogger with connected laptop

200 Laptop A133 Datalogger

202 Communication cable A175 Indicating and control unit
X1313.S Plug / interface

1.2 Preparation
Ensure that the PDL software is installed on your PC/laptop.
Switch off the ignition.
Connect the datalogger A133 to the PC/laptop 200, using the communication cable ID no.
9067426, see Fig. 1.
Switch on the ignition.
Start the Liebherr LHDL program.
The login screen is displayed at the laptop/PC.

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Fig. 2 Login dialog

1.3 Login
Enter the relevant details in the input fields of the login dialog.

1.3.1 Sprache / Language

The software interface is currently available in German and English. Select your language in the
Sprache / Language field.
Click the arrow beside the input field and select the desired language (e.g. English).

1.3.2 Identification
After entering a 6-digit numerical code, the user can then access the menu options and read and
edit data, depending on the user rights assigned to the authorised personnel at the plant.
Enter the code assigned to you (available from service trainer) in the "Identification" field.

1.3.3 Serial port

Select the serial port to be used for transferring the logger data.
Click the arrow beside the input field and select the respective port,
e.g. COM1.

1.3.4 LOGIN
After all input fields are filled, you can log on to the datalogger.
Using your mouse, click the "Login" button:
The Datalogger LHDL start window, is displayed, see Fig. 3.

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General

Fig. 3 Datalogger LHDL start window

1.4 Datalogger LHDL

The Datalogger LHDL menu contains the following submenus (see sections 4 - 9).
Select the desired submenu by clicking it.
Using the mouse, click the desired submenu.
The selected submenu is opened.

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Datalogger / General

2 Datalogger / General
This window contains general information regarding the operating status of the datalogger.

Fig. 4 "General" menu

The following details are displayed:
– Software version = current software version installed on the datalogger (this information changes
when the software is updated).
– Operational mode = current mode. This entry indicates whether the machine is standing still or is
in travel mode.

Note!
To read or write data, the machine must be in Motor off mode.
Otherwise, the message ....only available in motor off mode is displayed in certain menus.

– Operating hours since installation = operating hours since the filter has been installed.
– Remaining operating hours till service = operating hours until the next service is due.
– Errorcode(s) = pending errors (if any).
– serial number = serial number of the datalogger (only displayed from firmware version 6.0).
– Memory utilisation = memory utilisation on the storage device (D:) and the error memory (E:) in
%.

Note!
The data memory is a FIFO memory. This means that the oldest entry is automatically overwritten
with the latest one when a memory utilisation of 100% is reached.
The entries in the error memory are not overwritten.

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Datalogger / installation test

3 Datalogger / installation test

This window shows all currently applied parameters.
– Outputs
• extern signal-out = optional function for visual or acoustic warning signals (e.g. buzzer, auxil-
iary warning lamp) that can be enabled/disabled. By default, this function is disabled.
• Ignition barrage = by default, this function is disabled.
– Date / time
• Time of control unit = current time and date of datalogger
• Time of PC = current time and date of connected PC
– Sensor values
The sensor values section allows you to check the values from the captured measuring channels
of the datalogger. These values must be taken into account for the commissioning of the exhaust
gas system when the installation certificate is to be completed. In the event of an error or fault in
the system, the currently connected measuring channels can be checked.
• Ignition voltage = supply voltage of the datalogger
• Exhaust temperature = input temperature at the filter cartridge
This value is measured by a temperature sensor located at the filter inlet.
• Temperature 2 = outlet temperature at the filter cartridge
• Exhaust backpressure = status of the system or the filter load
• Number of revolutions = number of revolutions of the diesel engine
• sensor input = after connection of an additional sensor, the respective values are shown here
in percentages (function not yet implemented).

Fig. 5 "Installation test" menu

Compare the date and the time of the datalogger with those of your laptop/PC.
If they deviate from each other, click the Adjust watches button.
The date and time of the datalogger are synchronised with those of the laptop/PC.
The following information window is displayed, see Fig. 6.

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Datalogger / installation test

Fig. 6 Confirmation of time synchronisation

Click the OK button.
The information window is closed.
Check the exhaust gas backpressure in the menu.

Fig. 7 Differences between sensor values

If the values deviate greatly (e.g. motor off = exhaust gas backpressure of approx.
6 mbar, see Fig. 7), click the Calibrate zero point button.
The zero point is recalibrated.
The following information window is displayed, see Fig. 8.

Fig. 8 Confirmation of zero point calibration

Click the OK button.
The information window is closed.

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4 Datalogger
This menu contains tables for error codes and excessive pressure values as well as the buttons for
the reading of the data from the data memory.

4.1 Error memory

The error memory table lists all errors that occurred with their time of occurrence. For troubleshooting,
you can thus determine when (column Date / time) and how often (column Error codes) a certain
error occurred. For each error, a short description and instructions for elimination are displayed.

Note!
The errors are only listed here after they have been read from the datalogger, see 4.2.1.

4.2 Pressure exceedings

All exceedances of the limit value for the exhaust gas backpressure are recorded in the memory. It
is thus for example possible to determine the work practice that has led to the error.
– The time of occurrence of the exceedance is indicated in column Date / time.
– Column Duration indicates the duration of the pressure exceedance.
– Column Pressure (Max./Min.) shows the measure pressure value.
– Column Pressure average shows the average pressure across the duration of the exceedance.
To load the saved records from the hard disk of the PC for subsequent analysis, click the Load file
button.

4.2.1 Reading data memory

Read all data from memory

Click the Read data memory button to read all data from the datalogger to a directory on the hard
disk of the PC.

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Fig. 9 "Datalogger" menu - reading all data from logger

Click the Read data memory button.
The Save as ... dialog is displayed, see Fig. 12.

Partial readout
If you wish to read only a section of the data from the datalogger to a directory on the hard disk of the
PC, click the partial readout.

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Fig. 10 "Datalogger" menu - partial read-out

Click the partial readout button.
The selection window is displayed, see Fig. 11
Specify here the duration of the partial read-out (in hours) you wish to make. The selection is made
starting with the last saved record. Selection 2 h for example means that all records that were record-
ed in the last 2 hours are read out.

Fig. 11 Selection window for the time period of the partial read-out
Using the mouse pointer, move the slide control to select the duration of the partial read-out.
The number of hours is indicated below the slide control. Slide control to the left = shorter pe-
riod; slide control to the right = longer period.
When the desired duration is selected, click OK.
The Save as ... dialog is displayed, see Fig. 12.

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Fig. 12 "Save as" dialog

In the Save in: field, select a folder on your local disk.
A file name is automatically entered in the File name field (file name structure: datalogger se-
rial number_date_time).
If required, you can add more characters to the proposed name in field File name:.
Click the Save button.
The progress of the data download is indicated by the blue progress bar, see Fig. 13.

Fig. 13 Reading out data

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Depending on the memory utilisation, the data transfer process might take up to approx. 10 minutes.
After completion of the read-out process, the following information window is displayed, see
Fig. 14.

Fig. 14 Confirmation of successful data read-out

Click the OK button.
The information window is closed.
If required, you can print the tables.
To do this, click the Print table button, using the mouse pointer (a).
The tables are sent to the connected printer and printed.
Users also have the option to export the data in CSV (comma separated values) format. If errors are
logged, the relevant information is automatically compiled in a separate CSV file.
To do this export data in CSV format, click the Excel export button, using the mouse pointer (b).
The Save as ... dialog is displayed, see also Fig. 16.

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Fig. 15 "Excel export" menu

In the Save in: field, select a folder on your local disk, e.g. folder "Measurements".
In the File name: field, select the proposed name or enter a different one.
Click the Save button.
The data is saved in the form of a CSV file.
After completion of the data export, the following information window is displayed, see Fig. 16.

Fig. 16 Data export confirmation

The CSV files can be viewed in MS Excel.
In MS Excel, select the Data menu, see Fig. 17, and then select "Import external data".
The stored data is displayed in a spreadsheet in MS Excel, see Fig. 17.

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Fig. 17 Table values in Excel spreadsheet

Click the OK button.

The information window is closed.
If required, you can also view the data in the form of charts.
To do this, click the Show diagram button, using the mouse pointer (c), see Fig. 14.
The Diagram menu is displayed, see Fig. 18.
The bottom right section of the window shows the names of the measuring channels in colour
and the associated statuses (active/inactive).
The curves in the diagram appear in the colour of the respective channel (see diagram name).
You can show and hide curves:
Parameters shown in diagram:
– Temperature / °C = exhaust gas temperature (Y-axis, left)
– Pressure / mbar = exhaust gas backpressure (Y-axis, left)
– Number of revolutions / rpm = diesel engine speed (Y-axis, right)
– Date and time = recorded during curve recording (X-axis, bottom)
– Frequency distribution (chart in top right corner)

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Fig. 18 Table values for temperature 1, temperature 2, pressure and number of revolutions in
curve format
Using the mouse pointer (d), click the Active check box to activate (check) or deactivate (no
check) the respective parameter.
The respective curve (e.g. speed curve) is shown, see Fig. 18, or hidden respectively.
Using the mouse pointer (e), click for example the Number of revolutions button.
The distribution of the saved values is shown in the top right corner of the window, see Fig. 18.
Click for example the buttons for temperature 1 / temperature 2 or pressure.
A curve (distribution over time) showing the pressure/temperature during travel operation is dis-
played in the top right section, see Fig. 19.

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Fig. 19 Temperature and pressure distribution

To closely examine a section of the curve, you can zoom in on it.
Using the mouse pointer (f), click the diagram, see Fig. 18.
The diagram is magnified (zoom view).
To zoom in on a section of the diagram, click the mouse button and draw a rectangle around the area
you wish to examine.
Right-click the selected zoom area of the diagram.
The diagram is zoomed out by 1 magnification level.
It is also possible to view the errors and the time of their occurrence in the diagram.

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Fig. 20 Errors included in diagram

Check the Active box in the Event line.
The respective field is activated (check).
The respective errors and their time of occurrence are now shown in the diagram, see Fig. 20.

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Datalogger / "Settings" menu

5 Datalogger / "Settings" menu

In this menu, the current settings of the datalogger are displayed. The window also includes buttons
and input fields to change the settings. The values shown in blue (to the right of the input fields) rep-
resent the current datalogger values.
A) The settings in the top left section refer to the following parameters:
– Pressure value pre alarm = limit value for the begin of the pre alarm (red LED A is on - warning
on indicating/control unit A175)
– Pressure value main alarm = limit value for the begin of the main alarm (red LED A flashes -
warning on indicating/control unit A175 and buzzer sound is emitted)
– Level of working voltage of ignition = battery charge voltage = travel mode detection (from the
set voltage, the system assumes that the machine is in travel mode)
– Note of spacing = interval for the recording of the logger data (for each set interval, e.g. 10 sec-
onds, a record is written to the memory) This value affects the duration of the recording process
to the memory.
– Resulting record time = depends on the selected recording interval (the longer the interval, the
longer the recording time)
– Measurement of turns active default setting: enabled (check) = speed is recorded
– Thermocouple 2 attached (checked) = temperature 2 is recorded
B) The settings in the bottom left section refer to the following parameters:
– Transmission ratio between alternator and engine and number of poles of the alternator =
the correct settings for the model can be applied by loading the respective default parameters
• Pole count generator = number of poles of alternator
• Select motor = select engine type from drop-down list
• Save motor = safe engine data
C) The settings in the top right section refer to the following parameters:
– Long idling / low temperature

Prolong idling alarm

• Threshold values for Number of Revolutions with time limitation settings for signalling to the
display of the indicating/control unit A175 and error recording in the datalogger A133
If the threshold value is set to 0, see Fig. 21, the function is disabled.
Alternatively

Low temperature alarm

• Threshold values for Temperature with time limitation settings for signalling to the display of the
indicating/control unit A175 and error recording in the datalogger A133
If the threshold value is set to 0, see Fig. 21, the function is disabled.
• ignition lock = time after which the alarm signal is disabled after the diesel engine has been shut
down (function not implemented)
D) The settings in the centre-top right section refer to the following parameters:
– Control of filter damage
• Range 1 (bottom section) = minimum exhaust gas backpressure relative to engine speed
If the actual pressure value is below the tolerance range, check the system for leakage.
• Range 2 (top section) = minimum exhaust gas backpressure relative to engine speed
If the actual pressure value is above the tolerance range, check the pressure line and the parti-
cle filter for blockage.
If the measured exhaust gas backpressure relative to the speed drops below the set threshold, there
might be a filter break or leak in the exhaust gas line.
E) The settings in the lower centre right section refer to the following:
– Message output
Select here any additional optional warning devices to be activated (function not implemented).

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Datalogger / "Settings" menu

– display settings
• Select here the language, e.g English
• and the temperature unit, e.g. degree Celsius °C to be used at the display/control unit A175,
see also Fig. 26.
• hide RPM (check this box to hide the RPM)
All settings can be reset globally to the factory settings (default values).
F) The settings in the bottom right section refer to the following:
– Alarm Time Delays
• Time Delay Pressure Alarm = delay after which a pressure alarm is triggered
• Plausibility Pressure = trigger delay of offset pressure
• Plausibility Charging Voltage = trigger delay of charging voltage
• Plausibility Terminal W = trigger delay in the event of an interruption at terminal W

Fig. 21 "Settings" menu

Click the Open file button.
The Open dialog is displayed, see Fig. 22.

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Datalogger / "Settings" menu

Fig. 22 Loading/saving parameter records

In the Look in: field, select the C:\Program Files\Liebherr\LHDL\Parameter\LHB folder and the
file of the respective machine, e.g. AR900_A904_A914_A924_A944_ZW.dat.
This folder might also contain parameter records saved by the user, which can be loaded as default
records.
Click the Open button.
The factory settings or own settings for the machine are loaded.
After the settings have been loaded, the following information window is displayed, see Fig. 23.

Fig. 23 Loading confirmation for settings

Click the OK button.
The information window is closed.

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Datalogger / "Settings" menu

Fig. 24 "Settings" menu

Click the Save to datalogger button.
After the settings have been transferred, the following information window is displayed, see
Fig. 25.

Fig. 25 Saving confirmation

Click the OK button.
The information window is closed.
If required, you can change every individual value as well as the display settings for the indicating/
control unit A175. To do this, proceed as follows:

Fig. 26 Display settings

Select the interface language of the indicating/control unit A175 to suit your requirements. There are
currently five language versions available, namely German, English, French, Spanish and Italian:
Using the mouse pointer (g), click the arrow beside the language field in the display settings sec-
tion of the window and select the desired interface language, e.g. English.
At the display of the indicating/control unit A175, the designations for the values, e.g. temper-
ature 1, are now shown in English.
Adjust the display unit for temperature.
Using the mouse pointer (h), select the unit (e.g. °C) in the display settings section of the win-

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Datalogger / "Settings" menu

dow.
At the display of the indicating/control unit A175, the temperature values are now displayed in
degrees Celsius (°C).
You have the option to show or hide the diesel engine speed at the display of the indicating/control
unit.
Using the mouse pointer (j), click the hide RPM check box.
Show (check) or hide (no check) the engine speed.

Note!
All changes made in this menu must subsequently be transferred to the logger by pressing the Save
to datalogger button.

Click the Save to datalogger button, see Fig. 24.

After the settings have been transferred, the following information window is displayed, see
Fig. 25.

Fig. 27 Confirmation of saving of settings

Click the OK button.
The information window is closed.
The settings saved in the datalogger can also be read individually.
Click the Read from datalogger button, see Fig. 27.
The data is read from the memory.
The following information window is displayed, see Fig. 28.

Fig. 28 Confirmation of reading of settings

Click the OK button.
The information window is closed.

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Datalogger / "Service" menu

6 Datalogger / "Service" menu

In this menu, you can set the time of the next service (interval between services in operating hours).
If the preset interval has lapsed, message "Call service" is displayed on the indicating unit.

Note!
The interval must be re-entered after each service.

Fig. 29 "Service" menu

Using the mouse pointer (k), click the UP/DOWN arrows beside the input field for operating hours/
interval in the Service section.
The operating hours/interval are/is adjusted (e.g. from 1000 to 2000 hours).
Alternatively, the time of the next service can be entered directly in the field (in operating hours).
Using the mouse pointer (m), click the Set hours of operation till service button.
The following information window is displayed, see Fig. 30.

Fig. 30 Confirmation of service interval

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Datalogger / "Softwareupdate" menu

Click the OK button.

The information window is closed.

7 Datalogger / "Softwareupdate" menu

Call up this menu to update the software.

Caution!
The datalogger firmware must always be the latest available version. The version is shown in the
datalogger section, where the currently installed software version of the datalogger is displayed. If
this version does not correspond to the latest available version, you must perform a software up-
date.
When loading the latest software version, all values previously stored in the datalogger are lost. We
therefore strongly recommend the following:
Before updating the software read out all saved data, (see 4.2.1 on page8).

Fig. 31 "Softwareupdate" menu

Click the Select file button in the File section.
The Select file menu is displayed,see Fig. 32.

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Datalogger / "Softwareupdate" menu

Fig. 32 Software update dialog

In the Look in: field, select the C:\Program Files\Liebherr\LHDL\Firmware folder and the file of
the current firmware version.
Click the Open button.
In the Softwareupdate menu, the datalogger software version and the selected file are dis-
played, see Fig. 33.

Fig. 33 "Software update" menu

Click the Start update button.
The following information window is displayed, see Fig. 34.

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Datalogger / "Softwareupdate" menu

Fig. 34 Warning re. loss of data if unread data is not saved

If you have not yet read the data memory, return to the "Datalogger" menu and click the Read
data memory button, see Fig. 9.
If you have already read the data from the data memory, click the Yes button.
The software update is started, see Fig. 35.

Fig. 35 Window displayed during software update

Caution!
Interruption of the update process, e.g. by disconnecting the datalogger from the power supply, can
result in a permanent loss or corruption of the software data.
During the update process, ensure that the ignition is not switched off and that the electrical con-
nection between the datalogger and the laptop is not disconnected.

After the software update is completed, the following information window is displayed, see Fig.
36.

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Fig. 36 Confirmation of software update

Click the OK button.
The information window is closed.
The function to erase the data and the error memory is started, see Fig. 37 and Fig. 38.
After the data memories have been erased, the following information window is displayed, see
Fig. 39.

Fig. 37 Window displayed during data memory erasing

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Datalogger / "Softwareupdate" menu

Fig. 38 Window displayed during error memory erasing

Fig. 39 Confirmation of memory erasing

Click the OK button.
The information window is closed.
The Softwareupdate menu is displayed, showing the new datalogger software version, e.g.
version 6, see Fig. 40.

Fig. 40 Softwareupdate menu showing new software version, e.g version 6.2

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Error statuses

8 Error statuses
Valid from firmware 6.2

Speed recording parameters

a) Voltage Us > Ignition voltage threshold
b) Terminal W > 500rpm
c) Pressure P > 5 mbar

For the detection of errors or plausibility assessment, there are two distinct options, namely
operation with or without speed recording. For this purpose, the following parameters are defined:

Option 1: speed recording enabled (LHB default)

Sce Windows Repetiti

Us W P Display Error Travel
nari software Delay on
a) b) c) message code mode
o message interval
1 - - - Datalogger -- - no - -
ready for opera-
tion
2 - - x Pressure offset Pressure offset 0x01 no* 300 sec. 600 sec.
3 - x - Charge voltage Charge voltage 0x03 yes 300 sec. 600 sec.
error error
4 - x x Charge voltage Charge voltage 0x03 yes 300 sec. 600 sec.
error error
5 x - - Interruption at Interruption at 0x05 yes 300 sec. 600 sec.
terminal W terminal W
6 x - x Interruption at Interruption at 0x05 yes 300 sec. 600 sec.
terminal W terminal W
7 x x (P, T1, T2....) - - yes - -
8 x x x (P, T1, T2....) - - yes - -

*Scenario 2 After the delay time has lapsed, the datalogger is set to travel mode so that the error
can be generated and saved.

Option 2: speed recording disabled

Sce Windows Repetiti
Us W P Display Error Travel
nari software Delay on
a) b) c) message code mode
o message interval
1 - - - Datalogger -- - no - -
ready for opera-
tion
2 - - x Pressure offset Pressure offset 0x01 yes 300 sec. 600 sec.
3 - x - Pressure offset - no
4 - x x Pressure offset 0x01 yes 300 sec.
5 x - - Pressure error Pressure error 0x06 yes 300 sec. 600 sec.
6 x - x (P, T1, T2....) - yes 10 sec. 600 sec.
7 x x x Pressure error Pressure error 0x06 yes 300 sec. 600 sec.
8 x x x (P, T1, T2....) - - yes - -

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Error statuses

is ignored

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Group 5: Coupling / Splitterbox

Coupling ..................................................................................................................................5.10
1 Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.10.1
2 Construction and function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.10.1
3 Removal and installation of the torsional vibration damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.10.2
3.1 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.10.2
3.2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.10.3

Pump distribution gear - construction line DPVP ...............................................................5.30

1 Tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.30.1
2 General data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.30.2
3 Removal & installation of the pumps splitterbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.30.2
3.1 Weights of the parts to be lifted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.30.2
3.2 Removal of the pumps splitterbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.30.2
3.3 Installation of the pump assembly complete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.30.6
4 Disassembly and assembly of the splitterbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.30.7

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Service Manual Coupling
Use

Group 5: Coupling / Splitterbox

5.10: Coupling

1 Use
The elastic coupling (torsional vibration damper), is installed between the Diesel engine and the split-
terbox for the hydraulic pumps. It compensates for shaft (cranshaft-pump input shaft) misaligne-
ments, which could be caused by manufacturing and dimensional variations. It absorbs the residual
torsional vibration of the Diesel engine as well the torque jolts caused by load fluctuations.
It transfers engine power to the double pump directly and constantly, which
disengaged.

Fig. 1 Elastic coupling mounted to the flywheel

2 Construction and function

The disc 2 is bolted to the flywheel 7 of the Diesel engine. The hub 4 is axially guided by the circular
discs 5, riveted to the Hub.
The hub 4 can move radially on the disc 2. The springs 3 are arranged in a ring and form an elastic
connection which transfers the torque betwenn the disc 2 and the hub 4.

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Coupling Service Manual
Removal and installation of the torsional vibration damper

The power transmission between the Diesel engine and the pump assembly is carried out via theb
flywhhel 7, the mounting screws 6, the disc 2, the springs 3, the hub 4 with discs 5 and the driving
shaft of the pump assembly 10.
Any torsional vibration at Diesel engine start up and any load fluctuations are compensed by the
spring 3 compression and relaxation.

Fig. 2 Coupling section view

1 Elastic coupling 2 Disc
3 Springs 4 Hub
5 Disc 6 Mounting screw
7 Flywheel of engine 8 Flywheel housing of engine

3 Removal and installation of the torsional vibration damper

3.1 Removal
Remove the complete pump assembly from the flywheel housing 8 of the Diesel engine (see the
subgroup "Removal & installation of splitterbox", further down in this chapter).
Remove the mounting screws 6.
Notice the installation position of elastic coupling 1 (record the protrusion of the hub 4 in direction
of the engine and in direction of the pump assembly).
Remove the elastic coupling 1 from the flywheel on the Diesel engine.

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Service Manual Coupling
Removal and installation of the torsional vibration damper

3.2 Installation
Set the complete elastic coupling 1 onto the flywheel, hereby take care for the installation position
noticed during removal.
Reinstall the mounting screws 6*.
Reinstall the complete pump assembly onto the flywheel housing 8 of the Diesel engine (see the
subgroup "Removal & installation of splitterbox", further down in this chapter).

Fig. 3 Removal and installation of the coupling

1 Elastic coupling 6 Hexagonal screw

7 Flywheel of engine 8 Flywheel housing of engine
10 Pump assembly 11 Hexagon socket head cap screw
12 Washer

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Removal and installation of the torsional vibration damper

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Service Manual Pump distribution gear - construction line DPVP
Tasks

5.30: Pump distribution gear - construction line DPVP

1 Tasks
The pump distribution gear (also called pump splitter box) is a spur gear unit mounted between the
Diesel engine and the hydraulic pumps.
It is powered directly by the flywheel of the engine via an elastic coupling serving as torsional vibration
damper and transmits the power of the Diesel engine to the different hydraulic pumps.
The different gear transmission ratio to the main drives 13 for the working pumps 21 and 23 and to
the auxiliary drive 16 allow a precise adaptation of the pump flows delivered for the main movements
and for the remaining users.
On the machines equiped with a closed swing loop, the auxiliary drive 16 is used for the swing pump,
on all the remaining machines, the auxiliary drive is destined to the mounting of an additional hydrau-
lic pump employed to power some specific user.

Fig. 1 Pump distribution gear integrated in the twin pump DPVP

1 Pump splitterbox complete

10 Gear cover 11 Main housing
12 Input shaft 13 Shaft of the main power take off
15 Intermediate gear 16 Gear for auxiliary power take off
21 Driving mechanism P1 23 Driving mechanism P2

In the variable displacement twin pump DPVP the pump distribution gear 1 and the both working
pumps 21 and 23 constitute a single construction group, in which the spur gears for the different pow-
er take off and the driving mechanisms 21 and 23 of the working pumps are incorporated in the same
main housing 11.
The spur gears for the different power take off are however accessible without any intervention in the
driving mechanisms, after the removal of the complete DPVP unit and after the disassembly of the
gear cover 10 on the side of the input shaft 12.

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Pump distribution gear - construction line DPVP Service Manual
General data

2 General data

Installed in machines R 906 R 906 R 926

R 914 C
R 916 R 916 Classic
R 924 C
Classic Advanced Advanced
Pump distribution gear type PVG 352 C 357 PVG 352 C
(gear drive) 358
Weight of gear unit complete with kg 236 231 236
pumps, dry
Oil quantity in gear see group 3 - lubricants
Oil quality see group 3 - lubricants
Oil viscosity see group 3 - lubricants
Nominal speed of driving engine *
Main drives I for working pumps
Working pumps type DPVP 108
Gear ratio to working pumps P1 and 0,903 0,790
P2
Direction of rotation left
(as seen when facing the drive)
* For nominal speed of Diesel engine, oil delivery and hydraulic output of the different hydraulic pumps, see
page «Pumps Assembly» of the concerned excavator in group 7.

3 Removal & installation of the pumps splitterbox

3.1 Weights of the parts to be lifted

Machine types All R934C

Components but ..... & R944C Tunnel
Pump distribution gear with working twin pump, dry kg max 240 300
Swing pump kg - 50
Pump assembly complete kg 240 350

3.2 Removal of the pumps splitterbox

Hin

Notice
The sealing and repair works in the areas of the main working pumps 1, the auxiliary drive 2 and
the gear oil cooling pump 9 can be performed without removing the complete pumps assembly from
the engine and taking it out of the uppercarriage of the machine.
In this case it is however necessary to remove the connecting plate 11 or the swing pump from the
splitterbox. The removal of the complete pumps assembly is necessary for all remaining sealing and
repair works (in particular for all works in the area of the driving shaft).

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Service Manual Pump distribution gear - construction line DPVP
Removal & installation of the pumps splitterbox

Fig. 2 Practicable repairs in installed condition

1 Working pumps on the main drives 2 Auxiliary drive (for swing pump)
11 Connecting plate for working twin pump

3.2.1 Preparation for the removal

lete with pumps, the hydraulic circuit must be

opened at several points. The complete hydraulic circuit must therefore be completely depressur-
ized. In that order you must:

oil to a minimum, we recommend to install and

start the vacuum pump at the hydraulic tank, before interrupting the hydraulic circuits (see in group
2, special tool Nb 115).

3.2.2 Removal of the pump assembly complete

Remove the clean air pipe 31 between the air filter outlet and the turbocharger and the spiral hose
32 for dust separation. Remove the complete air filter 35.
Connect the vacuum pump to the hydraulic tank and start it.
Loosen the damping hoses 37 and 38 on both sides, at the high pressure connections of the work-
ing twin pump 21 and at the lower beam of the uppercarriage structure, and remove them.
Loosen and remove the upper casing supporting beam 17.
Drain the oil out of the pump distribution gear 20.
Loosen the both hoses leading to the heat exchanger for gear oil cooling at the distributor 50 with

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Pump distribution gear - construction line DPVP Service Manual
Removal & installation of the pumps splitterbox

pressure holding valve, fixed at the top on the middle of the splitterbox 20.
Disconnect all the control oil hoses 39 between the control oil unit 51 and the regulators of the twin
pump 21.
For the machines fitted with a swing pump for the closed loop swing drive you must:
40 at the regulator of the swing pump 23.
27 at the replenishing pump 24.
44 of the swing pump 23 and take the hose ends out of
the area of the pump assembly.
Remove the pressure hose 42 between servo oil pump 25 and control oil unit 51.
Close off the shut-off valve 30 at the hydraulic tank exit.
Drain the oil in the suction pipe 33 of the main twin pump via the therefore installed drain screw 34.
Disconnect the leak oil hoses from the respective pumps.
Disconnect the high pressure hoses 45 of the twin pump 21 and take the hose ends out of the
area of the pump assembly, as necessary remove the hoses completely or loosen the fixing
clamps.
Remove the suction pipe 33 at the inlet of the working pump 21, preferably keep the flange halves
and the screw on the pump housing.
If, on the machines fitted with an additional hydraulic installation for rotary drive (installation kit AS
1), the suction and high pressure hoses to the additional gear pump should obstruct the removal
of the pump assembly, loosen on both sides and remove these hoses .
For the machines fitted with an additional pump 71 for the drive of an optional electrical generator
you must:
72 at the suction port of the pump 71 and close off the suction hose
immediately, using a suitable blind flange previously provided and the removed flange halves.
73, the control hose 74 and the leak oil hose 75.

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Service Manual Pump distribution gear - construction line DPVP
Removal & installation of the pumps splitterbox

Fig. 3 Removal of the pump distribution gear

11 Bonnet above pump assembly 17 Casing supporting beam
20 Pump distribution gear 21 Working twin pump
23 Swing pump 24 Replenishing pump
25 Servo oil pump 26 Cooling pump
27 Suction hose 28 Suction hose
30 Shut off valve 31 Clean air pipe
32 Spiral hose - dust separation 33 Suction pipe for working pump
34 Drain screw of suction pipe 35 Air filter
37 Damping hose 38 Damping hose
39 Control oil hose 40 Control oil hose of swing pump
42 High pressure pipe 44 High pressure hose
45 High pressure hose 50 Distributor
51 Servo oil unit 71 Pump for generator drive
72 Suction hose 73 High pressure hose
74 Control hose 75 Leak oil hose
95 Mounting bolts

Attach adequate lifting devices to the pump assembly and fix the complete pump unit to the lifting
crane.

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Pump distribution gear - construction line DPVP Service Manual
Removal & installation of the pumps splitterbox

Loosen the bolts 95 fixing the distribution gear to the flywheel housing of the Diesel engine.
Pull the pump assembly forewards as far as the splitterbox centering comes out of the flywheel
housing and the spline shaft out of the tooth profile in the coupling hub.
Carefully lift it up the pump assembly, paying thereby attention that it does not strike against any
casing parts.
Deposit the complete pump assembly on a stable, previously arranged wooden support.
Close off or cover all the opened hydraulic connections at the pump asembly and at the uppercar-
riage of the machine.

3.3 Installation of the pump assembly complete

Using the lifting crane insert the pump assembly in the space between hydraulic tank and coun-
terweight. Pay thereby attention that the pump assembly does not strike against any casing parts..
Carefully approach the splitterbox of the Diesel engine. Pay thereby attention that the drive shaft
engages in the tooth profile in the coupling hub and that the splitterbox centering fits in the flywhell
housing of the engine.
.

Hin

Notice
Lightly oil the splitterbox centering and coat the spline shaft with « Optimol White T» grease before
assembly.

Insert and tighten the mounting bolts 95 of the pump distribution gear onto the engine flywheel
housing.
Remove the lifting device and get off the lifting crane.
For the machines fitted with an additional pump 71 for the drive of an optional electrical generator
you must:
72 of the pump 71 and reconnect the suc-
tion hose immediately.
73, the control hose 74 and the leak oil hose 75.
On the machines fitted with an additional hydraulic installation for rotary drive (installation kit AS
1) loosen on both sides and remove the suction and high pressure pipes to the additional gear
pump.
As necessary, on the machines fitted with an additional hydraulic installation for rotary drive (in-
stallation kit AS 1), reinstall the suction and high pressure hoses to the additional gear pump.
Connect the suction pipe 33 to the inlet of the working twin pump 21, using the flange halves and
the screws on the pump housing.
Reconnect the high pressure hoses 45 to the connecting blocks on the pressure exits of the twin
pump 21 and as necessary reinstall the removed fixing clamps.
For the machines fitted with a swing pump for the closed loop swing drive you must:
44 of the swing pump 23 .
40 to the regulator of the swing pump 23.
27 to the replenishing pump 24.
Reconnect the leak oil hoses of the respective pumps.
Retighten the drain screw 34 of the suction pipe 33.
Install the pressure hose 42 between servo oil pump 25 and control oil unit 51.
Reconnect all the control oil hoses 39 between the control oil unit 51 and the regulators of the twin
pump 21.
Reconnect the both hoses leading to the heat exchanger for gear oil cooling to the distributor 50
with pressure holding valve fixed at the top on the middle of the splitterbox 20.

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Disassembly and assembly of the splitterbox

Reinstall the upper casing supporting beam 17.

Reconnect the damping hoses 37 and 38 to the connecting block at the high pressure connections
of the working twin pump 21 and attach the hoses ends to the lower beam of the uppercarriage
structure.
Reinstall the complete air filter 35. Install the clean air pipe 31 between the air filter outlet and the
spiral hose 32 for dust separation.
Refill the pump distribution gear 20 with oil, until the level reaches the upper mark of the dipstick.
Open the shut-off valve 30 at the hydraulic tank exit and modify the connection of the vacuum
pump so that the pump now pressurizes the hydraulic tank.
When the tank pressurization is sufficiant, bleed the air of the hydraulic pumps with the Diesel en-
gine turned off.
Then run the engine at low idle for a few minutes and bleed the hydraulic pumps again, see in
group 7.
.

Hin

Notice !
On the machines powered by an electric motor, the air bleeding must be performed immediately
after starting the motor.

Stop the engine, check the oil level in the splitterbox and the hydraulic installation for leaks.
Remove the vacuum pump from the hydraulic tank.

4 Disassembly and assembly of the splitterbox

For this see the separately issued Repair Instructions for Variable Flow Twin Pump
DPVP 108.

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Pump distribution gear - construction line DPVP Service Manual
Disassembly and assembly of the splitterbox

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Group 6: Hydraulic system

Adjustment Check List...........................................................................................................6.63

R 914 C Li from serial number 19527

Adjustment Check List...........................................................................................................6.64

R 924 C Li from serial number 19846

Load Sensing Control ............................................................................................................6.68

1 Basic principle - general function description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.68.1
1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.68.1
1.2 Comparison between throttling control and Load Sensing Control . . . . . . . . . . . . . . . . . . . . . . 6.68.1
1.3 The LSC-System (Linde) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.68.2
1.4 Electronic intelligence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.68.3
2 Engine speed sensing with the solenoid valve Y50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.68.4
2.1 Regulation of the hydraulic power levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.68.4
2.2 Power selection through the mode switcher S86 (BBT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.68.4
3 Pump flow regulation for LS hydraulic circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.68.5
3.1 Function of the flow regulation «at user request» . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.68.5
4 Flow quantity upon regulating solenoid valve Y51 for flow limitation. . . . . . . . . . . . . . . . . . . . . . . . . . 6.68.7
4.1 Operating speed and precision control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.68.7
4.2 Adaptation of the flow quantity reduction to the working conditions . . . . . . . . . . . . . . . . . . . . . 6.68.8

Layout of hydraulic system ...................................................................................................6.69

1 Tank arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.69.1
1.1 Hydraulic tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.69.1
2 Hydraulic pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.69.2
2.1 Variable displacement pump 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.69.2
2.2 Gear pumps: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.69.3
3 Control valve block arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.69.3
4 Hydraulic oil cooling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.69.4
4.1 Functional description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.69.5
5 Oil feeder pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.69.6
6 Consumers / Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.69.7
6.1 Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.69.8
7 Servo control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.69.9

Hydraulic Schematics - Components List............................................................................6.80

R 914 C from serial number 19527
R 924 C from serial number 19846
1 Components list for hydraulic schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.80.1
2 Hydraulic diagram for basic excavator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.80.6

List of hydraulic schematics - Standard executions...........................................................6.90

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Service Manual Adjustment Check List

6.63: Adjustment Check List

R 914 C Li from serial number 19527
for machine with BST software - version a)
Date : Operating hours : Name :
Machine No. : Pump type : Pump No :

Value
Nominal lTest Actual View
Test Unit after
value point value Notes
adjust.

1 Basic adjustments
Machine specific datas
• Machine type a)
Version Display/BBT/BST a)
• Nominal RPM at step 10 min-1 1800-20
• Tooth specification 147
• Max idle RPM min-1 1950+20
• Low idle RPM. min-1 960±20
Transmitter mounted.

2 Test conditions
Preheat machine min.
Hydraulic oil tempera °C 50+10
ture
3 Servo pressure bar 30+2 49 Mode P (Step 10)
Adjustment at valve 51

4 Horsepower regulation Mesure using wires on Y50

Mode L/F
Regul. current ILR mA * 59
Regul. pressure P(LR) bar *

Mode E
Regul. current ILR mA * 59
Regul. pressure P(LR) bar *

Mode P
Regul. current ILR mA * 59
Regul. pressure P(LR) bar *

Regul. press. Power Test

P(LR)
bar 13 +1 59
BST Mode Mode Mode
Mode L
F E P

* ILR and P(LR) depdends of BST version, see table V.4.5.3 5 5 5 5

a) read values in menu «i-hours» –20 –20 –20 –20
400 500 520 565
±1 ±1 ±1
4 8 10 12 ±1

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Adjustment Check List Service Manual

Value
Nominal lTest Actual View
Test Unit after
value point value Notes
adjust.

5 Horsep. regul. pressure bar 6 ±0,5 59 Disconnect Y50

for safety operation P(LR) Flip valve into safety position (extract
pin and flip level)
see also chapter 7.42

6 Hydraulic regulation be- bar 70 +5 41 Disconnect connection on Y50/Y51

gin Prb (Pmin) of pumps Adjustment on pump screw 23.1 resp.
P1 (P2) 23.2
Sec. pressure limitation
valve 261(Extend bucket
cylinder) reduce under reg
ulation begin Prb (Pmin),
then increase slowly until
positioning pressure drops
on 43 resp. 44.

Connect Y50

7 Pressure difference adju- bar 30+2 41 / Mode P (Step 10)

stment ( -pls) 45 Button SF not active (Y51 discon-
Fully extend tilt cylinder to nected) read between 41 and 45.
the top Adjustment on pump screw 23.5
Turn out valve 261 until
pressure = 140 - 150 bar
on test point 41 - (Px)

Connect Y51. Quit error messages E

027 / 036.

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Service Manual Adjustment Check List

Value
Nominal lTest Actual View
Test Unit after
value point value Notes
adjust.

8 Check of diesel engine

output (Powertest)

Beforhand get ensured of the conformity of the Cooler fan

RPM (see “Check RPM of cooler fan” on page 7).

Hint :
This control process is to
be conduct only if required
(for ex. in case of reduced
engine power).

Reduce sec. pressure lim.

valve 242 (retract stick cyl
inder) below Ppowertest, .
Then reduce sec. pressure
lim. valve 261 (extend
bucket cylinder) below
Ppowertest, :
bar 118+2 41
Insert service plug
Mode P
Menu Powertest on screen
(I LR=100%).
Simultaneously increase
Sec. pressure lim. valve,
until nominal value is 1800
reached (read on display -
Menu I Hours).

Difference between test

bar < 10 bar
points 41 - 44 (ggf.43) :

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Value
Nominal lTest Actual View
Test Unit after
value point value Notes
adjust.

9 Secondary pressure 45 Mode P (level 10)

Screw in cut-off valve 101.

9.1 Attachment functions

9.2 Travel function

• front left bar 400-20 45 Valve 211
• rear left bar 400-20 45 Valve 212
• front right bar 400-20 45 Valve 213
• rear right bar 400-20 45 Valve 214

10 Cut-off pressure PLS bar 350 +10 41 Mode P (Step 10)

(= adjustment for LS pres Adjustment at valve 101
sure limitation)
Actuate bucket cylinder to
the stop

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Value
Nominal lTest Actual View
Test Unit after
value point value Notes
adjust.

11 Lowering speed of at- Mode P (Step 10)

tachment Screw adjustement screw =
Depends of equipment reduce lowering speed
and applications. Unscrew adjustement screw =
Stick adjustment screw increase lowering speed
116
Dimension d
Boom adjustment screw mm 42±1
115
Dimension d mm 42±1

Check pump pressure on 41

boom cylinder retract bar ~ 40
Stick cylinder extract bar ~ 66

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Value
Nominal lTest Actual View
Test Unit after
value point value Notes
adjust.

12 Swing motor.

Secondary pressures
• Max. adjustm. Pmax
Swing right (valve 131) Read Pmax while countering
bar 260±10 145
Adjustement via screws 1
Swing left (valve 132)
bar 260±10 146
• Basic adjustm. Pbr Read Pbr during deceleration wihout
Swing right (valve 131) countering
bar 120±5 145
Swing left (valve132)
bar 120±5 146

• Charachteristic Psek =
f(pst)
(Not to be checked or
readjusted under normal
circumstances)
Screw in PR valve 134 for
the duration of the test.
Adjust servo pressure Pst
via joystick to...
Then adjust screw 3 pf bar 14±0,5 147
valves 131/132 so to have
secondary pressure...
Swing right (valve 131) = bar 210+10 145

Swing left (valve132) = bar 210+10 146

Torque control character

(adjustement at valve 137)
Adjust servo pressure Pst
via joystick to... bar 16±0,5 147

• Then adjust the TC

valve so to have high
pressure = bar 195±10 145/
146

Working pressure PTC

(primary pressure)
(adjustement at valve 134)
• Swing right bar 145
240+10
• Swing left bar 146
240+10

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Service Manual Adjustment Check List

Value
Nominal lTest Actual View
Test Unit after
value point value Notes
adjust.

13 Travel engine
Slow travel speed
engaged, measure the
sprocket wheel speed

on left chain
• Backwards
min-1 23 ±2
• Size Y on screw 160.1
mm 9,2
• Vorwards
min-1 23 ±2
• Size Y on screw 160.2
mm 9,2
on right chain
• Backwards
• Size Y on screw 180.1 min-1 23 ±2
• Vorwards mm 9,2
• Size Y on screw 180.2 min-1 23 ±2
mm 9,2

14 Hydrostatic driven cooler

fan

DANGER !
Only diconnect and connect the solenoïd valve Y347 with die-
sel engine turned off and cooler fan stopped.
14.1 Check RPM of cooler fan
with 70°C. oil temperatur min-1 1500 ±25 *
with 90°C. oil temperatur min-1 1450 ±25 *
Measure this RPM with
diesel engine at nominal
RPM and Y347 discon
nected
*The RPM of the cooler
fan is not adjustable. Cor
responding high pressure
value is : bar (240 ± 5)

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Service Manual Adjustment Check List

6.64: Adjustment Check List

R 924 C Li from serial number 19846
for machine with BST software - version a)
Date : Operating hours : Name :
Machine No. : Pump type : Pump No :

Value
Nominal Test Actual View
Test Unit after
value point value Notes
adjust.

2 Test conditions
Preheat machine min.
Hydraulic oil tempera °C 50+10
ture
3 Servo pressure bar 30+2 49 Mode P (Step 10)
Adjustment at valve 51

4 Horsepower regulation Mesure using wires on Y50

Mode L/F
Regul. current ILR mA * 59
Regul. pressure P(LR) bar *

Mode E
Regul. current ILR mA * 59
Regul. pressure P(LR) bar *

Mode P
Regul. current ILR mA * 59
Regul. pressure P(LR) bar *

Regul. press. Power Test bar 13 +1 59

P(LR)

BST Mode Mode Mode

Mode L
F E P

* ILR and P(LR) depdends of BST version, see table V.4.5.3 5 5 5 5

a) read values in menu «i-hours» –20 – 20 –20 –20
400 500 520 565
±1 ±1 ±1
4 8 10 12 ±1

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Value
Nominal Test Actual View
Test Unit after
value point value Notes
adjust.

5 Horsep. regul. pressure for bar 6 ±0,5 59 Disconnect Y50

safety operation P(LR) Flip valve into safety position (extract
pin and flip level)
see also chapter 7.42

6 Hydraulic regulation begin bar 70 +5 41 Disconnect connection on Y50/Y51

Prb (Pmin) of pumps P1 Adjustment on pump screw 23.1
(P2) resp. 23.2
Sec. pressure limitation
valve 261(Extend bucket
cylinder) reduce under regu
lation begin Prb (Pmin), then
increase slowly until posi
tioning pressure drops on 43
resp. 44.

Connect Y50

7 Pressure difference adju- bar 30+2 41 / Mode P (Step 10)

Connect Y51. Quit error messages E

027 / 036.

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Value
Nominal Test Actual View
Test Unit after
value point value Notes
adjust.

8 Check of diesel engine

output (Powertest)

Beforhand get ensured of the conformity of the Cooler fan

RPM (see “Check RPM of cooler fan” on page 7).

Hint :
This control process is to be
conduct only if required (for
ex. in case of reduced
engine power).

Reduce sec. pressure lim.

valve 242 (retract stick cylin
der) below Ppowertest, . Then
reduce sec. pressure lim.
valve 261 (extend bucket
cylinder) below Ppowertest, :
bar 129+2 41
Insert service plug
Mode P
Menu Powertest on screen
(I LR=100%).
Simultaneously increase
Sec. pressure lim. valve,
until nominal value is 1800
reached (read on display -
Menu I Hours).

Difference between test

bar < 10
points 41 - 44 (ggf.43) :
bar

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Value
Nominal Test Actual View
Test Unit after
value point value Notes
adjust.

9 Secondary pressure 45 Mode P (level 10)

Screw in cut-off valve 101.

9.1 Attachment functions

• Boom cylinder extend bar 400-20 45
• Boom cylinder retract bar 400-20 45
• Stick cylinder retract bar 400-20 45 Valve 221
• Stick cylinder extend bar 400-20 45 Valve 222
• Bucket tilt cylinder retract bar 400-20 45 Valve 242
• Bucket tilt cylinder extend bar 400-20 45 Valve 241
Valve 262
9.2 Travel function Valve 261
• front left bar 400-20 45
• rear left bar 400-20 45
• front right bar 400-20 45 Valve 211
• rear right bar 400-20 45 Valve 212
Valve 213
Valve 214

10 Cut-off pressure PLS bar 350 +10 41 Mode P (Step 10)

(= adjustment for LS pres Adjustment at valve 101
sure limitation)
Actuate bucket cylinder to
the stop

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Value
Nominal Test Actual View
Test Unit after
value point value Notes
adjust.

11 Lowering speed of attach- Mode P (Step 10)

ment Screw adjustement screw =
Depends of equipment and reduce lowering speed
applications. Unscrew adjustement screw =
Stick adjustment screw 116 increase lowering speed
Dimension d
mm 42±1
Boom adjustment screw 115
Dimension d
mm 42±1

Check pump pressure on 41

boom cylinder retract bar ~ 40
Stick cylinder extract bar ~ 66

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Value
Nominal Test Actual View
Test Unit after
value point value Notes
adjust.

12 Swing motor.

• Charachteristic Psek =
f(pst)
(Not to be checked or read
justed under normal circum
stances)
Screw in PR valve 134 for
the duration of the test.
Adjust servo pressure Pst
via joystick to...
Then adjust screw 3 pf bar 14±0,5 147
valves 131/132 so to have
secondary pressure...
Swing right (valve 131) = bar 210+10 145

Swing left (valve132) = bar 210+10 146

Torque control character

(adjustement at valve 137)
Adjust servo pressure Pst
via joystick to...
bar 16±0,5 147
• Then adjust the TC valve
so to have high pressure
= bar 195±10 145/
146

Working pressure PTC

(primary pressure)
(adjustement at valve 134)
• Swing right bar 240+10 145

• Swing left bar 240+10 146

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Value
Nominal Test Actual View
Test Unit after
value point value Notes
adjust.

13 Travel engine
Slow travel speed engaged,
measure the sprocket wheel
speed

on left chain
• Backwards
min-1 23 ±2
• Size Y on screw 160.1
mm 9,2
• Vorwards
min-1 23 ±2
• Size Y on screw 160.2
mm 9,2
on right chain
• Backwards min-1 23 ±2
• Size Y on screw 180.1 mm 9,2
• Vorwards min-1 23 ±2
• Size Y on screw 180.2 mm 9,2

14 Hydrostatic driven cooler

fan

DANGER !
Only diconnect and connect the solenoïd valve Y347 with die-
sel engine turned off and cooler fan stopped.
14.1 Check RPM of cooler fan
with 70°C. oil temperatur min-1 1450 ±25 *
with 90°C. oil temperatur min-1 1500 ±25 *
Measure this RPM with die
sel engine at nominal RPM
and Y347 disconnected
*The RPM of the cooler fan
is not adjustable. Corre
sponding high pressure
value is : bar (240 ± 5)

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Service Manual Load Sensing Control
Basic principle - general function description

6.68: Load Sensing Control

1 Basic principle - general function description

1.1 General
The Litronic generation of Liebherr hydraulic excavators is equiped with a LS-hydraulic control (Load
Sensing control).
Advantages:
– Reduced power requirement (fuel consumption due to optimum match of pump flow to require-
ment)
– Quicker and more precise work due to automatic synchronization of momentsof several users if
maximum flow is exceeded. This also applies to the regulating range of the pump.

1.2 Comparison between throttling control and Load Sensing Control

1.2.1 Control elements

Control piston in directional valves or control valve blocks are used in our machines to distribute the
available pump flow. They are moved hydraulically by the operator via pilot controls.

1.2.2 Flow diameter

The flow diameter for the pump flow meter between piston pump chanel and user is determined
through a given control pressure, which is set by the operator.
This means:
Small lever / pedal stroke on pilot control
= low control pressure on piston
= small flow diameter
= low speed of user
However:
Large lever / pedal stroke on pilot control
= high control pressure on piston
= large flow diameter
= high speed of user

1.2.3 Flow quantity

According to physics principles, the flow quantity to the user depends on the pressure difference be-
tween the pump channel (pump pressure) and the user (load pressure).
This means:
Large p = large flow quantity
Small p = small flow quantity

Q = A p

1.2.4 Throttling control

To be able to obtain a constant speed of movement for the user (flow quantity) at constantly changing
load pressures, the operaotr must change the opening diameter of the pistons for the current user to
hold the output from the flow diameter A and the p (before and behind the control piston) constant.

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Basic principle - general function description

The pump flow which is not needed by the user is directed via a pressure relief valve at the maximum
pressure relief setting (primary pressure) back to the tank.

1.2.5 Load Sensing Control

The regulating pump receives the user pressure. The volume flow is controlled by the operator
through the flow diameter of the directional valves. The pressure drop on the control piston remains
the same. This significantly improves the energy balance of the hydraulic circuit, because the re-
quired pump capacity is matched very closely to the actual power requirement (oil requirement) of all
users. If the oil requirement of the user exceeds the flow capacity of the pumps, then the state of the
pressure drop and therefore also the control is canceled.
The desired control comfort would also be canceled.
Another optimization is offered by LINDE through the LSC-system (Linde Synchron Control), which
is installed in the excavator’s hydrualic system.

1.3 The LSC-System (Linde)

The new LSC system is a Load Sensing system with a control piston (test orifice) for each user and
a pressure balance therafter.
The load pressure of each user (LS-signal) is taken on the pressure channal to the user. The highest
load pressure is reported to the working pump via the change over valve and applies to the pressure
balance at the same time.
The p given by the pressure spring of the LS-regulator (located on the working pump) is used as
the standard p for the system.
The pump supplies in proportion to the test orifice diameters A1 and A2. The p on the test orifices
( p1 and p2) is the same due to the pressures P1’ = P2’, see Fig. 1.
If several users are actuated and the pump flow QP is not sufficient to take care of the test orifice
diameters, p1 and p2 are reduced. Due to the highest load pressure signal P2 reported on all
pressure balances, the flow distribution continues independent of load pressure according to the con-
dition:
QV1 A
----------- = -----1-
QV2 A2

1.3.1 Proportional flow distribution

If a user is actuated with the required amount Q = for example 300 l / min, the oil quantity is supplied
by the regulating pump as needed.
If a second user needs Q = 150 l / min, then the maximum pump flow Q = 400 l / min is divided to
both users according to the following proportion :
400 / (300 + 150) = 0,88
This way, the first user will receive:
Qv1 = 300 x 0,88 = 266,5 l / min
and the second user receives :
Qv2 = 150 x 0,88 = 133,5 l / min

1.3.2 Power distribution

The power distribution shows the ratio of pump output to utilization capacity and loss capacity. The
pump output equals flow Q1 + Q2 multiplied by the highest user pressure (load pressure + p).

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Service Manual Load Sensing Control
Basic principle - general function description

The loss is the result of required amount of the other users multiplied by the corresponding difference
pressures ( p to highest load pressure).
A higher loss capacity occurs if a user is run at pressure cut off.

Fig. 1 LSC-System principle (Linde)

VI User 1 A1 Control piston

VII User 2 A2 Control piston
LK Load compensator D1 Pressure cut off
P-Vent Pump valve U1 Change over valve
LS-Ltg LS-Line U2 Change over valve
V-Pump Hydraulic pump P-Ltg P-Line
P-Verst. Positioning piston LS-Reg LS-Regulator

1.4 Electronic intelligence

Role of the electronics:
– Commutation of functions
– Publication and management of main operation parameters
– Supervision of safety groups and devices
– Publication of errors and functionning condition
– Checkup of functions and sequences
– Regulation according to activity

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Load Sensing Control Service Manual
Engine speed sensing with the solenoid valve Y50

– Solenoid valves Y50 and Y51

2 Engine speed sensing with the solenoid valve Y50

2.1 Regulation of the hydraulic power levels

The engine speed sensing depends on the spring characteristic situated at the power regulator of the
pump and on the current of the solenoid valve Y50.

2.2 Power selection through the mode switcher S86 (BBT)

By actuating the switch S86 situated on the control panel, 4 different modes can be selected :
– L: Mode LIFT (level 5 - sensitive load lifting).
– F: Mode FINE (level 10 - land levelling).
– E: Mode ECO (level 8 - economic mode).
– P: Mode POWER (level 10).
Mode L / F: If the current ILR is included between 300 and 500 mA => then the control pressure pLR
will be included between 4 and 10 bar.
Mode E / P: If the current ILR is included between 500 and 1000 mA => then the control pressure
pLR will be included between 10 and 20 bar.
Accurate data: see adjustment protocol

Fig. 2 Engine speed sensing in the LSC-system

21 Pump splitterbox S86 Mode switch

23.2 Power regulator U16 Excavator control (BST)
220 Control spool Y50 Solenoid valve (LR)

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Service Manual Load Sensing Control
Pump flow regulation for LS hydraulic circuit

235 Hoist cylinder

If the current is lower than 300 mA, pLR = 0 bar (tank pressure), consequently the regulation’s begin
equals the basic regulation’s begin and the power’s drop of the pump is infinitesimal.
If the current is higher than 300 mA, then the control pressure increases and the regulation’s begin
starts later than the basic regulation’s begin and the power’s drop of the pump increases.

3 Pump flow regulation for LS hydraulic circuit

On machines with LS hydraulic circuit, the pump flow is regulated «at user request», this means taht
the working pump 20 / 21 is swivelled out so to deliver only the oil flow which is realy needed by the
different users.
All the energy losses due to unnecessary oil circulation are thereby avoided.

3.1 Function of the flow regulation «at user request»

If all the control valves (220, 240, ...) are in neutral position (no oil flow to the users), the pump delivers
only so much oil that the pump is maintained at a pressure which is sufficient to compensate the pre-
tension of the spring 1 of the LS-Regulator 23.5.
The oil flow of the power gear is nearly zero, since the pump delivers only the oil which is necessary
to balance its internal leakage, at a relative low pressure (approx. 25 - 30 bar), determined by the
spring of the LS-Regulator 23.5.
As soon as a control valve is actuated, the pump begins to deliver oil and the pressure at the user’s
guide increases. This pressure is transmitted via the LS-line to the spring side of the regulating valve
23.5, which will go on swivelling out the pump, until the pressure difference p between pump exit
and LS-line (user pressure) reaches a constant preadjusted value.

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Load Sensing Control Service Manual
Pump flow regulation for LS hydraulic circuit

Fig. 3 Pump swivelling out

The oil flow via the bores inside the control pistons 223 / 224 is equivalent with the flow thourgh an
orifice gauge. When the flow quantity to the user increases, the pressure drop at this throttling in-
creases too.
The system will come to balance when the pressure loss in the control spool is equal to the pread-
justed p value (pump pressure - user pressure in LS-line) adjusted in the LS regulator.
The cross section of each control valve is determined so that the pressure loss in the valve spool cor-
responds to the pressure difference p(LS) adjusted at the regulator, when the nominal oil flow is
reached, and with the valve spool fully actuated.
When the control valve 223 is shifted back into an intermediate position, the cross section of the or-
ifice gauge is reduced and the pressure loss p(LS) is reached already for a smaller oil flow. Since
the pump is attempting ti maintain the pressure difference constant, the pump will swivel back.

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Flow quantity upon regulating solenoid valve Y51 for flow limitation

Fig. 4 Pump swivelling out

If several control valves are actuated at the same time, the oil flow necessary for the different users
will exceed the maximum possible delivery of the pump. The value of p(LS) is by the fact reduced,
but seeing that this value is the same for all the actuated users, all the oil flows will be reduced in the
same proportion.

4 Flow quantity upon regulating solenoid valve Y51 for flow limita-
tion

4.1 Operating speed and precision control

The solenoid valve Y51 is solicited by the control pressure (pst), which, via the %-regulation prese-
lectioned by the BST, and the pMLS, will counter the spring force of the flow regulator (LS) and also
reduce P.
This means that the pression difference P is smaller and that the pump can maintain this reduced
difference P with a lower oil volume.

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Load Sensing Control Service Manual
Flow quantity upon regulating solenoid valve Y51 for flow limitation

The pump only pivots until the flow at the pump output is reached.

Fig. 5 Flow quantity regulation in LSC-system

21 Pump splitterbox H1 Display

23.5 Flow quantity regulator S354 Switch (SF)
B33 Geber Y51 Solenoid valve ( p lowering)

4.2 Adaptation of the flow quantity reduction to the working conditions

Flow quantity reduction Display Switch Setting

SF: Driver’s setting SF = M8 S354 (SF) Set SF
External: setting depending I1 - I4 (Opt.1-4) B33-2/I... Set pump
on the user
Internal: setting depending on M1 - M7 B33-1 /M... Set data / set pump
the excavator

Reduction of the pump flow quantity:

I Ls < 300 mA = pMLS = 0 bar (tank pressure) p = basic setting

Note!
The working speeds can be tested, via SF-interface activated, with the joysticks.

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Service Manual Layout of hydraulic system
Tank arrangement

6.69: Layout of hydraulic system

1 Tank arrangement

Fig. 1 Hydraulic tank and fuel tank 1

1 Hydraulic tank 4.1 Return filter

2 Bleed filter 5 Integrated check valve
3 Shut-off valve B14 Electrical oil level sensor
4 Return filter

1.1 Hydraulic tank

Task:
– Intake of the hydraulic oil for the entire system
– Separation of suction and return-flow area and settling of the oil by way of plates in the interior
– Supply of hydraulic pumps with purified oil
– collecting sump for return oil with purification via return filter
– Pressurisation of oil volume to prevent cavitation

Filter units:
– Return filter 4 with 2-stage fibreglass filter elements and safety check valve 5 (installed in the re-
turn filter)
– Servo sensor return filter 4.1 with single-stage fibreglass filter element
Filter elements:
– Bleed filter for standard applications and dust-intensive applications 2 µ
Maintenance:
– Replacing the hydraulic oil
– Replacing the return-flow filter element and bleed filter

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Layout of hydraulic system Service Manual
Hydraulic pumps

– Drainage of the tank

– See maintenance guidelines in Group 3

2 Hydraulic pumps

Fig. 2 Variable displacement pump 23 for R 924 Litronic Compact

20 Variable displacement pump 24 Control unit

22 Control unit 24.5 LS-contol

2.1 Variable displacement pump 20

Drive:
– via diesel engine
– via torsion damper (elastic coupling)
Design:
– Axial piston swash plate
Structure:
– Axial piston pump
– Adjusting mechanism with swash plate
– Control unit with governor (GLR) and flow controller (LS-control)
Technical data and functional description:
– See also variable displacement pump in Group 7

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Service Manual Layout of hydraulic system
Control valve block arrangement

Fig. 3 Gear pump 33

2.2 Gear pumps:

Gear pump 33 for hydraulic fan drive:
– Pump drive (flange-mounted)
– Supply of hydraulic fan drive
– Pump flow, see „Technical Data“ in Group 3

3 Control valve block arrangement

Fig. 4 Control valve block 100 with swing axle and conversion kit axle
Assembly:
– Control plate 100, with pressure and return flow connections, screwed in pressure relief
valves and flange-mounted directional control valves
– Integrated LSC-control

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Layout of hydraulic system Service Manual
Hydraulic oil cooling

– Input section
– 5 control pistons
– Two pressure weighers with toggle switch applied to each control piston
– Flange-mounting possibilities for additional sections, for example sections added for auxiliary di-
rectional control valves for mounting kits
– Secondary protection in the directional control valves via screwed in pressure relief valves (with
suction function) for the attachment.
– Suction valves for travel gear.
– Stroke limitation of control pistons
– Vent valves of the control caps
– Functional description, see Group 7

4 Hydraulic oil cooling

Fig. 5 Oil cooling

6 Oil cooling B2 Water temperature sensor

13 Blower motor B14 Oil level sensor
14 Pressure relief valve Y347 Proportional solenoid valve

Assembly:
– Four-piece cooling aggregate, comprising of oil cooler 6 for hydraulic oil cooling (bottom), engine
water cooler for diesel engine (middle), charge air cooling for diesel engine (top) and capacitor for
the air-conditioning system (front)
– Hydrostatic fan drive, dependent on temperature of hydraulics, coolant and charge air tempera-
ture and the air-conditioning system with high air flow rate
– Fan speed is regulated in accordance with the temperature (electronic) via proportional solenoid
valve Y347

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Service Manual Layout of hydraulic system
Hydraulic oil cooling

4.1 Functional description

If the temperature of the hydraulic oil, coolant or charge air is the same as or below the prescribed
limit value B8 (min.), B2 (min.) or B98 (min.), the output current to solenoid valve Y347 of BST (U16)
is equal to I Y347 (max.).
In this case, the pressure at proportional valve Y347 is reduced to minimum value. As a result, the
fan speed is reduced to minimum working speed n fan (min.). The surplus delivery volume of the pump
33 flows back to the tank via solenoid valve Y347 and check valve 38.
If the temperatures rise above the prescribed limit values B8 (max.), B2 (max.) or B98 (max.), the
current at the solenoid valve is compensated accordingly I Y347 (min.).
Nearly all of the pump's oil flow 33 flows to the fan motor 13. The speed of the fan n fan (max.) , as well
as the oil pressure in the hydraulic drive p(max.), attain maximum values.
Within the prescribed minimum and maximum values, the current of the BST (B16) to solenoid valve
Y347 runs linear, thus, each intermediate temperature corresponds with a certain current I and pres-
sure p between min. and max., whereby a certain fan speed is attained (see diagram).

Fig. 6 Hydraulic circuit diagram for fan control

Note!
Speed in emergency operation:(outage Y347)
Inot => approx. 1700 rpm

Air-conditioning system activated:

370 mA* = approx. 1000 rpm of fan blade

* The current intensity to solenoid Y347 is dependent on the BST versions, see Group 8.

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Layout of hydraulic system Service Manual
Oil feeder pipe

5 Oil feeder pipe

Fig. 7 Oil feeder pipe

Task:
– Implementation of hydraulic oil from the uppercarriage to the undercarriage or vice versa
Assembly:
– Rotary connection 195 for high pressure
• Travel drive, blade support, leak oil
– Rotary connection 196 for low pressure
• Gear shifting
Description, see Group 7

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Service Manual Layout of hydraulic system
Consumers / Tools

6 Consumers / Tools

Fig. 8 Consumers and tools

Task:
– Conversion of hydraulic energy into mechanical energy
Arrangement:
– Hydraulic device for transfer of a propulsive or tractive force with linear movement in restricted
stroke
– Hydraulic device for transfer of a torque with rotational movement

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Layout of hydraulic system Service Manual
Consumers / Tools

6.1 Cylinders

Fig. 9 Arrangement of consumers and tools

Design:
– Differential cylinder
• without end-of-stroke damper
• with end-of-stroke damper on one side or on both sides
Functional description, see Group 7
Arrangement:
– Hoist cylinder 235 for movement of the pivoting arm with end-of-stroke damper on the piston
crown side
– Stick cylinder 255 for movement of the stick with damper on both sides
– Bucket cylinder 275 for movement of the bucket with damper on piston crown side
– Blade adjusting cylinder (conversion kit AHS 1)

6.1.1 Oil motor

Design:
– Axial piston swash plate
• Constant (with constant displacement)
• Regulated (with variable displacement)
Functional description, see Group 7
Arrangement:
– Swing gear constant motor 130 with integrated control for drive of the uppercarriage via swing
gear transmission
– Travel motors 200 - 201 for drive of the travel gear chains via travel gear transmission with travel
brake valve 205

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Service Manual Layout of hydraulic system
Servo control

7 Servo control

Fig. 10 Servo oil unit 50 and view of the servo controls in the operator's station
Task:
– Hydraulic control of all working and travel movements of the machine via hand-operated or foot-
operated control unit (servo controls / sensor equipment)
Assembly and function:
– Generation of pressure via separate gear pump 30
– Servo oil unit 50 for regulation, monitoring, filtering, storage and distribution of the required servo
control oil or pressure
Proportional solenoid valves Y50 / Y51 for control of the variable displacement pumps 23; Solenoid
valve Y3 for cutting off the servo control pressure Y7; Control of fast travel Y24.
Servo controls 80 - 87 with controller characteristics for comfortable operation of the machine:
– Servo control 80 and 81 with joystick control for actuation of swing gear and attachment
– Servo control 82 with foot pedal for actuation of the travel gear
– Servo control 85 with foot pedals for actuation of the auxiliary attachment (conversion kit)
– Servo control 87 with foot pedals for actuation of the levelling blade (Type 198 only)
– Control lines from the servo controls to the control caps of the respective control pistons
Maintenance:
– Replacement of the filter element (servo oil filter on the servo oil unit)
Description, see maintenance guidelines in Group 3.

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Layout of hydraulic system Service Manual
Servo control

6.69.10 R 914 C / R 924 C

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Service Manual Hydraulic Schematics - Components List
Components list for hydraulic schematic

6.80: Hydraulic Schematics - Components List

R 914 C from serial number 19527
R 924 C from serial number 19846

1 Components list for hydraulic schematic

Hydraulic schematic, page 1 / 2

See
Positions
Group
1 Hydraulic tank
2 Breather filter
3 Shut off valve
4 Return filter
4.1 Leakage filter
5 Bypass valve / Return filter (pressure)
6 Oil cooler
9 Collector
13 Motor oil cooler
20 Double pump regulating valve complete
21 Pump P1
21.1 Control piston
22 Servo control cylinder
22.1 Governor valve P1
22.3 Restrictor
22.6 2-way check valve
23 Pump P2
23.1 Control piston
24 Servo control cylinder
24.1 Governor valve P2
24.3 Restrictor
24.5 Flow regulator (LS) P1 / P2
24.6 2-way check valve
28 Check valve
30 Gear pump servo control
33 Gear pump / Fan
39 Check valve
43 Measuring point / Actuating pressure P1
44 Measuring point / Actuating pressure P2
49 Measuring point control pressure M1
50 Control oil unit
51 Pressure relief valve
52 Pressure filter
53 Check valve

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Hydraulic Schematics - Components List Service Manual
Components list for hydraulic schematic

See
Positions
Group
54 Accumulator
57 Measuring point servo pressure LS
59 Measuring point servo pressure power control LR
80 Pilot control valve / Left joystick 4 ways
81 Pilot control valve / Right joystick 4 ways
82 Pilot control valve / Travel left left / right
88P Distribution block / Servo pressure
88T Return block servo oil
100 From / To control block
130 To swing gear motor
155 To swing brake
160 To directional control valve / Travel motor right
180 To directional control valve / Travel motor left
220 To control piston / Boom cylinder

240 To control piston / Stick cylinder

260 To control piston / Bucket cylinder

B40 Pressure switch drive pedal / Attachment movements

Y3 Solenoid valve / Servo control
Y7 Solenoid valve / Swing brake
Y24 Solenoid valve / Travel speed increase
Y50 Proportional solenoid valve / Power control
Y51 Proportional solenoid valve / LS control

Y78 Solenoid valve grapple - bucket operation

Y347 Proportional solenoid valve fan

Hydraulic schematic, page 2 / 2

See
Positions
Group
1 To hydraulic tank
6 To oil cooler
20 From double pump regulating valve complete
24.5 Power supply regulator (LS) P1 / P2 (X22)
41 Measuring point xP (pump pressure)
45 Measuring point xLS (LS pressure)
50 From control oil unit
80 From pilot control valve / left joystick 4 ways
81 From pilot control valve / right joystick 4 ways
82 From pilot control valve / Travel left left / right

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Service Manual Hydraulic Schematics - Components List
Components list for hydraulic schematic

See
Positions
Group
88P From distribution block / Servo pressure
88T From return block servo oil
100 Control block
101 Pressure cut off (Ls-pressure)
102 Pump valve
104 Control piston / Travel speed
105 Control valve / Travel movements
106 Valve / LS-cut off grapple
107 Pressure control valve / Return flow T
108 Pressure control valve / Return flow P
110 Regeneration block
110.1 2-way check valves
110.2 Control valve
112 2-way check valve
113 Piston
114 Piston
115 Lowering throttle boom cylinder
116 Lowering throttle stick cylinder
130 Swing gear motor, complete with directional control valve
131 Secondary pressure relief valve / Turn right
132 Secondary pressure relief valve / Turn left
133 Control piston / Turn
134 Pressure relief valve / Control pressure turn
135 Throttle check valve stick / Turn right
136 Throttle check valve stick / Turn left
137 Pressure relief valve / Torque Control valve
138 Priority valve pivoting / Pressure balance
139 Supplying valve
140 Check valve high pressure
141 Check valve LS pressure
142 Check valve / Tank pressure
145 Measuring point / Turn right
146 Measuring point / Turn left
147 Meausring point control pressure
150 Minimum flow regulator
155 Swing brake
156 Swing motor
160 Directional control valve / Travel motor right
160.1 Stroke limitation stick / Travel motor right forwards
160.2 Stroke limitation stick / Travel motor right backwards
160.3 Throttle check valve stick / Travel motor right backwards

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Hydraulic Schematics - Components List Service Manual
Components list for hydraulic schematic

See
Positions
Group
160.4 Throttle check valve stick / Travel motor right forwards
160.7 Pressure relief breather valve
160.8 Pressure relief breather valve
161 Suction valve / Travel motor right
162 Suction valve / Travel motor right
163 Control piston / Travel motor right
165 Pressure balance load compensator
166 Pressure balance load compensator
167 Toggle switch
168 Toggle switch
180 Directional control valve / Travel left
180.1 Directional control valve / Travel motor left forwards
180.2 Directional control valve / Travel motor left backwards
180.3 Throttle check valve stick / Travel left backwards
180.4 Throttle check valve stick / Travel left forwards
180.7 Pressure relief breather valve
180.8 Pressure relief breather valve
181 Suction valve / Travel motor left
182 Suction valve / Travel motor left
183 Control piston / Travel motor left
185 Pressure balance load compensator
186 Pressure balance load compensator
187 Toggle switch
188 Toggle switch
195 5 way rotary connection
196 1 way rotary connection
200 Travel gear motor left
201 Travel gear motor right
202 Travel motors / Adjusting cylinders
203 Control piston / Travel motor displacement
205 Travel brake valve complete
206 Hydraulic brake valve
207 Two way check valve / Brake control pressure
208 Brake control pressure reducing valve
209 Travel gear brake
211 Secondary pressure relief valve / Travel gear left forwards
212 Secondary pressure relief valve / Travel gear left backwards
213 Secondary pressure relief valve / Travel gear right forwards
214 Secondary pressure relief valve / Travel gear right backwards
220 Control piston / Boom cylinder
220.1 Stroke limitation boom cylinder

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Service Manual Hydraulic Schematics - Components List
Components list for hydraulic schematic

See
Positions
Group
220.2 Stroke limitation boom cylinder
220.3 Throttle check valve control pressure
220.7 Pressure relief breather valve
220.8 Pressure relief breather valve
221 Extend secondary pressure relief valve
222 Retract secondary pressure relief valve
223 Control piston boom cylinder
225 Pressure balance load compensator
226 Pressure balance load compensator
227 Toggle switch
228 Toggle switch
233 Distribution block
235 Boom cylinder
240 Control piston / stick cylinder
240.1 Stroke limitation stick cylinder
240.2 Stroke limitation stick cylinder
240.3 Throttle check valve control pressure
240.7 Pressure relief breather valve
240.8 Pressure relief breather valve
241 Extend secondary pressure relief valve
242 Retract secondary pressure relief valve
243 Control piston stick cylinder
245 Pressure balance load compensator
246 Pressure balance load compensator
247 Toggle switch
248 Toggle switch
249 Pressure relief valve / Bypass valve
255 Stick cylinder
260 Control piston / Bucket cylinder
260.1 Stroke limitation bucket cylinder
260.2 Stroke limitation bucket cylinder
260.7 Pressure relief breather valve
260.8 Pressure relief breather valve
261 Extend secondary pressure relief valve
262 Retract secondary pressure relief valve
263 Control piston / Bucket cylinder
265 Pressure balance load compensator
266 Pressure balance load compensator
267 Toggle switch
268 Toggle switch
275 Bucket cylinder

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Hydraulic Schematics - Components List Service Manual
Hydraulic diagram for basic excavator

2 Hydraulic diagram for basic excavator

See next page.

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Service Manual List of hydraulic schematics - Standard executions

6.90: List of hydraulic schematics - Standard executions

Valid
Machine Ident no. Schematic no.
from to
R 914 C 19527 ... 10080316 1062 7010 00 001
R 924 C 19846 ...

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Service Manual

Group 7: Hydraulic Components

Hydraulic pump: Removal, installation, Start-up. ...............................................................7.01

1 Variable displacement pump 20 / working hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.01.1
1.1 Dismantling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.01.1
1.2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.01.2
1.3 Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.01.2
1.4 Bleeding the hydraulic pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.01.3
2 Gear pump 33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.01.4
2.1 Dismantling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.01.4
2.2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.01.4
2.3 Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.01.4

Variable-displacement twin pump DPVP..............................................................................7.11

1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.11.1
2 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.11.1
3 Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.11.1
4 Operating mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.11.2
5 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.11.4
5.1 Function of powertrain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.11.4
5.2 Pump adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.11.6
5.3 Shuttle valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.11.7
6 Servo-control pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.11.8
7 LR / LS - Regulation of DPVP twin pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.11.8
7.1 Overview of the regulators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.11.8
7.2 Construction of the regulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.11.9
7.3 Function of LR - regulation axis (power regulation). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.11.11
7.4 Function of SD - axis (regulation of pressure difference rPLS) . . . . . . . . . . . . . . . . . . . . . . . . 7.11.13
7.5 Hydraulic diagramm LR/SD/DA regulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.11.15

Hydraulic motors schedule ...................................................................................................7.20

1 Swing motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.20.1
2 Travel motors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.20.1

HMF 75-02P hydraulic fixed-displacement motor ...............................................................7.25

1 Function and design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.25.1
2 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.25.4
3 Functional description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.25.4
3.1 Way valve 133, Fig. 4 and Fig. 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.25.4
3.2 Priority valve 138 (input pressure balance), see Fig. 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.25.7
3.3 Torque control, see Fig. 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.25.7
3.4 Secondary pressure relief valves with suction function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.25.8
3.5 Feeder valves 139 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.25.9
3.6 Outlet function (see «Hydraulic daigram» on page 5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.25.9
4 Maintenance and repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.25.9

Hydraulic cylinders ................................................................................................................7.30

1 Job definition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.30.1
2 System description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.30.1
2.1 Cylinder variants, see Fig. 17 / Fig. 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.30.4

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3 Functional description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.30.5

3.1 For end-of-stroke damper on one side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.30.5
3.2 For end-of-stroke damper on both sides, see Fig. 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.30.5
4 Installing / dismantling hydraulic cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.30.6
4.1 Dismantling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.30.6
4.2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.30.7
4.3 For cylinders with fitted air bleeding plugs, see Fig. 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.30.7
5 Changing the seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.30.8
5.1 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.30.8
5.2 Assembly, see Fig. 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.30.8
6 Assembly of sealing and guide elements on the piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.30.11
6.1 Fitting the piston (with thread) on the piston rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.30.11
7 Fitting shock absorber sleeve 84 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.30.12
7.1 Cylinder with double-sided end-of-stroke damper, see Fig. 12 . . . . . . . . . . . . . . . . . . . . . . . . 7.30.12
7.2 Fitting the piston rod bearing 8 (inserted) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.30.13
7.3 Fitting the piston rod bearing 8 (screwed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.30.13
8 Replacing the piston rod head and cylinder sleeve bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.30.13
8.1 Variants with rotary shaft seal (see Fig. 19 on page18) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.30.14
8.2 Variants with pivot bushings (see Fig. 19 on page18) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.30.14
9 Variants of piston rod bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.30.14
10 Piston variants on hydraulic cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.30.15
11 End-of-stroke damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.30.16
12 Stroke reduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.30.17
13 Cylinder rod head bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.30.18

Extension and retraction speeds ......................................................................................... 7.31

Installations for pistons and piston nuts by hydraulic cylinders...................................... 7.32

1 Application and purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.32.1
2 Requirements / description of procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.32.1
2.1 Tightening with assembly wrench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.32.2
2.2 Tightening with hydraulic assembly device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.32.4
3 Torque table - Status 02.06.2010 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.32.7
3.1 Tightening with assembly wrench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.32.7
3.2 Tightening with hydraulic assembly device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.32.10

Hydraulikzylinder - R 914 C / R 924 C .................................................................................. 7.38

Control oil and control unit................................................................................................... 7.45

1 Job definition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.45.1
2 System description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.45.1
2.1 Arrangement of test points. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.45.2
3 Functional description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.45.2
3.1 Generating the servo pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.45.3
3.2 Function of the solenoid valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.45.3
3.3 Proportional solenoid valves Y50 / Y51 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.45.3
4 Characteristics of proportional solenoid valves Y50 and Y51 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.45.4
5 Emergency position of the proportional solenoid valves Y50 / Y51 . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.45.4
5.1 Setting the emergency position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.45.4

1-way servo control ............................................................................................................... 7.50

1 System description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.50.1
2 Functional description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.50.1

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3 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.50.2
3.1 Dismantling the control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.50.2
3.2 Assembly of the control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.50.2
3.3 Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.50.3
3.4 Sectional drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.50.4

2-way servo control................................................................................................................7.51

1 System description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.51.1
2 Functional description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.51.1
3 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.51.2
3.1 Dismantling the control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.51.2
3.2 Assembly of the control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.51.2
3.3 Setting the servo control in the zero position. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.51.2
3.4 Checking the 2-way check valves 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.51.3
4 Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.51.4
5 Sectional drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.51.5

4-way servo control (Rexroth)...............................................................................................7.55

1 System description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.55.1
2 Functional description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.55.1
3 Control curve of the servo control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.55.2
4 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.55.3
4.1 Setting down the control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.55.3
4.2 Dismantling the control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.55.3
4.3 Assembly of the control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.55.3
4.4 Setting the servo control in the zero positionsee Fig. 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.55.4
4.5 Fitting the control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.55.4
5 Exploded views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.55.4
6 Sectional drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.55.7

Hydraulic pilot control device with 2 pedals and damping system...................................7.56

1 System description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.56.1
2 Functional description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.56.1
3 Dismantling and installing the control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.56.4
3.1 Dismantling the control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.56.4
3.2 Installation of control unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.56.4

Control valve complete ..........................................................................................................7.61

1 Tasks in general . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.61.1
1.1 Circuit diagram - control valve block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.61.2
1.2 Control valve block - directional control valves for standard equipment . . . . . . . . . . . . . . . . . . 7.61.5
2 Specifications for auxiliary equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.61.6
2.1 Circuit diagram - control valve block auxiliary equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.61.7
2.2 Control valve block - directional control valves for standard equipment . . . . . . . . . . . . . . . . . 7.61.10

Control plate ...........................................................................................................................7.62

1 Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.62.1

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Service Manual

2 Function of the valves in control plate 100. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.62.5

2.1 Pressure cut-off valve 101 see Fig. 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.62.5
2.2 Pump valve 102 see Fig. 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.62.5
2.3 Control valve 104 for travel motor adjustment see Fig. 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.62.5
2.4 Control valve 105 for travel movements see Fig. 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.62.6
2.5 Control valve 106 for grapple operation see Fig. 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.62.7
2.6 Pressure control valves 107 and 108 see Fig. 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.62.9
2.7 Valve 110 for yielding return oil for boom and stick see Fig. 7 . . . . . . . . . . . . . . . . . . . . . . . . . 7.62.9

Inspecting the control valve blocks for leak oil .................................................................. 7.64
1 Job definition and function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.64.1

1-way rotary connection........................................................................................................ 7.75

1 System description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.75.1
2 Connections and hydraulic fastenings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.75.1
3 Dismantling and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.75.2
3.1 Dismantling the 1-way rotary connection to carry out sealing work, see Fig. 2 . . . . . . . . . . . . . 7.75.2
3.2 Installing the 1-way rotary connection following the sealing work, see Fig. 2 . . . . . . . . . . . . . . 7.75.2
4 Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.75.4
5 Sectional drawing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.75.5

5-way rotary connection........................................................................................................ 7.77

1 System description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.77.1
2 Connections and hydraulic fastenings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.77.2
2.1 R 900 C-Litronic and R 904 C-Litronic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.77.2
2.2 R 924 Compact - type 911. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.77.2
3 Dismantling and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.77.2
3.1 Dismantling the 5-way rotary connection to carry out sealing work, see Fig. 2 . . . . . . . . . . . . . 7.77.2
3.2 Installing the 5-way rotary connection following the sealing work, see Fig. 2 . . . . . . . . . . . . . . 7.77.3
4 Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.77.5
5 Sectional drawing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.77.6

7-way rotary connection........................................................................................................ 7.79

1 System description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.79.1
2 Connections and hydraulic fastenings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.79.1
2.1 R 904 C-Litronic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.79.1
2.2 R 924 Compact - type 198. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.79.2
3 Dismantling and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.79.2
3.1 Dismantling the 7-way rotary connection to carry out sealing work, see Fig. 2 . . . . . . . . . . . . . 7.79.2
3.2 Installing the 7-way rotary connection following the sealing work, see Fig. 2 . . . . . . . . . . . . . . 7.79.3
4 Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.79.5
5 Sectional drawing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.79.6

Brake valve for hydraulic travel gear motor........................................................................ 7.97

1 Purpose of the brake valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.97.1
2 Functional description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.97.2
2.1 Functioning of the hydraulic brake piston 206 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.97.2
2.2 Functioning of the hydraulic brake piston 206 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.97.3
2.3 Output in the travel motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.97.3

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R 914 C / R 924 C
ADMIN
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Service Manual Hydraulic pump: Removal, installation, Start-up.
Variable displacement pump 20 / working hydraulics

Group 7: Hydraulic Components

7.01: Hydraulic pump: Removal, installation, Start-up.

Caution!
Unsecured hydraulic pumps can cause severe crush injuries and harm.
Always lift and secure hydraulic pumps using suitable slings and lifting gear.

Note!
For a clean and almost oil-free removal and installation of the hydraulic pump we recommend the
use of a vacuum pump (tool no. 115 - 125 in group 2.03).
The same pump can also be used as a compressor with monitored low pressure of 300 - 500 mbar
to bleed the system.
Also refer to service information no. 06 - 03 - 22 / 2003

1 Variable displacement pump 20 / working hydraulics

Fig. 1 Hydraulic pumps 20

1.1 Dismantling
Close the shut-off valve on the hydraulic tank, (position b), see Fig. 2.
Catch the hydraulic oil in a suitable container.
Hook and secure the hydraulic pump 20 onto a suitable lifting accessory and lifting gear.
Disconnect the hoses / lines on the pumps 20 and 30 and catch the hydraulic oil.
Loosen and unscrew the cylinder head screws 6.
Dismantle the hydraulic pump 20.

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R 914 C / R 924 C
copyright by

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Hydraulic pump: Removal, installation, Start-up. Service Manual
Variable displacement pump 20 / working hydraulics

Fig. 2 Shut-off valve on the hydraulic pump

a = open
b = closed

1.2 Installation

Note!
Carefully clean the piping and hoses prior to installation and check for damages.

Flange-mount the hydraulic pump 20 on the diesel engine.

Fit the cylinder head screws 6 and tighten with the prescribed tightening torque see Fig. 1.
Connect all hoses / lines to the pump 20.
Remove the oil sump.

1.3 Start-up

Note!
Before start-up of the working pumps the pump housings mut be filled with oil and the regulating
valves must be bled!

Before initiating start-up, fill the hydraulic tank up to the upper oil level mark and open the shut-off
valve on the hydraulic tank (position a).
Continue to unscrew the leak oil lines T and Fe on the pump 20 and 30 until hydraulic oil without
foam is exuded.
Screw together the leak oil lines T and Fe once again.
Start the machine.
Check the threaded unions and lines for leaks.
Seal the suction hose airtight (retighten connection or pipe clamps).

7.01.2Wednesday, 25.December 2019 17:16 printed this protected document! R914C-R924C_en.pdf

R 914 C / R 924 C
ADMIN
copyright by

MJFCIFSS
Service Manual Hydraulic pump: Removal, installation, Start-up.
Variable displacement pump 20 / working hydraulics

1.4 Bleeding the hydraulic pumps

Note!
After working on the hydraulic pumps or following an oil-change of the hydraulic system, as well as
when using a vacuum pump, the hydraulic pump must be bled.Before starting up the pump for the
first time, following repair or following replacement of the pump, the pump housing must be filled
with hydraulic oil via leak oil connection T.

Initial start-up following pump replacement or after using a vacuum pump

Allow the diesel engine to turn for approx. 10 sec. using a starter, however, do not allow it to start.
Start up the diesel engine and allow it to run for approx. 7 min. at lower idle speed.
Monitor the oil level in the hydraulic tank and top up as required.
Loosen the leak oil line T to the variable displacement pump 20, however, do not unscrew com-
pletely.
Bleed the pump with the diesel engine running at lower idle speed.
until hydraulic oil without foam begins to flow out of the leak oil connection
Tighten the leak oil line again; not necessary if gear pumps are featured.
Run the hydraulic system up to full load so that the hydraulic oil heats to an operating temperature
of at least 50°C.
Check the setting of the pressure relief valve of the hydraulic system.
As pressure increases pay attention to any suppression in engine speed.
If necessary, check electrical signals and adjustment values, see adjustment protocol and set-
ting instructions in Group 6.
Inspect the system for leaks.

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Hydraulic pump: Removal, installation, Start-up. Service Manual
Gear pump 33

2 Gear pump 33

Fig. 3 Gear pump 33

Gear pump 33 for the hydraulic fan drive

2.1 Dismantling
Close the shut-off valve 3 on the hydraulic tank (position b).
Place a suitable oil pan beneath the hydraulic pumps as a precautionary measure.
Disconnect the hoses / lines from the pumps and catch the hydraulic oil.
Loosen and unscrew the cylinder head screws or hexagon head screws.
Dismantle the hydraulic pump.

2.2 Installation
Install the hydraulic pump.
Fit the cylinder head screws or hexagon head screws and tighten with the prescribed tightening
torque see Fig. 3.
Connect all hoses / lines to the pump.
Check the threaded unions and lines for leaks.

2.3 Start-up
Before initiating start-up, fill the hydraulic tank up to the upper level mark and open the shut-off
valve 3 on the hydraulic tank (position a).
Check the threaded unions and lines for leaks.

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Service Manual Hydraulic pump: Removal, installation, Start-up.
Gear pump 33

Note!
No refilling is necessary if gear pumps are featured. For bleeding of the gear pumps 33 :
Loosen the threaded unions of the respective pressure hose (P)
Bleed the pump with the diesel engine running at lower idle speed
Until oil without foam flows out of the pressure connection.
Tighten the threaded unions with the prescribed tightening torque see Fig. 3.
Check the connection for leaks

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Hydraulic pump: Removal, installation, Start-up. Service Manual
Gear pump 33

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Service Manual Variable-displacement twin pump DPVP
General

7.11: Variable-displacement twin pump DPVP

1 General
The DPVP variable-displacement pump mainly consists of a splitterbox 1 (pump distribution gear)
with two axial piston units 21 and 23 mounted in parallel in the same main housing 11. The both piston
units are of swash-plate construction type and are driven directly by the input shaft 12 of the pump
splitterbox. The deliveries of both pump units can be adjusted independently from each other.

2 Technical data
See in group 3.

3 Design

Fig. 1 Variable displacement twin pump DPVP

1 Pump splitterbox complete 3 Connecting plate of the twin pump

10 Gear cover 11 Main housing
12 Input shaft 13 Shaft of the main power take off
15 Intermediate gear 16 Gear for auxiliary power take off
21 Driving mechanism P1 22 Positioning piston - pump P1
23 Driving mechanism P2 24 Positioning piston - pump P2
25 Regulation unit complete - pump P1 26 Regulation unit complete - pump P2
28 Swash plate 29 Connecting link
30 Servo oil pump

The variable-displacement twin pump DPVP consists of the following 7 assemblies tightly arranged
to a complete unit:
– The splitterbox 1 with main housing 11, gear cover 10, input shaft 12, shafts 13 of the main power
take off, intermediate gear 15 and gear 16 for auxiliary power take off.
– the both power mechanisms of the axial piston units 21 and 23, which are mounted in the housing
11, arranged in parallel on the shafts 13 of the main power take off.
– the both pump regulator 25 and 26, which are flanged to the main housing 11.

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Variable-displacement twin pump DPVP Service Manual
Operating mode

– the connecting plate 3 comprising the bearing of the driving mechanism of the both pump units
and the positioning pistons 22 and 24, which are connected with the pump regulators 25 and 26
via internal boreholes in the connecting plate and in the main housing. The connecting plate 3 also
integrates the combined suction port and the both pressure ports for the twin pumps.
– the gear pump 30 mounted to the front of the connecting plate 3 and driven directly by the shaft
of the right pump unit 23. The gear pump 30 is used to generate the servo oil pressure.

4 Operating mode
The input shaft 12 the pumps splitterbox powers the driving mechanisms (drive shafts, cylinders and
pistons) of the variable-displacement twin pump DPVP.
The variable-displacement twin pump takes up hydraulic oil through a suction connection «S» in the
connecting plate 3 and feeds the oil through the pressure connections A1 and A2 into the working
circuits of the hydraulic installation.
The leak oil of the variable-displacement pump flows back to the tank through the leak oil connection
T at the main housing 11.
The positioning pistons 22 and 24 adjust, via the connecting links 29, the swivel angle of the swash
plates 28, and by the fact the deliveries of the pump units depending on the actual pump high pres-
sure and on other external regulating pressures connected to the regulators 25 and 26.
The elaboration of the regulating pressures and the principle of operation of the regulation valvesmay
vary depending on the type of regulation.
WITH THE PUMP REGULATION «SL-SD» the swivel angle variations are controlled depending on :
• the pump high pressure (linked to the regulators via internal bores in the connecting plate),
• the upcoming power regulating pressure «LR» (connections X31 and X32 of regulators)
• the control pressure «SD» for swivel angle limitation (connections X11 and X12 of regulators)
• the high pressure of the second pump unit (connections X71 and X72 of regulators)

Fig. 2 Hydraulic diagramm of variable pump DPVP (with SL - SD regulation valves)

WITH THE PUMP REGULATION «LR-LS» the swivel angle variations are controlled depending on :
• the pump high pressure (linked to the regulators via internal bores in the connecting plate),
• the upcoming power regulating pressure «LR» (connections X31 and X32 of regulators),
• the «LS» pressure (applied to connection X22 of regulator 26), which corresponds to the highest
user pressure of the circuit and is transmitted via the main control valve block,
• the control pressure «SD» for flow limitation (connection X42 of regulator 26).

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Service Manual Variable-displacement twin pump DPVP
Operating mode

Fig. 3 Hydraulic diagramm of variable pump DPVP (with LR - LS regulation valves)

WITH THE PUMP REGULATION «LR-SD-DA» the swivel angle variations are controlled depending
on :
• the pump high pressure (linked to the regulators via internal bores in the connecting plate),
• the upcoming power regulating pressure «LR» (connections X31 and X32 of regulators),
• the control pressure «SD» for swivel angle limitation (connections X11 and X12 of regulators)
• the oversteering pressure of the cut off valves which, as their response pressure is reached,
swivel the pumps back to Qmin (connections X51 and X52 regulators)

Fig. 4 Hydraulic diagramm of variable pump DPVP (with LR - SD - DA regulation valves)

Connections on pump
A1 High pressure exit P1 A11 High pressure connection P1
A2 High pressure exit P2 A21 High pressure connection P2
Fa Connection for auxiliary pressure Fe Exit for servo oil pressure
S Suction connection of the twin pump T Leak oil connection of the twin pump
X11 bis X82 Connections for regulating pressures on the pump regulators

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Variable-displacement twin pump DPVP Service Manual
Function

5 Function
Both variable-displacement pumps are driven by the drive shaft of the splitterbox.
The variable-displacement pump takes up hydraulic oil through a suction connection «S» and feeds
the oil through the pressure connections A1 and A2 into the working circuits of the hydraulic unit.
The leak oil of the variable-displacement pump flows through the leak oil connection T to the tank.

5.1 Function of powertrain

Fig. 5 Sectional drawing - Powertrain with swash plate

1 Pump housing 30 Servo-control pump

5 Mounting plate 31 Pistons with slipper
21 Drive shaft 32 Sliding disc
22 Roller bearing 33 Return plate
23 Snap ring 34 Return ball
24 Radial shaft seal ring 35 Pressure spring
25 Journal bearing 36 Pilot plate
29 Cylinder drum 41 Swash plate

The drive shaft 21 is mounted on a roller bearing in the pump housing and through a journal bearing
25 in the mounting plate 5. The pump housing 1 encloses 9 pistons 31 that are arranged in a circle
around the drive shaft 21 (in parallel with the shaft). They are moved in axial direction in the cylinder
drum 29, which is permanently connected through the spline profile to the drive shaft 21. The bottom
ends of the pistons are designed as ball joints and sit in slippers. The return plate 33 holds the slipper
on the swivelling yet not rotating swash plate 41 with sliding disc 32.
The pistons 31 are equipped with hydrostatic bearings. The boreholes in the pistons and slippers
supply the contact faces of the sliding disk 32 with pressure oil. This ensures that the disc surfaces
are covered with a thin oil film so that surface pressure is reduced to a minimum.

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Service Manual Variable-displacement twin pump DPVP
Function

When not pressurised, the pressure springs 35 built into the return ball 34 push the cylinder 29 onto
the pilot plate 36.
When the pressure increases, the cylinder 29 and pilot plate 36 are balanced by hydraulic forces in
such a way that the oil film at the control surface is maintained at all times, even under high loads,
and the amount of leak oil is reduced to a minimum.
The leak oil lubricates all the moving parts of the powertrain, and then flows to the tank.
With every rotary motion of cylinder 29, the pistons 31 complete a double stroke. The length of the
stroke is determined by the inclination of swash plate 41. The stroke length determines the flow rate.
The power train is controlled through kidney-shaped openings in the pilot plate 36.
At any given moment, four of the pistons in motion are connected to the tank side through a kidney-
shaped opening, thus taking up hydraulic oil.
Another four of the nine pistons are connected to the pressure side through a kidney-shaped opening
that is divided into three sections, and displace the oil through the pressure cut-off into the hydraulic
system. A ninth piston is situated in the area of the dead centre, i.e. at the point of return of motion.

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Variable-displacement twin pump DPVP Service Manual
Function

5.2 Pump adjustment

There is a mechanical connection between the swash plate 41 and the positioning piston 53. The ax-
ial movement of the positioning piston 53 results in a change of the pivoting angle of the swash
plate 41 from the maximum to the minimum pivoting angle. The regulation piston 75 built into the
regulator 8 (respectively 9) controls the swivel angle change, as it connects the large positioning pis-
ton side with the tank or the high pressure side respectively. The small positioning piston side is al-
ways connected to the high pressure side.
The stop screw 56 delimits the minimum angulation of the swash plate 41. In neutral position (Qmin)
of the swash plate 41, the pistons 31 have a mininum stroke to cover the losses due to leaks and
there is also no output. The delivery of the pump is proportional to its angulation.

Fig. 6 Sectional drawing - Pump adjustment

1 Pump housing 50 Splice plate

5 Mounting plate 51 Stud
8/9 Left / right pump regulator 52 Sleeve
29 Cylinder drum 53 Positioning piston
31 Pistons with slipper 54 Spring pin
41 Swash plate 55 Pin
42 Roller bearing 56 Stop screw
43 Stand 57 Lock nut
45 Rod 75 Regulation piston
46 Sleeve

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Service Manual Variable-displacement twin pump DPVP
Function

5.3 Shuttle valve

The high pressure and the servo-control pressure (Fa) stand at the shuttle valve 110. The most im-
portant of these two pressures acts on the small positioning piston side 53 for the adjustment in Qmin
direction and also on the regulator as control pressure. The large positioning piston side, for the ad-
justment in Qmax direction, ist fed by the regulator through the restriction 115. The restriction 115
impacts on the response time of the pump positioning.

Fig. 7 Shuttle valve

5 Mounting plate Fa Servo-control pressure

53 Positioning piston pSt Positioning pressure
56 Stop screw Qmin pHD High pressure going to the high pressure
piston
58 Test point M1/M2 (positioning pressure)
110 Shuttle valve
115 Restriction

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Variable-displacement twin pump DPVP Service Manual
Servo-control pump

6 Servo-control pump
The servo-control pump, intergrated in the mounting plate, is a gear pump. It is driven by the drive
shaft 121 of the right pump. It takes up hydraulic oil through the suction connection «S» and feeds
the oil through the pressure connections Fe. Some oil provided by this pump is conducted to the con-
nexion Fa and used to position the pumps.

Fig. 8 Servo-control pump

5 Mounting plate
121 Drive shaft
122 Needle bearing - both sides
123 Pump housing
124 Internal rotor
125 External rotor
126 Cover
127 Hexagon socket head cap screw

7 LR / LS - Regulation of DPVP twin pump

7.1 Overview of the regulators

The LR/LS regulation is a combination of a load sensing flow regulation (SD) and a power regulation
(LR).
Pumps with this regulation can be used as well in two loops systems as in single loop systems.
• In a two loops system one pump is fitted with a LR/LS regulator and the other with a LR regula-
tor, and the shared LS - positioning pressure is redirected via the port X8 to the second pump.
• In a single loop system the both pumps are fitted with a LR/LS regulator.

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Service Manual Variable-displacement twin pump DPVP
LR / LS - Regulation of DPVP twin pump

Notice!
With this type of regulation, pumps are used in hydraulic circuits together with LSC (Load Sensing
Controlled) main control valves.

Fig. 9 Arrangement of the regulators on the DPVP twin pump

21 Left pump unit P1 23 Right pump unit P2
25 Regulator (LR) of left pump 21 26 Regulator (LR/LS) of right pump 23

7.2 Construction of the regulators

Fig. 10 Regulating axis and hydraulic connections on LR & LR / LS regulation units

22.1Power regulator (LR) of pump P1 24.1Power regulator (LR) of pump P2

24.5Swivel angle limiter (SD) of pump P2
X2 Connection Load Sensing pressure pLS - (feedback of highest user pressure)
X3 Connection for power regulating pressure pLR
X4 Connection for regulating pressure for LS flow limitation
X8 Port for interconnection of the LS positioning pressures

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Variable-displacement twin pump DPVP Service Manual
LR / LS - Regulation of DPVP twin pump

7.2.1 Section view of the LR / LS and LR - regulators

Fig. 11 LR / LS and LR - regulators

25 LR - regulator complete 26 LR / LS - regulator complete
22.1LR-regulation axis of pump P1 24.1LR-regulation axis of pump P2
61 LR - adjustment screw 62 Counter nut
63 Threaded sleeve 64 Bushing
65 Regulating spring 66 Regulating spring
67 Spring plate 68 Ball
69 Valve sleeve 70 Regulating spool
71 Needle roller
72 Lever 73 Axle
74 High pressure measuring piston 75 Return piston
76 Pressure spring 77 Plug
78 Screw plug 79 Dowel pin
102Dampening orifice for LR reg. pressure
24.5LS-regulation axis of pumps P1 / P2
81 Adjustment screw 82 Counter nut
83 Threaded sleeve 84 Counter nut

7.11.10 R 914 C / R 924 C

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Service Manual Variable-displacement twin pump DPVP
LR / LS - Regulation of DPVP twin pump

85 Pressure spring 86 Pressure spring

87 LS pressure measuring piston 88 Bushing
89 Regulating spool 90 Valve sleeve
91 High pressure measuring piston 94 Plug
101 Screw plug 102 Dampening orifice
104 Dampening orifice

7.3 Function of LR - regulation axis (power regulation)

The large positioning piston face S is connected through the restrictor 115 to the centre groove of the
regulating piston 70.
When the regulating spool 70 is shifted to the right, it connects the larger face S of the positioning
piston with the pump high pressure through the already opened control edge S2 and the pump is shift-
ed towards Qmax.
The return piston 75 is connected mechanically with the positioning piston of the pump and to each
location of the positioning piston corresponds a well-defined position of the return piston 75, and in
fact so that the lever arm between high pressure measuring piston 74 and lever axle 73 is proportional
to the swivel angle of the pump.
If the swivel angle is maximum, the return piston 75 is shifted all the way to the right.

22 Positioning piston of pump P1 24 Positioning piston of pump P2

25 LR - regulator complete 26 LR / LS - regulator complete
22.1LR-regulation axis of pump P1 24.1LR-regulation axis of pump P2
43 Test point / Positioning pressure P1 44 Test point / Positioning pressure P2

The high pressure measuring piston 74 is in addition exposed in permanence to the pump high pres-
sure via boreholes in the regulator housing and in the return piston 75.
The force exerted onto the regulating spool 70 via lever 72 and needle roller 71 is therefrom equal to
the product of the pump high pressure by the pump delivery this means equal to the effective instan-
taneous hydraulic power of the pump.

R 914 C / R 924 C 7.11.11

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Variable-displacement twin pump DPVP Service Manual
LR / LS - Regulation of DPVP twin pump

When the pump power is low, the force of the springs 65 and 66 overcomes the force transmitted by
the lever 72 and displaces the regulating spool 70 to the right so the control edge S2 opens. The both
faces S and s of the positioning piston are now exposed to the same pump pressure and the posi-
tioning piston is shifted toward Qmax (max. swivel angle of the pumpe).
The delivery of the pump increases as long as the pump power returned by the lever 72 corresponds
exactly to the pretension force of the regulating springs 65 / 66.
When the pump pressure increases, the feedback force at the lever 72 rises at the same time. The
control edge S1 opens, so that hydraulic oil can flow from the larger face S of the positioning piston
to the tank. The positioning piston 24 is thereby moved to the left in direction Qmin.
The pump swivel angle is reduced until a new equilibrium is reached between the pump swivel angle,
the pump high pressure and and the preset tension of springs 65 / 66.
Across the entire regulating range, each pump high pressure value corresponds to a specific position
of the positioning piston 24 for which the regulating spool 70 is at equilibrium, the control edges S1
and S2 are closed and the restoring forces of the regulating springs 65 / 66 are in balance with the
force transmitted by the lever 72.
In the regulating range, the pretension of the regulation springs 65 / 66 defines a characteristic curve
for which the hydraulic power of the pump is constant. In the "P-Q diagramm" of the pump this char-
acteristic is represented by an hyperbola (pump power = P x Q = constant) .
The end positions of the positioning piston determine the maximum and minimum swivel angle.

Notice!
The Qmax stop of the pump is not adjustable.
The Qmin stop screw has been adjusted at factory to a value specific for the type and the kind of
regulation of the pump. This screw must not be readjusted.

Fig. 12 Characteristic curve - power regulation (LR) of the pump

7.11.12 R 914 C / R 924 C

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Service Manual Variable-displacement twin pump DPVP
LR / LS - Regulation of DPVP twin pump

7.3.1 External control of the pump power

The characteristic curve of the power regulation can be hydraulically changed during operation while
applying a modifiable regulation pressure to the connection X3 of the power regulator.
If a pressure is applied to the chamber B (via the connection X3 (LR) of the regulator), an additional
force proportional to the power regulating pressure LR is generated and applied to the spool 70.
The regulating spool 70 can retrieve balance conditions only after the pump power has increased by
an amount corresponding to this additional force.
The higher the pressure LR is, the higher lays the power hyperbola where the pump regulation oc-
curs.
The pump regulation furthermore happens as described in previous section «function of power reg-
ulation LR». The regulating characteristic is however shifted in the P-Q diagram towards a higher
pressure (i.e. higher pump load). This shifting is proportional to the power regulating pressure pLR at
connection X3.
Basically, the pressure pLR is the output pressure of the regulation solenoid valve Y50 (LR valve).

7.4 Function of SD - axis (regulation of pressure difference PLS)

The purpose of Load Sensing regulator 24.5 is to adapt the oil delivery of the pump to the oil flow
needed by the supplied users. The Load Sensing regulator 24.5 is is mounted in series (hydraulically
speaking) with the both power regulators 22.1 and 24.1.
The piston 89 connects the groove to the positioning piston either with tank pressure (the control
edge S3 opens and the pump is swivelled back to minimal flow), or with the pump high pressure (the
control edge S4 opens and the pump swivels out to Qmax).

24.5LS-regulation axis of pump P2 26 LR / LS - regulator complete

The pretension force of the springs 85 and 86 (which determines the adjustment of the P value)
and the force created by the pressure in chamber LS, acting onto the control surface of the LS pres-
sure measuring piston 87 wirkt, push the piston 89 in direction Qmax.
The hydraulic force due to the action of the pump high pressure acting onto the control surface of the
high pressure measuring piston 91 displaces the regulation piston 89 in direction Qmin.
InWhen the piston is in neutral position, these three forces compensate each other. This means that
the piston 89 regulates so to maintain in permanence between the chambers pLS and pHD a pressure
difference ( P) corresponding to the pretension of the springs.
This pressure difference is independing on the instantaneous pump delivery.

R 914 C / R 924 C 7.11.13

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Variable-displacement twin pump DPVP Service Manual
LR / LS - Regulation of DPVP twin pump

7.4.1 Limitation of the maximum pump delivery (reduction of P)

If applying a pressure to the connection X42 of the regulator, an additional force appears on the spool
89 and acts again the pretension of the springs 85 and 86.
The spool 89 now regulates so to maintain a new pressure difference between LS and P, and the
pump will swivel back as soon as a reduced P-value will be reached.
The pump can now only be swivelled out until reaching a flow rate Q (given by the relation Q= f( P)
in spools of the main control valves supplying the respective users) erreicht wird.
See also the descriptions for Load Sensing control valves and for Load Sensing hydraulic circuit.
The following charachteristic curve show the relation between P, maximum possible pump delivery
and regulation pressure p( P ) for reduction of P at connection X42.

Fig. 13 Characteristic curve - flow limitation / reduction of P-LS

If for example the regulation pressure on X42 is equal to 11 bar, the pump unit will swivel back as
soon as a P(LS) of 5 bar is reached and the maximum swivel angle of the pump is limited to 50%
of Qn.

7.11.14 R 914 C / R 924 C

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Service Manual Variable-displacement twin pump DPVP
LR / LS - Regulation of DPVP twin pump

7.5 Hydraulic diagramm LR/SD/DA regulation

1 Pump splitterbox complete

21 Driving mechanism P1 22 Positioning piston - pump P1
23 Driving mechanism P2 24 Positioning piston - pump P2
25 Regulator complete - pump P1 26 Regulator complete - pump P2
22.1LR regulation axis - pump P1 24.1LR regulation axis - pump P2
22.2SD regulation axis - pump P1 24.2SD regulation axis - pump P2
22.3Pressure cut-off -pump P1 24.3Pressure cut-off -pump P2
30 Servo oil pump
43 Test point / positioning pressure P1 44 Test point / positioning pressure P2
102Dampening orifice - LR pressure 103Dampening orifice - SD pressure
104Dampening orifice - pressure cut-off 115Dampening orifice - positioning pressure

Fig. 14 Hydraulic diagramm - DPVP twin pump with LR/SD/DA regulation

R 914 C / R 924 C 7.11.15

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LR / LS - Regulation of DPVP twin pump

7.11.16 R 914 C / R 924 C

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Service Manual Hydraulic motors schedule
Swing motors

7.20: Hydraulic motors schedule

1 Swing motors

Machine type Hydraulic Motor Description

Machine
(Serial number) Type - Size see subgroup
1062
1063
R 914 C HMF 075 7.25
1064
1065
R 924 C 1066
1067
1068
HMF 075 7.25
1136
1174
1069

2 Travel motors

Machine type Hydraulic Motor Description

Machine
(Serial number) Type - Size see subgroup
1062
1063
R 914 C FMV 075 7.27
1064
1065
R 924 C 1066
1067
1068 FMV 075 7.27
1136
1174
1069 FMV 100 7.27

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Travel motors

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Service Manual HMF 75-02P hydraulic fixed-displacement motor
Function and design

7.25: HMF 75-02P hydraulic fixed-displacement motor

1 Function and design

The hydraulic fixed-dsiplacement motor is a axial piston motor of the swash plate type designed for
an open circuit. The high-pressure hydraulic motor has a constant pivot angle. It is used to drive the
slewing gezr mechanism of the machine and features all that are required for optimised slewing gear
operation.
– Way valve function for rotation
– Priority valve for slewing gear
– Torque Control
– Secondary and suction valve 131/132 with controllable characteristic
– Feeder valve
– Anti-reaction function
– Outlet function
The hydraulic fixed-displacement motor 130 consists of three main components:
– The motor housing 1 encases the drive shaft and the complete powertrain.
– The valves are combined in a compact unit in the control base receptacle 2.

Fig. 1 Hydraulic fixed-displacement motor 130

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HMF 75-02P hydraulic fixed-displacement motor Service Manual
Function and design

Fig. 2 Basic design of powertrain

1 Motor housing 7 Cylinder block

2 Control base receptacle 131 Secondary pressure relief valve / swivel-
ling right
3 Radial shaft seal ring 132 Secondary pressure relief valve / swivel-
ling left
4 Shaft 141 Check valve / LS pressure
5 Working piston 142 Check valve / tank return line
6 Control base

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Service Manual HMF 75-02P hydraulic fixed-displacement motor
Function and design

Fig. 3 Exploded view of control base receptacle 2

131 Secondary pressure relief valve / turning 145 Measuring point / turning right
right
132 Secondary pressure relief valve / turning 146 Measuring point / turning left
left
133 Pilot control piston / turning 147 Measuring point / control pressure
134 TC pressure relief valve 148 Shuttle valve
135 Restrictor check valve / control pressure d1 Nozzle in restrictor check valves
136 Stroke limiter / control piston d2 Nozzle in actuating circuit of pressure relif
valve 131/132
137 Torque Control valve d3 Pilot control pressure nozzle (for torque
control)
138 Input pressure balance d4 Nozzle / LS pressure at input pressure
Priority switching / swivelling balance
139 Feeder valve d5 Nozzle for torque control valve 137
141 Check valve / LS pressure d6 Housing flushing nozzle
142 Preload valve
Return check valve

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HMF 75-02P hydraulic fixed-displacement motor Service Manual
Technical data

2 Technical data

Machine series R 914 C-Li R 924 C-Li

from serial numbal 19527 19846
Type of oil motor HMF 75-02P
Flow consumption cm3 75.9
Leak oil max. at (200 bar) l / min 9.0
Start of movement bar 8,5±0,5
Control piston 133

Nozzle dimensions
Nozzle d1 mm 0,4
Nozzle d2 mm 0,6
Nozzle d3 mm 0,8
Nozzle d4 mm 0,6
Nozzle d5 mm 1,3
Nozzle d6 mm 1,6

Tightening torques
Sealing flange nut 16 Nm 60
Lock nut 125 Nm 50
Lock nut 127 Nm 5
Secondary pressure relief valve 131/132 Nm 80+10
Lock nut 117 at secondary pressure relief valves 131/ Nm 70
132
Restrictor check valve 135 Nm 9
Sealing flange nut at TC pressure relief valve Nm 60
Torque Control valve 137 Nm 100

Tab. 1 Technical data

3 Functional description

3.1 Way valve 133, Fig. 4 and Fig. 5

The control piston 133 of the way valve is used to actuate the hydraulic motor. It is centred in its neu-
tral position by the two springs 15. The pump pressure acts on the motor through the connection P.
Using the pilot control unit, the operator can build up the control pressure in the spring chamber X/Y
necessary to perform the desired swivelling motion.
The control piston 133 is shifted according to the preselected control pressure and the oil flows from
P to A (B) and to B (A) and T.
The open channel acts as a gauge orifice after which the LS pressure is measured and transmitted
to the pump controller. The oil flow (slewing gear speed) is adjusted according to the control pressure.
The piston stroke can be restricted with a stop crew 17 so that the maximum flow rate is limited. The
restrictor check valves 135 attenuate the spool movement in both directions.

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Service Manual HMF 75-02P hydraulic fixed-displacement motor
Functional description

Fig. 4 Hydraulic diagram

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HMF 75-02P hydraulic fixed-displacement motor Service Manual
Functional description

Fig. 5 Sectional drawing of the control base receptacle 2

15 Pressure spring 139 Feeder valves

16 Sealing flange nut 140 High pressure check valve
17 Stop crew 141 Check valve / LS pressure
18 Shims 142 Preload valve / Return check valve
19 Control cap 145 Measuring point / turning right
22 Pressure spring 146 Measuring point / turning left
23 Pressure spring 147 Measuring point / control pressure
130 Slewing gear motor with way valve 148 Shuttle valve
131 Secondary pressure relief valve / turning d1 Nozzle in restrictor check valves 135/136
right
132 Secondary pressure relief valve / turning d2 Nozzle in actuating circuit of pressure
left relief valves 131/132
133 Control piston / turning d3 Pilot control pressure nozzle (for torque
control)
134 TC-Druckbegrenzungsventil d4 Nozzle / LS pressure at input pressure
balance

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Service Manual HMF 75-02P hydraulic fixed-displacement motor
Functional description

135 Drosselrückschlagventil Steuerdruck d5 Nozzle for torque control valve 137

136 Hubbegrenzung Steurkolben d6 Housing flushing nozzle
137 Torque Control Ventil d7 Nozzle for A-B connection
138 Prioritätschaltung Schwenken / Ein-
gangsdruckwaage

3.2 Priority valve 138 (input pressure balance), see Fig. 7

The priority valve 138 is installed in the channel P in front of the control piston 133, see Fig. 5.
The system LS pressure that is applied onto the hydraulic motor through the connection LS does not
affect the control system of the input pressure balance 138, and the check valve 141 in the control
base receptacle 2 prioritises the slewing gear.

Fig. 6 Control base receptacle 2, see Fig. 2

3.3 Torque control, see Fig. 6

The TC valve 137 determines the acceleration pressure. The machine operator selects teh desired
oi flow rate as well as the variable acceleration pressure at the pilot control unit. This prevents the
pressure relief valves 131/132 (secondary valves) from being opened. The maximum acceleration
pressure is set at the TC pressure relief valve 134.

Fig. 7 Sectional drawing, see Fig. 5

18 Piston 134 TC pressure relief valve

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HMF 75-02P hydraulic fixed-displacement motor Service Manual
Functional description

20 Regulating piston 137 Torque control valve

22 Spring 138 Priority switching swivelling / input pres-
sure balance
23 Adjusting spring

3.4 Secondary pressure relief valves with suction function

The secondary pressure relief valves 131/132 are adjustable. They are factory-set to a basic value.
When a control pressure of > 5 bar is applied at the connections X/Y, (see «Hydraulic diagram» on
page 5) the set valve pressure is changed from the basic value to the maximum value. The control
pressure of the way valve is used as the actuating pressure.
During the acceleration phase , the associated secondary pressure relief valve is adjusted to the
maximum set value, depending on the control pressure and along a characteristic. If the machine op-
erator wishes to make smooth movements, the pilot control unit must be held in 0 position, and the
uppercarriage is moved against the basic settings of the secondary pressure relief valves 131/132
(minimum setting 50 bar).
If the operator desires hard braking of the uppercarriage, he must change the setting of the respective
secondary pressure relief valve 131/132 to the maximum value. The uppercarriage is now slowed
down against maximum pressure. Depending on the control pressure set by the machine operator,
the controllable secondary pressure relief valves 131/132 can be used to adjust the brake pressure
along a defined characteristic with minimum and maximum value.
The minimum and maximum value are mechanically adjustable from the outside. The control pres-
sure can be adjusted along the TC characteristic from the outside.
The outlet side of the pressure relief valves 131/132 is exposed to the preload tank return pressure,
facilitating reloading through the suction valves.

Fig. 8 Secondary pressure relief valves 131/132

70 Piston 119 Adjusting screw

71 Needle piston 120 Stop screw
72 Spring 121 Spring
73 Spring 124 Adjusting screw
76 Valve cone 125 Lock nut
77 Spring 126 Adjusting screw
115 Spring 127 Lock nut
116 Piston T/T1 to hydraulic tank
117 Lock nut x/y Control pressure connections

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Service Manual HMF 75-02P hydraulic fixed-displacement motor
Maintenance and repairs

3.5 Feeder valves 139

To prevent cavitation, it is possible to supply the slewing gear system directly through the feeder
valves 139 that are connected to the preloaded tank return line in the control block.

Fig. 9 Feeder valve 139

3.6 Outlet function (see «Hydraulic daigram» on page 5)

The tank return line (channel T) is always preloaded. A metered amount of oil is fed through the noz-
zle D3, acting as flushing oil to cool the housing of the hydraulic motor. It then leaves the housing
together with any leak oil to the connection L/U.

4 Maintenance and repairs

Note!
Liebherr oil motors do not require any maintenance whatsoever. For instructions regarding sealing
and repair work, refer to the separate repair manual "Liebherr HMF fixed displacement oil mo-
tors".

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HMF 75-02P hydraulic fixed-displacement motor Service Manual
Maintenance and repairs

7.25.10 R 914 C / R 924 C

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Service Manual Hydraulic cylinders
Job definition

7.30: Hydraulic cylinders

1 Job definition
The Liebherr hydraulic cylinders for the earth-moving machinery are classified in design as differen-
tial cylinders.
The cylinder is extended by supplying the hydraulic oil to the piston crown side; supplying hydraulic
oil to the piston rod side retracts the cylinder.
The maximum forces are dependent on the respectively effective surfaces,

Extending => Piston crown side

Retracting => Piston rod side

as well as the maximum permissible operating pressure, thus the forces are greater for extension
than for retraction due to the difference in surface area.
The speed of the extending or retracting cylinders depends on the quantity of oil being supplied per
time unit, as well as the surface area. Speed properties are completely opposite to those of the force,
therefore speed is greater during retraction than during extension.
The Liebherr hydraulic cylinders differ for each individual application area in the required stroke (ex-
tension), diameter (force) and the respective absorption system (end-of-stroke damper).
The hydraulic cylinders installed in our machines come with and without end-of-stroke damper.

Note!
There are many variants of seals, guides, pistons and absorption systems installed in the machines
which can not be completely documented in the Service Manual. Details can be obtained in the
spare-parts catalogue or Lidos.

Fig. 1 Hydraulic cylinders

2 System description
Hydraulic cylinders are comprised in essence of cylinder liner 10 with welded cylinder base and bear-
ing bore, screw-fastened piston rod bearing 13 (also serves as a cylinder head) and piston rod 8 with

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Hydraulic cylinders Service Manual
System description

bearing bore, as well as screw-fastened piston 12.

O-rings with supporting rings, as well as Glyd seal, Rimseal and Stepseal sealing rings have been
fitted in the piston 12 and piston rod bearing 13 to seal the pressure chambers on the inside and
outside. The scraper ring in the piston rod bearing 13 protects against any contaminants penetrating
the piston rod 8.
The guide rings on the piston 12 and in the piston rod bearing 13 ensure proper guidance of the piston
rod.
For precise assembly of the sealing elements of the piston 12 and piston rod bearing 13, see Fig. 3.
For further configurations of piston see Fig. 16, end-of-stroke damper, see Fig. 17 and stroke reduc-
tion see Fig. 18.

Fig. 2 Exploded view of a hydraulic cylinder

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Service Manual Hydraulic cylinders
System description

1 Bushing 13 Complete piston rod bearing 32 Threaded bushing

2 Sleeve (stroke reduction, not 15 Rotary shaft seal 33 Washer
featured as standard)
3 Sleeve (stroke reduction, not 16 Pivoting bearing 60 Screw
featured as standard)
4 Piston nut 18 Circlip 65 Cylinder head screw
8 Piston rod 20 Hexagon head screw 82 Shock absorber body
9a/9b Shock absorber sleeve 25 Snap ring 84 Sleeve
10 Cylinder 30 Split ring with O-ring 990 Socket wrench for pos. 32
(see group .2)
12 Complete piston 31 Shock absorber body

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System description

Fig. 3 Sealing elements on piston 12 and piston rod bearing 13

9a Shock absorber sleeve 13 Piston rod bearing

9a.18 O-ring 13.3 Complete scraper ring with O-ring.
9a.19 Sealing ring 13.6 Scraper ring
12 Piston 13.7 O-ring
12.2 Piston guide ring 13.8 Supporting ring
12.3 O-ring 13.9 Rimseal ring (secondary pressure limita-
tion)
12.4 Turcon Glyd ring 130 Turcon Stepseal (primary pressure limita-
tion
12.6 Piston guide ring 131 O-ring
12.7 Supporting ring 132 O-ring
12.8 O-ring 133 Guide ring
25 Ring

2.1 Cylinder variants, see Fig. 17 / Fig. 18

The undamped hydraulic cylinders (variant I) are primarily used for support and for certain (less
used) cylinders of the attachment, such as grapple and adjusting cylinder for road travel for example.
Damped hydraulic cylinders feature an end-of-stroke damper on either one or both sides, see variant
II (one sided) or variant III and variant IV (both sides).

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Service Manual Hydraulic cylinders
Functional description

Cylinders may be applied with stroke reduction, depending on the respective application. To attain a
reduction in the stroke, a sleeve is incorporated on the piston base side 2 (variant G) or a piston is
incorporated on the piston rod side 3 (variant H), thus effecting the desired reduction.
Pivoting bearing bushings 16 (variant Z1) or sealed bushings 1 (variant Z2) are installed on the pis-
ton rod head. Sealed bushings 1 (variant Z2) are installed on the cylinder sleeve.

3 Functional description

3.1 For end-of-stroke damper on one side

3.1.1 Extending piston rod 8

The hydraulic oil from the control valve block flows through the connection on the base side of the
cylinder 10 and pressurises the piston 12. The piston rod extends and forces the oil on the piston
base side through the control valve block to the tank.
Shortly before the end of stroke, the shock absorber sleeve 9 is pushed into the damping bore of the
piston rod bearing 13.
Immersion of the shock absorber sleeve 9 in the borehole reduces the clearance opening of the sup-
pressed oil, thus the oil flows back out of the hydraulic cylinder to the control valve block via three
keyways arranged around the circumference of the sleeve 9.
An intense restriction of the return oil effects a deceleration of the extension motion of the piston rod
(damping).

3.1.2 Retracting piston rod 8

Fig. 4 Sectional drawing of hydraulic cylinder

3.2 For end-of-stroke damper on both sides, see Fig. 5

3.2.1 Extending piston rod 8

The hydraulic oil from the control valve block flows through the connection into the cylinder base and
pressurises the shock absorber body 82, as well as pressurising the piston 12 via the longitudinal
grooves.
The piston rod 8 extends (see 3.1 on page5).

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Installing / dismantling hydraulic cylinders

3.2.2 Retracting piston rod 8

The hydraulic oil from the control valve block flows through the connection into the piston rod bearing
13 and pushes through the annular clearance between shock absorber sleeve 9 and piston rod 8 onto
the face surface of the shock absorber sleeve 9. The hydraulic oil pushes through the radial bores
and keyways of the shock absorber sleeve 9 onto the piston 12.
The piston rod retracts and forces the oil on the piston base side to the tank. Shortly before the end
of stroke, the shock absorber body 82 is pushed into the base of the cylinder 10. Immersion of the
shock absorber sleeve 84 into the damping bore reduces the clearance opening of the suppressed
oil, thus the oil flows back out of the hydraulic cylinder to the control valve block via two keyways ar-
ranged around the circumference of the sleeve 84 or the body 31.
An intense restriction of the return oil effects a deceleration of the retraction motion of the piston rod
(damping).

Fig. 5 Partial section of end-of-stroke damper

4 Installing / dismantling hydraulic cylinders

Caution!
Before dismantling the respective cylinder, the following special measures are to be taken to pre-
vent any risk of injury to the mechanic and his assistants:
Position the vehicle on flat ground and place the attachment or the supports on the ground. En-
sure that the cylinder is in a suitable position to be able to install or dismantle comfortably.
Switch off the diesel engine. With the ignition and servo control switched on, relieve the hydraulic
pressure lines of pressure by repeatedly deflecting the servo control as far as it will go.
Lower pretension of hydraulic tank by loosening the ventilation filter in the maintenance cover.
Secure the hydraulic cylinder by hooking it onto the lifting gear. If necessary, also secure any
attachment parts which may become loose.

4.1 Dismantling
Disconnect the hydraulic hoses and catch any escaping oil in a suitable container
If necessary, unscrew the terminal block with pressure line on the piston rod bearing and cylinder
base
Seal the lines using end plates or threaded unions / plugs, etc.

4.1.1 For sealing tasks on the machine

Release and strike out the bearing pins of the piston rod or pull out stiff pins using an extraction
press

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Installing / dismantling hydraulic cylinders

4.1.2 For complete dismantling

Release and strike out both bearing pins or pull out stiff pins using an extraction press

4.2 Installation
Fit the hydraulic cylinder into the bearing block using the lifting gear, ensuring that the bearing
bores of the cylinder base and attachment part or support are flush
Lightly grease the bearing pin and hammer or pull in
Bleed the hydraulic cylinder
Connect the line on the base side and extend the cylinder slowly and carefully at minimum idle
speed so that the air in the cylinder can dissipate completely on the rod side (it is imperative that
any escaping oil is caught in a suitable container)
Then connect the lines on the piston rod side and retract and extend the cylinder repeatedly slowly
and carefully at minimum idle speed so that the remaining air in the cylinder can dissipate into the
tank. Then connect all lines and check the screw connections of the flange for correct tightening
torque
Start up the diesel engine and extend or retract the hydraulic cylinder so far that the bearing bore
of the piston rod and attachment part or support are flush
Lightly grease the bearing pin and hammer or pull in
Secure both bearing pins accordingly
Move the attachment or support and check functioning or sealing of the cylinder with hydraulic
connections

4.3 For cylinders with fitted air bleeding plugs, see Fig. 6

Caution!
The cylinders are pressurised.
When loosening and unscrewing the plugs 1 the plugs can be forced out of the thread by pressure
which is still in the system, causing serious injury.

Ensure that a suitable container is on-hand

Loosen the plug 1 and unscrew carefully (with newer configurations, it is possible to fit the installed
vent valves with an oil drainage hose)
Screw in the miniature test ports with oil drainage hose
Extend the cylinder slowly and carefully all the way with minimum idle speed
The air-oil mixture escapes through the hose into the container prepared beforehand
Remove the miniature test ports again
Screw in the plugs again after bleeding (tightening torque 40 Nm)

Fig. 6 Air bleed plugs in the hydraulic cylinder

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Changing the seal

5 Changing the seal

Fig. 7 Partial section of the hydraulic cylinder

5.1 Disassembly

Note!
Hefty forces are required for assembly and disassembly of the piston nut and the piston 12. It should
therefore be ensured that the piston rod 8 is locked using the respective tensioning device or anti-
twist device. It is essential that the piston rod surface does not sustain any damage whatsoever.

Unscrew the hexagon head screw 20 with washer 33 and pull the piston rod bearing 13 , complete
with piston rod 8 and piston 12 out of the cylinder
Set the piston rod down in a place which has been cleaned beforehand. All damage must be
avoided
Remove the piston guide rings 12.6
Remove the circlip 25 and unscrew the piston nut 4 (if featured)
Screw the piston key, see Group 2 to obtain information regarding special tools, onto the piston
12 and unscrew the piston from the piston rod 8
For hydraulic cylinders with end-of-stroke damper: extract the shock absorber sleeve 9

Pull the piston rod bearing 13 from the piston rod 8

Remove all sealing elements from the piston and piston rod bearing

5.2 Assembly, see Fig. 10

Assembly in the piston rod bearing

Carefully remove all dust, dirt, swarf and any other foreign bodies
Check all parts meticulously for reusability
Should any damage be ascertained on piston rods, for example dents and scratches, it is im-
perative that the piston rod is replaced by a specialist mechanic
Apply a coating of hydraulic oil to all parts and sealing elements before fitting
Apply Castrol-Tarp anticorrosive to the installation space of the seals (ID no. 8611031)
Fit the O-rings 13.11 / 13.12 in the piston rod bearing 13. Fit the sealing rings 13.9 and 13.10 in
the bearing 13, see Fig. 10 and Fig. 11

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Changing the seal

Note!
It is imperative that the installation position and direction of the sealing rings 13.9 and 13.10 is cor-
rect (due to the pressure direction of the oil). Note also the information regarding variations!
• Zurcon - Rimseal 13.9 (dark grey or turquoise) secondary - flexible - rubber-like
• Turcon - Stepseal 13.10 (bright grey) primary

Fig. 8 Kidney shaped formation of sealing ring and scraper ring for assembly
Press the Stepseal / Rimseal together into a kidney shape ensuring that no kinks are resulted
Place the Stepseal / Rimseal pressed together over the O-ring 131 / 132 and press into the groove
in the direction indicated by the arrow
Press the scraper ring 13.3 or 13.6 also into a kidney shape and insert, see Fig. 8
Fit the O-ring 13.7 and supporting ring 13.8
Push the complete piston rod bearing 13 and shock absorber sleeve 9 (not applicable for hydraulic
cylinders without end-of-stroke damper) onto the piston rod 8

Fig. 9 Concave supporting ring

)

Note!
Distinguishing features of the sealing rings 13.9 / 13.10. The different shape of the Rimseal 13.9
compared with the Stepseal 13.10 can be seen in see Fig. 10.
– Variant A : Piston rod bearing inserted.
– Variant B : Piston rod bearing screwed.

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Changing the seal

Fig. 10 Distinguishing features of the sealing rings

13.9 Rimseal ring a Flank - inclined

13.10 Stepseal ring b Flank - straight

• Colour Rimseal 13.9 => dark grey - shiny or turquoise (new)

Stepseal 13.10 => Bright grey - matt
• Elasticity Rimseal 13.9 => Flexible
Stepseal 13.10 => Inflexible
• Shape Rimseal 13.9 => Inclined flank
Stepseal 13.10 => Straight flank

7.30.10 R 914 C / R 924 C

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Assembly of sealing and guide elements on the piston

6 Assembly of sealing and guide elements on the piston

Fig. 11 Fitting on the piston 12

Note!
For fitting, the Turcon Glyd ring 12.4 must be pushed onto the piston via the outer edges in the
groove and is thus expanded accordingly.
The Turcon Glyd ring 12.4 should be heated in an oil bath or water bath to ensure easier fitting
(approx. 60°C).
Pull the O-ring 12.3 and Turcon Glyd ring 12.4 onto the piston mounting sleeve 12 using a
mounting sleeve a and spreader sleeve b (see Special tools in Group 2).
It is imperative that the Glyd ring 12.4 is reshaped immediately after fitting using a piston ring
compressor.
For a perfect assembly, calibration sleeves (mounting sleeves in Group 2) are available for fitting
the piston.

Fit the first supporting ring 12.7, O-ring 12.8 and second supporting ring one after the other into
the piston and lightly grease the O-ring with Castrol Tarp
Fit and secure the piston key or special tool (see Group 2) onto the piston

Clean all contact, threaded and bearing surfaces between piston rods, pistons and piston nuts
thoroughly and apply a thin coating of “Gleitmo 800“ lubricant (ID no. 8300004) on both sides (see
Fuels and Lubricants Group 1)

6.1 Fitting the piston (with thread) on the piston rod

R 914 C / R 924 C 7.30.11

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Fitting shock absorber sleeve 84

Note!
See works standard 4121 B in Group 1 for fitting of the piston
The actual works standard 4121 can be obtained from the spare-parts catalogue / Lidos. The draw-
ing number and date of installation are engraved on the cylinder. The code* can be obtained from
the hydraulic cylinder installation or is stamped on the newly fabricated piston
If the components are fitted without first applying a coating of grease, the prescribed movement in
accordance with the factory standard can not be achieved and subsequent disassembly is no longer
possible. Erosion of components! It is imperative that assembly parts are greased with “Gleitmo
800“ (ID no. 8300004).
Tighten the piston 12 onto the piston rod 8 in compliance with the assembly guideline, see group
1.22.

Remove the piston key.

Screw the piston nut 4 onto the piston rod 8.
Tighten the piston nut on the piston rod 4 using an appropriate piston nut wrench and in compli-
ance with the assembly guideline, see Group 1.22.
Remove the piston nut wrench.
Secure the piston nut 4 with a circlip 25 (if necessary, rebore the piston rod)

7 Fitting shock absorber sleeve 84

7.1 Cylinder with double-sided end-of-stroke damper, see Fig. 12

Clean the thread of the shock absorber body 82 (free of grease)
Apply a coating of Loctite no. 270 to the thread of the shock absorber body 82 and a coating of
“Gleitmo 800“ to the screw cone.
Fasten the sleeve 84 to the piston rod 8 using the shock absorber body 82 (tightening torque 130
Nm)

7.1.1 Installing the piston rod in the cylinder liner

Fit the inner piston guide strap 12.6 (hard) and outer piston guide strap 12.2 (soft) on the piston 12
Fit the piston ring compressor or mounting sleeve onto the piston 12 and apply light tension to the
guide rings 12.2 and 12.6 on the piston
Push the piston rod 8 complete with piston 12 carefully into the cylinder 10
Remove the piston ring compressor or mounting sleeve following insertion

Fig. 12 Fitting the shock absorber sleeve 32

7.30.12 R 914 C / R 924 C

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Replacing the piston rod head and cylinder sleeve bushing

7.2 Fitting the piston rod bearing 8 (inserted)

Fig. 13 Fitting the piston rod bearing

13.8 Supporting ring 13 Piston rod bearing

13.7 O-ring 20 Washer
10 Cylinder liner 33 Screw

Observe the correct installation position of supporting ring 13.8 and O-ring 13.7 (concave)
Push the piston rod bearing 13 into the cylinder 10, ensure correct positioning of the hydraulic con-
nections
Screw in the hexagon head screw or hexagon socket screw 33 with washer 20, wherever featured
Observe the different tightening torques of the screws 33, see Group 1.26

Note!
Never use an impact wrench to carry out this task, always use a torque wrench! Once assembled.
install the complete hydraulic cylinder into the basic machine or in the attachment (see “Installation”
on page 7).

7.3 Fitting the piston rod bearing 8 (screwed)

Fasten the piston rod bearing (special tool Group 2.12) on the piston rod bearing 13
Push the piston rod 8 and piston 12 into the cylinder 10
Screw the bearing head into the cylinder 10 using a wrench and tighten with the prescribed tight-
ening torque (see Group 1.24)

Fig. 14 Installation wrench on piston rod bearing

8 Replacing the piston rod head and cylinder sleeve bushing

Carefully remove all dust, dirt, swarf and any other foreign bodies

R 914 C / R 924 C 7.30.13

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Variants of piston rod bearing

Check all parts meticulously for reusability

Should any damage be sustained by the sealing rings, pivoting bearings, circlips or bushings, they
must be replaced immediately by a specialist mechanic
Apply a coating of lubricant to all parts and sealing elements before fitting

8.1 Variants with rotary shaft seal (see Fig. 19 on page18)

Remove the rotary shaft seal 15
Extract the bushing 1, clean it and replace as necessary
Insert the rotary shaft seal 15
.

Note!
It is imperative that correct installation position and direction of rotary shaft seal is observed 15.
Replace wherever wear is determined.

8.2 Variants with pivot bushings (see Fig. 19 on page18)

Remove the circlip 18
Extract the pivot bearing 16, clean it and replace as necessary
Insert the circlip 18
.

Note!
The joint of the pivot bearing 16 should be positioned at a right angle to the direction of load.

9 Variants of piston rod bearing

Fig. 15 Variants of piston rod bearing

D Piston rod bearing inserted

E Piston rod bearing screwed

7.30.14 R 914 C / R 924 C

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Service Manual Hydraulic cylinders
Piston variants on hydraulic cylinders

10 Piston variants on hydraulic cylinders

Fig. 16 Piston variants 12

A Piston 12 secured with piston nut

B Piston 12 with integrated piston nut

R 914 C / R 924 C 7.30.15

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Hydraulic cylinders Service Manual
End-of-stroke damper

11 End-of-stroke damper

Fig. 17 Variants of end-of-stroke dampers and stroke reduction

Variant I without end-of-stroke damper

Variant II end-of-stroke damper on one side
Variant III end-of-stroke damper on both sides
(old)
Variant IV end-of-stroke damper on both sides
(new)

9 Shock absorber sleeve 82 Shock absorber body

31 Shock absorber body 84 Shock absorber sleeve
32 Threaded bushing

7.30.16 R 914 C / R 924 C

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Service Manual Hydraulic cylinders
Stroke reduction

12 Stroke reduction

Fig. 18 Cylinder with stroke reduction

Variant G with stroke reduction (sleeve)

Variant H with stroke reduction (piston)

R 914 C / R 924 C 7.30.17

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Hydraulic cylinders Service Manual
Cylinder rod head bushing

13 Cylinder rod head bushing

Fig. 19 Cylinder rod head and cylinder sleeve bushing variants

Variant Z1 with pivot bushing (piston)

Variant Z2 with rotary shaft seal (sleeve)

7.30.18 R 914 C / R 924 C

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Service Manual Extension and retraction speeds

7.31: Extension and retraction speeds

Determining the extension and retraction times using the diagram

Fig. 1 Extension time Va and speed T(s) of a hydraulic cylinder

Fig. 2 Retraction time Ve and speed T(s) of a hydraulic cylinder

The diagram overleaf provides the extension and retraction times if the piston diameter D, the rod
diameter d, the piston stroke H and the delivery rate Q are known, see examples overleaf.

Note!
– For dimensions D, d and H of the cylinder, see corresponding Subgroup «Assembly of hydrau-
lic cylinders»
– To obtain dimension Q the flow rate of a working pump must be halved (one pump supplies two
cylinders, e.g. the bucket tipping cylinder) or the flow rate of both working pumps added together
(one cylinder is supplied by both pumps, e.g. the stick cylinder)
– Any flow rate which may be installed must be taken into account for the respective movements.
For excavators featuring Load Sensing control, any nominal delivery rates of the piston rod in
the spool valve must be taken into account.
– The flow rates specified in the «Hydraulic circuit» or «Pump aggregate» groups only apply with
the diesel engine running at nominal speed and if the pumps are new.
– Moreover, the pressure must remain below the pressure for regulation begin during extension or
retraction of the cylinder. Otherwise the flow rate is reduced via normal pump regulation (this oc-
curs shortly before the stop position for cylinders featuring end-of-stroke dampers, for example).

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Service Manual Extension and retraction speeds

Note!
D : Piston diameter of cylinder
d : Rod diameter of cylinder
D equiv. : Equivalent diameter for cylinder retraction.
2 2
Dequiv 2 = Dext dint

Examples
Example 1 :
One cylinder with D = 140 mm and d = 95 mm is retracted by 800 mm, with a supply rate of 85 l./min.
The cylinder motion time totals 4.7 seconds.
Example 2 :
One cylinder with D = 150 mm is extended by 1500 mm, with a supply rate of 480 l./min.
The cylinder motion time totals 3.4 seconds.

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Service Manual Installations for pistons and piston nuts by hydraulic
Application and purpose

7.32: Installations for pistons and piston nuts by

hydraulic cylinders
According to standard 4121 C (06/2008)

1 Application and purpose

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

2 Requirements / description of procedure

For the valid torque value number, refer to the drawing. The standard may not be adopted or trans-
ferred to apparently similar geometries.
Use this number to find the applicable turning distance and angle in the torque table (siehe Kap. 3,
”Torque table - Status 02.06.2010” auf Seite 7).
The torque values have been determined empirically and are subject to changes. This standard dif-
ferentiates between two tightening procedures, which are identified with 3-digit and 4-digit numbers
respectively (see chapters 2.1 and 2.2).

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Installations for pistons and piston nuts by hydraulic Service Manual
Requirements / description of procedure

2.1 Tightening with assembly wrench

This tightening procedure applies to 3-digit tightening numbers.

2.1.1 Preparation
Clean the contact surfaces (threads contact faces between piston rod, piston and piston nut) and ap-
ply a thin layer of Gleitmo high-performance lubricating grease (ID no. 8300 004, 40 g tube) to both
sides.

2.1.2 Definitions

Pretightening torque (Mv)

The piston (A) is secured with a torque wrench (B) applied to the square/hexagon head of the assem-
bly wrench (C). The position of the torque wrench must be carefully noted (see Fig. 1 on page2).

Turning distance (4)

Radian measure [mm] travelled as a result of the tightening of the piston, or piston nut along the outer
thread diameter, after application of the pretightening torque (see Fig. 2 on page3).

Turning angle (5)

Angle [°] travelled by the piston or piston nut respectively, after application of the pretightening torque
(see Fig. 2 on page3).

Fig. 1 Torque wrench

A Piston C Assembly wrench

B Torque wrench

When applying the pretightening torque (Mv), the torque wrench (B) must point in the same direc-
tion as the assembly wrench (C). Proceed in the same way to tighten the piston nut, using a suitable
assembly wrench.

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Service Manual Installations for pistons and piston nuts by hydraulic
Requirements / description of procedure

Fig. 2 Markings, turning distance, turning angle

1 Markings on the piston and the piston rod thread after application of the
pretightening torque
2 Markings on the piston rod thread
3 Markings on the piston after tightening
4 Turning distance
5 Turning angle
6 Markings on the piston nut and the piston rod thread after application of the
pretightening torque
7 Markings on the piston nut after tightening

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Installations for pistons and piston nuts by hydraulic Service Manual
Requirements / description of procedure

2.2 Tightening with hydraulic assembly device

This tightening procedure applies to 4-digit tightening numbers.

2.2.1 Preparation
Clean the contact surfaces (threads contact faces between piston rod, piston and piston nut) and ap-
ply a thin layer of Gleitmo high-performance lubricating grease (ID no. 8300 004, 40 g tube) to both
sides.

2.2.2 Definitions

Pretightening torque
Torque applied on the piston or piston nut with the torque wrench (A) via the hexagon head (B) of the
torque converter (C) (see Fig. 3 on page4).

Turning angle
Angle [°] travelled by the piston or piston nut respectively, after application of the pretightening torque
(see Fig. 5 on page6).

Fig. 3 Torque wrench

A Torque wrench
B Hexagon head
C Torque converter

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Service Manual Installations for pistons and piston nuts by hydraulic
Requirements / description of procedure

2.2.3 Operation of the assembly device

See separate operating manual of the assembly device (H).
For suitable adapters for the piston rod, piston and piston nut, refer to the piston parts list (see Fig. 4
on page5).

Fig. 4 Operation of the assembly device

A Piston rod
B Piston
C Adapter for piston
D Adapter for piston rod
E Piston nut
F Adapter for piston nut
G Torque converter
H Assembly device

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Installations for pistons and piston nuts by hydraulic Service Manual
Requirements / description of procedure

Fig. 5 Angle scale

A Dial
B Adjusting screw
C Angle scale

Before tightening, set the dial (A) with the adjusting screw (B) to position 0° on the angle scale (C).
The angle scale indicates the turning angle.
If the opening angle of the assembly device is not sufficient to achieve the prescribed turning angle,
mount the device again for a second tightening process. Note the previously completed angle.
Before continuing the tightening process, set the dial to the last achieved angle value.
Repeat this process as often as necessary to achieve the prescribed turning angle.

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Service Manual Installations for pistons and piston nuts by hydraulic
Torque table - Status 02.06.2010

3 Torque table - Status 02.06.2010

3.1 Tightening with assembly wrench (siehe Kap. 2.1, ”Tightening with assembly
wrench” auf Seite 2)

Piston Piston nut

Pretightening Turning Turning Thread M
WN 4121 No Turning angle Turning angle
torque [N.m] distance distance [mm]
~ [°] ~ [°]
[mm] [mm]
071 100 11 +1 30 21 +1 57 42x1,5
072 100 21 +1 57 21 +1 57 42x1,5
073 100 18 +1 49 19 +1 52 42x1,5
074 100 16 +1 44 - - 42x1,5
075 100 19 +1 52 21 +1 57 42x1,5
078 100 20 +1 55 14 +1 38 42x1,5
079 100 11 +1 30 21 +1 57 42x1,5
080 100 18 +1 49 - - 42x1,5
091 100 13 +1 30 19 +1 44 50x2
092 100 25 +1 57 19 +1 44 50x2
093 100 24 +1 55 19 +1 44 50x2
095 100 13 +1 30 19 +1 44 50x2
096 100 10 +1 23 9 +1 21 50x2/SW65
097 100 17 +1 39 19 +1 44 50x2
098 100 17 +1 39 - - 50x2
099 100 24 +1 55 19 +1 44 50x2
103 100 9 +1 21 - - 50x2
111 100 16 +1 33 18 +1 37 56x2
112 100 17 +1 35 18 +1 37 56x2
113 100 17 +1 35 19 +1 39 56x2
114 100 19 +1 39 - - 56x2
115 100 18 +1 37 - - 56x2
116 100 19 +1 39 - - 56x2
121 150 15 +1 29 19 +1 36 60x2
123 150 17 +1 32 19 +1 36 60x2
126 150 14 +1 27 - - 60x2
127 150 22 +1 42 - - 60x2
129 150 7 +1 13 8 +1 15 60x2
131 150 15 +1 28 - - 60x2
151 150 15 +1 27 19 +1 34 65x2
152 150 20 +1 35 19 +1 34 65x2
153 150 20 +1 35 - - 65x2
171 150 12 +2 20 18 +1 30 68x2
172 150 21 +2 35 18 +1 30 68x2
173 150 19 +2 32 18 +1 30 68x2
174 150 25 +2 42 18 +1 30 68x2
175 150 25 +2 42 18 +1 30 68x2
176 150 19 +2 32 18 +1 30 68x2

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Installations for pistons and piston nuts by hydraulic Service Manual
Torque table - Status 02.06.2010

Piston Piston nut

Pretightening Thread M
WN 4121 No Turning Turning
torque [N.m] Turning angle Turning angle [mm]
distance distance
~ [°] ~ [°]
[mm] [mm]
177 150 19 +2 32 18 +1 30 68x2
179 150 11 +2 19 18 +1 30 68x2
180 150 20 +2 34 18 +1 30 68x2
181 150 20 +2 34 - - 68x2
183 200 - - 40 +2 67 68x2
201 200 17 +2 26 16 +1 24 76x2
202 200 26 +2 39 16 +1 24 76x2
203 200 27 +2 41 16 +1 24 76x2
204 200 27 +2 41 16 +1 24 76x2
205 200 13 +2 20 - - 76x2
206 200 25 +2 38 25 +1 38 76x2
207 200 23 +2 35 - - 76x2
208 200 15 +2 22 - - 76x2
209 200 30 +2 45 - - 76x2
231 200 8 +2 11 16 +1 22 85x3
232 200 17 +2 23 16 +1 22 85x3
234 200 22 +2 30 - - 85x3
235 200 17 +2 23 - - 85x3
236 200 15 +2 20 - - 85x3
237 200 19 +2 26 - - 85x3
261 250 20 +2 25 10 +1 12 95x3
265 250 24 +2 29 10 +1 12 95x3
267 250 24 +2 29 - - 95x3
268 250 20 +2 24 - - 95x3
281 250 20 +2 23 13 +1 15 100x3
282 250 25 +2 29 - - 100x3
283 250 25 +2 29 21 +1 24 100x3
284 250 14 +2 16 - - 100x3
285 250 18 +1 20 - - 100x3
301 300 21 +3 22 20 +2 21 110x3
302 300 18 +3 19 20 +2 21 110x3
303 300 20 +3 21 20 +2 21 110x3
304 300 23 +3 24 20 +2 21 110x3
305 300 9 +3 9 - - 110x3
306 300 24 +3 25 - - 110x3
307 300 27 +3 28 - - 110x3
331 400 23 +3 22 20 +2 19 120x3
332 400 11 +3 11 - - 120x3
333 400 27 +3 26 - - 120x3
334 400 20 +3 19 20 +2 19 120x3
335 400 30 +3 29 - - 120x3
336 400 29 +3 28 - - 120x3

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Service Manual Installations for pistons and piston nuts by hydraulic
Torque table - Status 02.06.2010

Piston Piston nut

Pretightening Thread M
WN 4121 No Turning Turning
torque [N.m] Turning angle Turning angle [mm]
distance distance
~ [°] ~ [°]
[mm] [mm]
461 600 12 +3 9 - - 150x4
501 200 21 +2 30 - - 80x2
531 500 34 +3 28 - - 140x3
561 100 10 +1 25 - - 45x1,5

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Torque table - Status 02.06.2010

3.2 Tightening with hydraulic assembly device (siehe Kap. 2.2, ”Tightening with
hydraulic assembly device” auf Seite 4)

Pretightening Piston Piston nut

Thread M
WN 4121 No torque Mv
Turning angle Turning angle [mm]
[N.m] ~ [°] ~ [°]
1000 300 27+1 8+1 240x4
1001 300 18+1 8+1 200x4
1002 300 18+1 8+1 150x4
1003 300 23+1 8+1 170x4
1004 300 21+1 8+1 140x4
1005 300 18+1 8+1 180x4
1006 300 30+1 8+1 150x3
1007 300 27+1 3+1 160x4
1008 300 31+1 5+1 180x4
1009 300 20 +1 - 200x4
1010 300 27 +1 5 +1 180x4
1011 300 18 +1 - 260x4
1012 300 33 +1 - 200x4

7.32.10 R 914 C / R 924 C

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Service Manual Hydraulikzylinder - R 914 C / R 924 C

7.38: Hydraulikzylinder - R 914 C / R 924 C

Installa
Drawing Eff. WN
tion
Cylinder Utilisation No. D (mm) d (mm) stroke 4121
no. length
H (mm) no. *
L (mm)
Stroke
Gooseneck attachment 9904402 2 130 90 1275 1810 153
Gooseneck attachment 9924985 2 140 90 1275 1810 153
Stick
Industrial boom 9198235 2 125 85 1160 1690 126
Boom 9957903 1 140 95 1400 2000 171
Boom (only 924C) 9957905 1 150 105 1400 2000 171
Boom (only 924C - 7800mm 9601234 1 160 100 1500 2120 181
Spezial)
Adjusting
Adjustment of boom, in height 9957540 2 90 50 410 740 074
and to the side
Pivoting arm 9588094 1 160 95 1000 1500 201
Bucket move-
ment
Bucket tipping cylinder 9957904 1 125 85 970 1610 121
Bucket tipping cylinder 9957906 1 125 70 970 1500 126
Bucket tipping cylinder «MU» 9966417 1 120 80 895 1535 115

Fig. 1 Main body of hydraulic cylinder

* The no. XXX of works standard 4121 is definitive for the tightening specifications of the cylinder pis-
ton and the piston nut, see group 2

Note!
As a rule, the number to be observed for works standard 4121 should be stamped onto the piston
and on the piston rod.

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Service Manual Control oil and control unit
Job definition

7.45: Control oil and control unit

1 Job definition
The control oil and control unit generate the servo pressure for the servo control, as well as the control
pressures for the working pumps.
Pressure signals from diverse working procedures are also generated.

Fig. 1 Control oil and control unit

2 System description
The servo oil unit 50 is comprised essentially of an aluminium block. The pressure relief valve 51 is
screwed into the front side of this block in the form of a cartridge.
Solenoid valves Y3, Y7, and Y24 are integrated in the block on the top side of the unit. Additionally,
solenoid valve Y78 for grapple-bucket operation is installed in the side of the servo oil unit Y78. Test
point 49 and the accumulator are also screwed into the top side of the unit.
The test points 57 ( p - lowering) and 59 (load control) are screwed into the top side of the unit.
On the underside of the unit alongside the proportional solenoid valves Y50 and Y51 the pressure
filter 52 is screwed in. The check valve 53 is installed in the block of the servo oil unit.

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Control oil and control unit Service Manual
Functional description

2.1 Arrangement of test points

For measuring of the pressures of the servo oil unit, stationary test points 49, 57 and 59 have been
provided.

2.1.1 Test point 49

The actual servo pressure for the entire servo control is measured here, see also the pressure in-
spection in Group 6.

2.1.2 Test point 57

The control pressure generated from solenoid valve Y51 for the p-lowering is measured here, see
also flow rate reduction in Group 16.

2.1.3 Test point 59

The control pressure generated from solenoid valve Y50 for the load control is measured here, see
also output modification in Groups 7.02 and 7.05.

Fig. 2 Control oil and control unit 50

49 Test point control pressure Y3 Solenoid valve servo enabling

50 Control oil and control unit Y7 Solenoid valve / swing gear brake
51 Pressure relief valve Y24 Solenoid valve / travel regulation motors
52 Pressure filter Y50 Proportional solenoid valve / load control
53 Check valve Y51 Proportional solenoid valve / LS-control
54 Accumulator Y78 Solenoid valve / grapple operation

3 Functional description
(see Fig. 2 on page2)

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Service Manual Control oil and control unit
Functional description

3.1 Generating the servo pressure

The servo oil unit is supplied with the flow rate of the gear pump via connection P. The pressure relief
valve 51, screwed into the unit in the form of a cartridge, restricts the control pressure to a specific
value (see adjustment protocol).
The oil continues to flow through the filter 52 and the check valve 53 to the accumulator 54.
This accumulator 54 allows a limited amount of actuations to be carried out after the diesel engine
has been switched off or in the event that the gear pump fails.
The control unit of the working pumps is supplied with control pressure via connection P1, arranged
directly after the filter 52 .

3.2 Function of the solenoid valves

The pressure oil also charges switch solenoid valves Y3, Y7, Y24 and the variable solenoid valves
Y50 and Y51 via internal pressure channels in the servo oil unit.
In the switched condition, switch solenoid valves Y3, Y24 and Y7 connect outputs A1, A2 or A3 with
the control pressure. In the rest position the same outputs are connected with the tank.
Solenoid valve Y3 enables control pressure for the servo controls via connection A1.
Solenoid valve Y7 controls the multi-disc brake in the swing gear transmission via connection A3.
Solenoid valve Y24 charges the circuit for the control of Qmax. / Qmin. of the travel regulation motors
via connection A2.
Solenoid valve Y78 controls cut-off of the LS-pressure for closing of the grapple with grapple opera-
tion active via connection P1 - A.

3.3 Proportional solenoid valves Y50 / Y51

The proportional solenoid valves for load control Y50 or flow rate limitation Y51 of the working pumps
on the servo oil unit generate a pressure at their output which is dependent on their electrical mag-
netic current.
Output “LR“of solenoid valve Y50 is connected with connection “GLR“, pressure connection for load
control of the working pumps.
Proportional solenoid valve Y51 regulates the control pressure p(LS) which is definitive for restriction
of the swing angle for the working pumps. Furthermore, this pressure is connected with connection
Pst of the pump controller and effects a reduction of the pre-set pLS ( P - lowering) via the LS
controller, and thus a restriction of the maximum flow rate. This pressure is therefore referred to in
subsequent groups of this handbook as p ( Pred).

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Control oil and control unit Service Manual
Characteristics of proportional solenoid valves Y50 and Y51

4 Characteristics of proportional solenoid valves Y50 and Y51

Fig. 3 Control diagram

The control characteristics shows the dependency between supply rate (I) of the control magnets and
control pressure (p) to outputs LR or LS.
The effect of the pressures p (GLR) at output LR or p ( Pred) at output LS on the output control or
on the restriction of swing angle for the respective working pumps can be viewed in Group 7.
The control characteristics of a proportional solenoid valve can be checked by measuring a few pres-
sure values at the output LR (or LS) in correlation with magnet current ILR from Y50 (or Iev from
Y51).
The measurements and the setting of the currents ILR and IEV at fixed values can be resulted with
sufficient accuracy using the menus on the display, see Group 8.71.

5 Emergency position of the proportional solenoid valves Y50 / Y51

By removing the cotter pin 2 and tilting the lever 3 into a horizontal position, the solenoid valves Y50
and Y51 can be manoeuvred into a specific, adjustable position. The valves are now in the emergen-
cy position.
During operation in the emergency position, the plug connection 1 to the proportional solenoid valve
must be unplugged to ensure that no predominant influences of the control current occur.

5.1 Setting the emergency position

The respective control pressure is to be set to the desired fixed pressure value as follows:
Connect a pressure transducer to test point 57 or 59.
Loosen the lock nut 5 with the motor running and the lever 3 tilted into the horizontal position, con-
tinue to turn the adjusting screw 4 until the desired pressure has been attained.
Tighten the lock nut 5 while retaining the adjusting screw 4 and check the set pressure again.

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Service Manual Control oil and control unit
Emergency position of the proportional solenoid valves Y50 / Y51

Fig. 4 Emergency position of variable solenoid valves Y50 and Y51

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Control oil and control unit Service Manual
Emergency position of the proportional solenoid valves Y50 / Y51

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Service Manual 1-way servo control
System description

7.50: 1-way servo control

1 System description
The servo control with foot pedal, arranged on the right-hand side in front of the operator's seat in the
step plate / operator's station basic component, allows the driver of the vehicle to control the opera-
tional functions for the travel gear.
A regulating piston 12 (pressure control valve) is inserted axially in the housing 6 featuring pressure,
return and control connections. The pedal fitted at the top 2 is used to actuate the regulating piston
12. Each time the pedal is pushed down, the pedal 2 pushes against the spring-loaded tappet. This
leads to actuation of the regulating piston 12 with governing spring 25 and reset spring positioned
below, forcing the pressure channel opening position P (output A).
The tappet, guide bushing etc. are protected against contamination via a protective cap.

Fig. 1 1-way servo control with hydraulic circuit diagram

2 Functional description
Fig. 3 / Fig. 4
The servo control works to the principle of a pressure regulating valve, whereby the regulating piston
12 of the servo control is pressurised by a build up of pressure from the discharge side between servo
control and control valve block and is pushed against the force of the pressure spring 25.
Upon actuation of the pedal 2 the tappet 98.1 is pushed downwards and at the same time pushes the
regulating piston 12 via governing spring 25. Control oil then flows via the radial bore and axial bore
in the regulating piston 12 from the pressure channel P through connection 1 and the control line to
the solenoid valve Forwards / Reverse travel and to the control connections on the control valve block
6.
A pressurisation of the control piston 12 in the housing 6 builds up a certain pressure (Fig. 2) propor-
tional to the prescribed lever stroke which effects the piston area of the regulating piston 12 and push-
es the regulating piston 12 against the governing spring 25 until the connection to the channel P
becomes blocked.

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1-way servo control Service Manual
Repair

Depending on the position of the pedal 2 and the stroke of the tappet 98.1 , a specific servo pressure
is regulated which pushes the control piston 12 proportionally. At a certain degree of pressure which
corresponds with the end of the fine control phase of the control piston, the regulating piston 12 is
moved downwards directly via the tappet 98.1. The max. control pressure thus pressurises the con-
trol piston.

3 Repair

3.1 Dismantling the control unit

Unscrew the hexagon head screws 86
Remove the protective cap 98.5 and take off the plate 1 complete with pedal 2
Extract the tappet 98.1 with bushing 98.2 from the housing 6, push the tappet 98.1 out of the bush-
ing 98.2 and remove the O-ring 98.4 and the PDF seal 98.3 from the bushing 98.2
Push the regulating piston 12 complete with pressure springs 25 and 26, as well as spring retainer
15 with washer 23 out of the housing 6 from underneath.
Remove the split washer 23 from the spring retainer 15
Take out the regulating piston 12 and remove the pressure spring 25 with flat washers 37 / 38

3.2 Assembly of the control unit

Clean all parts prior to assembly and check thoroughly for reusability.
Fit the flat washers 37 / 38, pressure spring 25 and spring retainer 15 on the regulating piston 12
and insert the split washer 23
Push the spring retainer 15 complete with preassembled regulating piston 12 and pressure spring
25 , as well as pressure spring 26 into the housing 6 and bushing 17
Fit the new O-ring 98.4 and a new PDF seal 98.3 into the bushing 98.2
Push in the tappet 98.1 and insert the bushing 98.2 complete with tappet 98.1 into the housing 6
Fit the complete plate 1 and screw in the screws 86 with washers 85
Screw in the pins 7 with lock washers 9 and secure these with cotter pins 11 see Fig. 3
Fit the protective cap 98.5 and check the servo control for proper functioning

Fig. 2 Diagram: c = control pressure in bar, d = lever stroke as an angular degree

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Service Manual 1-way servo control
Repair

Installed in machines onwards of serial number Point a Point b

R 900 C Litronic 6.5 bar 25 bar
R 904 C Litronic 6.5 bar 25 bar

3.3 Exploded view

Fig. 3 Exploded drawing of servo control

1 Plate 26 Pressure spring (return spring)

2 Pedal 37 Flat washer
6 Housing 38 Flat washer
7 Pin 85 Lock washer
9 Washer 86 Hexagon head screw
11 Cotter pin 98 Repair kit
12 Regulating piston 98.1 Tappet
15 Spring retainer 98.2 Bushing
17 Press-fit bushing 98.3 PDF seal
23 Washer 98.4 O-ring
25 Pressure spring (governing spring) 98.5 Protective cap

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1-way servo control Service Manual
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3.4 Sectional drawing

Fig. 4 Sectional drawing of servo control

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Service Manual 2-way servo control
System description

7.51: 2-way servo control

1 System description
Both servo controls with foot pedal, arranged on the left-hand side in front of the operator's cab in the
step plate / operator's station basic component, allows the driver of the vehicle to control the opera-
tional functions for the hydraulic installation kit.
Two regulating pistons 12 (pressure control valves) are inserted axially in the housing 1 featuring
pressure, return and control connections. The step plates 2 and 3 fitted above serve actuation of the
regulating piston 12.
Each time the step plates 2 / 3 are moved downwards, they press against a spring-loaded tappet via
a threaded pin . This actuates the regulating piston 12 with governing spring and reset spring situated
below, thus forcing it into the pressure channel opening position P - output 1 / 2.
The tappet, guide bushing etc. are protected against contamination via a protective cap .

Fig. 1 2-way servo control with hydraulic circuit diagram

2 Functional description
see Fig. 3 / Fig. 4
The servo control works to the principle of a pressure regulating valve, whereby the regulating piston
12 of the servo control is pressurised by a build up of pressure from the discharge side between servo
control and control valve block and is pushed against the force of the pressure spring 25.
Upon actuation of the step plate 2 and / or 3 (pedal), the threaded pin 47 pushes the tappet 98.1
downwards and at the same time pushes the control piston 12 via the governing spring 25. Control
oil flows through the radial and axial bore in the regulating piston 12 from the pressure channel P via
connection 1 or 2 see Fig. 4 and the control line to one of the control connections on the
auxiliary axle of the control valve block.
A pressurisation of the control piston in the control valve block builds up a certain pressure propor-
tional to the prescribed lever stroke see Fig. 2, which effects the piston area of the regulating piston
12 and pushes the regulating piston 12 against the governing spring 25 until the connection to the
channel P becomes blocked.

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2-way servo control Service Manual
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Depending on the position of the step plate 2 / 3 and the stroke of the tappet 98.1, a specific servo
pressure is regulated which pushes the control piston proportionally. At a certain degree of pressure
which corresponds with the end of the fine control phase of the control piston, the regulating piston
12 is moved downwards directly above the tappet 98.1 . The max. control pressure thus pressurises
the control piston.
The valve insert 20, 2-way check valve between the control connections, is inserted in the housing
1 of the servo control. If control pressure is channelled to the control valve block via a control con-
nection upon actuation of the servo control, the control oil pressurises the 2-way check valve 20 at
the same time. The ball 45 in the valve 20 closes the connection to the other control connection so
that the released pressure remains on-hand for other controls via connection 7 (connection 7 is cur-
rently closed).

3 Repair

3.1 Dismantling the control unit

Lift the step plate 2 / 3
Remove the protective caps 98.5, unscrew the screws 46 and remove the plate 10 complete with
step plates 2 / 3
Remove the tappet 98.1 with bushing 98.2 from the housing 1
Push the tappet 98.1 out of the bushing 98.2
Remove the O-ring 98.4 and the PDF seal 98.3 from the bushing 98.2
Push the regulating piston 12 complete with pressure springs 25 and 26 , as well as spring retainer
15 with washer 23 out of the plate 10 from underneath.
Remove the washer 23 from the spring retainer 15
Pull out the regulating piston 12
Remove the pressure spring 25 with flat washers 49 / 50

3.2 Assembly of the control unit

Clean all parts prior to assembly and check thoroughly for reusability.
Fit the flat washers 49 / 50, pressure spring 25 and spring retainer 15 onto the regulating piston
12 and insert the washer 23
Push the spring retainer 15 complete with preassembled regulating piston 12 and pressure spring
25 / 26 into the housing 10 and bushing 16
Fit the new O-ring 98.4 and PDF seal 98.3 into the bushing 98.2
Push in the tappet 98.1 and insert the bushing 98.2 complete with tappet 98.1 into the housing 1
Fit the plate 10 complete with step plates 2 / 3 and screw in the screws 46
Fit the protective caps 98.5
Set the servo control

3.3 Setting the servo control in the zero position

The servo control should be set so that the max. control pressure can be attained upon reaching the
end position / stop and the step plates 2 / 3 can be actuated in a comfortable, fatigue-free position.
For setting, loosen the lock nut 48 and turn the stud bolt 47 see Fig. 1 until the step plates meet the
prerequisites described for the neutral position or the final position.

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Service Manual 2-way servo control
Repair

For measuring of the control pressure between connection 1 / 2 and the connection on the respective
control piston / control valve block, install a test point.

3.4 Checking the 2-way check valves 20

Heat the valve insert 20, glued in with Loctite, and unscrew completely from the housing using an
Allen key. At the same time observe the ball 45
Inspect the valve for contamination or damage
Insert the ball 45, fit the sealing ring 40, attach the valve insert 20 complete with Loctite 572 and
screw it on (tightening torque 10 Nm).
.

Fig. 2 Diagram: c = control pressure in bar, d = lever stroke as an angular degree

Point a Point b
5.8 -0.3 bar 24.3 bar

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2-way servo control Service Manual
Exploded view

4 Exploded view

Fig. 3 Exploded drawing of servo control

1 Housing 40 Sealing ring

2 Left-hand step plate 41 Flat washer
2.1 Bushing 42 Flat washer
3 Right-hand step plate 45 Ball
3.1 Bushing 46 Hexagon nut
10 Plate 47 Threaded pin
11 Pin 48 Hexagon nut
12 Regulating piston 50 Screw plug
13 Press-fitted bushing 51 Sealing ring
15 Spring retainer 52 Circlip
16 Bushing 98 Repair kit
20 Valve insert 98.1 Tappet
23 Washer 98.2 Bushing
25 Pressure spring (governing spring) 98.3 PDF-seal
26 Pressure spring (return spring) 98.4 O-ring
33 Screw plug 98.5 Protective cap

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Service Manual 2-way servo control
Sectional drawing

5 Sectional drawing

Fig. 4 Sectional drawing

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2-way servo control Service Manual
Sectional drawing

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Service Manual 4-way servo control (Rexroth)
System description

7.55: 4-way servo control (Rexroth)

1 System description
Both servo controls with joystick, arranged on the left and right-hand sides of the operator's seat, al-
low the machine operator to control the working functions for hoist, stick and bucket movements, as
well as slewing of the uppercarriage.
Regulating pistons 26 (x2) and 27 (x2) (pressure control valves) are installed axially in the housing
10 with pressure, return and control connections. The handle positioned at the top 5 (joystick) with
cardan joint 6 and bearing plate 6a serves actuation of the control pistons 26 and 27.
Freely moveable in all directions, the handle 5 pushes against one or more spring-loaded tappets
24.2 / 25.2 moving within tappet guides 25.1, by way of a screwed on bearing plate 6. This will then
actuate the spool valve 26.1 / 27.1 with governing spring 26.2 / 27.2 see Fig. 4 and reset spring 28
see Fig. 4 positioned below, thus effecting opening position pressure channel P - outlet 1 / 2 / 3 / 4.
Cardinal joint, tappet, guide bushing etc. are protected against contamination by the bellow 12.

Fig. 1 Joystick

2 Functional description
see Fig. 5
The reset springs 28 (x4) hold the servo control in the zero position. The servo control connections
1, 2, 3, 4 are connected with the tank via opened control edges «t»

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4-way servo control (Rexroth) Service Manual
Control curve of the servo control

Upon actuation of the handle 5, the bearing plate 6, pushes the tappet 24 / 25 downwards against
the reset springs 28 and governing springs 26.2 / 27.2. The control springs first move the spool valve
26.1 / 27.1 downwards, blocking the respective control connection to the return flow channel
T (control edge «t»).
At the same time, the respective connection to the pressure channel P is connected via control edge
«p».
The control phase is initiated as soon as the control piston has attained its balance between the gov-
erning spring and hydraulic pressure forces in the respective servo control connection (1, 2, 3, or 4).
Due to the interaction of the spool valve 26.1 / 27.1 and governing springs 26.2 / 27.2, the servo pres-
sure in the respective connection is proportional to displacement of the tappet 24 / 25 and thus to
the position of the handle 5

3 Control curve of the servo control

see Fig. 2
In the neutral position and up to an angle deflection of ~10% of the servo sensor, the pressure re-
mains at 0 bar at connections 1, 2, 3, 4.
Upon reaching 10% of the overall deflection, the pressure increases suddenly to ~6 bar.
Between ~10% and ~90% of the angle deflection, the pressure increases evenly between ~6 bar and
~25 bar.
At 90%, the pressure increases to maximum value (input pressure «pst») .
For connections 1 and 3 (servo control movement to the left or to the right) the highest angle deflec-
tion is ~25°.
For connections 2 and 4 (servo control movement backwards or forwards) the highest angle deflec-
tion is ~20°.

Deflection Deflection Deflection

10 % 90 % 100 %

Effective torque Connections 1 or 3 actuated 1.2 2.5 3.0

(in N.m)
Connections 2 or 4 actuated 0.9 1.5 2.1

Diagonal movement 1.5 2.9 3.6

Fig. 2 Diagram: c = control pressure in bar, d = lever stroke as an angular degree

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Service Manual 4-way servo control (Rexroth)
Repair

4 Repair

4.1 Setting down the control unit

Remove the bellow 12 from the plate 15, see Fig. 4
Pull up the bellow, but leave it in the groove of the lever handle 5, loosen the nut 105 between
sleeve 100 and cardinal joint 6.
Unplug the hydraulic hoses 52 from connections 1 ,2 ,3 ,4, P and T.
Unplug plugs 81 and 82 from the instruments in the console.
Remove the four screws 55 and washers 56.
Lift the whole servo sensor unit from the console (electrical components and servo control 50)
Unplug the cable set 80 from the locking device 7a in the plate 7, lift the sleeve 100, unscrew the
whole servo control unit 50 and remove the plate 15 and the servo control.
If the bellow 12 is to be replaced, remove it also from the groove in the lever handle 5.

Do not dismantle the lever handle 5 to remove the servo control 50 or the bellow 12. The han-
dle shell halves must remain secured to the sleeve 100.

4.2 Dismantling the control unit

Counter the housing 10 and unscrew the cardinal joint 6, see Fig. 5.
Remove the cardinal joint 6 and the plate 7
Pull the tappet units 24 and 25 completely from the housing 10

Mark the different tappet unit positions. The tappets for connections 2 and 4 vary from those
for connections 1 and 3.
The tappet units must not be dismantled, tappet pins, tappet guides and tappet seals are not avail-
able as separate replacement parts.

Remove the regulating pistons 26 and 27 completely and pull the reset springs 28 from the hous-
ing 10.

Mark the different regulating piston positions. These vary between connections 2 and 4 and
connections 1 and 3.
The regulating pistons can not be dismantled and are only available as replacement parts as a
whole unit.

To avoid oil leakages, do not remove the plugs 29.

4.3 Assembly of the control unit

Clean all parts prior to assembly and check thoroughly for reusability.
Insert the reset springs 28 and regulating pistons 26 / 27 completely in the housing 10.
Insert the tappet units 24 / 25 completely in the housing 10
Fit the plate 7 and screw in the cardinal joint 6, while at the same time countering the housing 10.
Set the servo control into the neutral position

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4-way servo control (Rexroth) Service Manual
Exploded views

4.4 Setting the servo control in the zero positionsee Fig. 5

The bearing plate 6a and tappet 24.2 / 25.2 must be set without clearance to one another with the
servo control actuated.
To carry out the setting, loosen the nut 105 and turn the bearing plate 6a until all four tappets are in
the zero position and clearance is no longer featured between bearing plate 6a and all tappets 24.2
/ 25.2. When setting has been carried out successfully tighten the nut 105.

4.5 Fitting the control unit

Should the bellow 12 require replacing, fit it into the groove of the lever handle 5 see Fig. 3
Pull the cable set 80, with lever handle 5, through the plate 15 and insert into the locking device
7a in the plate 7.
Screw in the sleeve 100, do not tighten
Insert the whole servo sensor unit in the console (electrical components and servo control 50)
Screw in the four screws 55 and washers 56.
Insert the plugs 81 and 82 in the instruments in the console.
Screw in the hydraulic hoses 52 in connections 1 ,2 ,3 ,4, P and T see Fig. 4
Tighten the nut 105 between sleeve 100 and cardinal joint 6. At the same time ensure correct set-
ting of the lever handle 5.
Fit the bellow 12 onto the plate 15

5 Exploded views

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Service Manual 4-way servo control (Rexroth)
Exploded views

Fig. 3 Servo control with electric components

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4-way servo control (Rexroth) Service Manual
Exploded views

Fig. 4 Servo control

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Service Manual 4-way servo control (Rexroth)
Sectional drawing

6 Sectional drawing

Fig. 5 Sectional drawing of servo control

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4-way servo control (Rexroth) Service Manual
Sectional drawing

5 Lever handle 26 Regulating piston complete (axles 2-4)

6 Cardinal joint 26.1 Spool valve
6a Bearing plate 26.2 Governing spring
7 Retaining plate 27 Regulating piston complete (axles 1-3)
10 Housing 27.1 Spool valve
12 Bellow 27.2 Governing spring
15 Plate 28 Reset spring (return spring)
24 Tappet unit complete (axles 2-4) 29 Plugs
24.1 Tappet pin 80 Cable set
24.2 Tappet guide 81 Plug
25 Tappet unit complete (axles 1-3) 82 Plug
25.1 Tappet pin 100 Sleeve
25.2 Tappet guide 105 Nut

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Service Manual Hydraulic pilot control device with 2 pedals and damp-
System description

7.56: Hydraulic pilot control device with 2 pedals and

damping system

1 System description
The pilot control device with 2 pedals, mounted on the cab floor, controls the travel function of the
excavator.

Fig. 1 Servo control

2 Functional description
see Fig. 2
The servo control works to the same principle as a pressure control valve.
It comprises of an assembly which integrates a double step plate 101, four pressure governors 111,
four attenuation systems 112, two bellows 113 and a housing 106 .
Each pressure governor is comprised of a regulating piston 102, a governing spring 103, reset spring
104, and tappet 105.
The attenuation system comprises of a tappet 108, nozzle 109 and reset spring 110.
The reset springs 110 retain the servo control in the zero position when in rest mode.
Actuation of the pedal pushes the control tappet and the tappet of the attenuation system downwards.
The hydraulic oil is restricted by the nozzle with a pressure which is dependent upon the manoeuvring
speed. (Likewise, with a return movement into the neutral position, the pedal forces the hydraulic oil
out of the attenuation chamber via the reset springs. The return speed is restricted by the oil flow
through the nozzle.)
The control tappet pushes down the reset spring and the governing spring simultaneously. The gov-
erning spring first moves the control slide downwards, which blocks the corresponding control con-
nection to return flow channel T. At the same time, the corresponding control connection is connected
to pressure channel P. The control phase is initiated as soon as the control piston has attained its
balance between the governing springs and hydraulic pressure forces in the respective connection
(A : connections 1 - 3, B : connections 2 - 4).

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Hydraulic pilot control device with 2 pedals and damp- Service Manual
Functional description

Due to the interaction of the control slide 102 and governing springs 103, the servo pressure in the
respective connection is proportional to the shifting of the tappet 105 and thus to the foot lever posi-
tion.
This pressure regulation, depending on the foot lever position and the governing spring characteristic
103, allows the proportional hydraulic control of the 2-way valves, and regulation of the pumps and
motors.

Fig. 2 Sectional drawing of the servo control

101 Step plate 109 Nozzle

102 Regulating piston 110 Reset spring
103 Governing spring 111 Pressure throttle
104 Reset spring 112 Attenuation system
105 Tappet 113 Bellow
106 Housing A Connections 1 - 3
107 Borehole B Connections 2 - 4
108 Tappet

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Service Manual Hydraulic pilot control device with 2 pedals and damp-
Functional description

Fig. 3 Servo control hydraulics diagram

Fig. 4 Servo control unit characteristics

c Control pressure in bar d Foot pedal stroke in mm

Note!
The following measures must be taken when using the servo control:
– A counterpressure (minimum 2 bar) should be retained in the tank T to ensure filling of the atten-
uation chambers.
– Replace the worn bellow to ensure sealing of the pedal
– The counterpressure for T eases supply of the attenuation unit and the rapidity of ventilation fol-
lowing assembly of the equipment onto the machine.
– The attenuation unit reaches full efficiency during operation, following ventilation.
– Avoid using the servo control before connecting to the hydraulic circuit, otherwise air could infil-
trate the attenuation circuit which is required for ventilation..

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Hydraulic pilot control device with 2 pedals and damp- Service Manual
Dismantling and installing the control unit

3 Dismantling and installing the control unit

Note!
The following precautionary measures must be taken during assembly:
– Flange surface: flatness = 0.5 mm
– Screw head dimension = Ø 16 mm
– Tightening torques for flange screws = max. 40 Nm
– Tightening torques for connections = max. 30 Nm

3.1 Dismantling the control unit

Dismantling the upper section

see Fig. 5
The same procedure applies for dismantling of left-hand and right-hand parts:
Take the pedal covering 15 / 25 off its base 10 / 20.
Unscrew the screws 11 / 21.
Remove the base 10 / 20.

Dismantling the lower section

see Fig. 6
The same procedure applies for dismantling of left-hand and right-hand parts:
Push the bellow upwards 5 and pull it out
Loosen the threaded pin 7.2 and push the axles 7.3 outwards
Release the control plate 6 and unscrew the screws 7.4
Remove the plate 7.1
Remove the seals 12.2, the springs 13, the tappets 8, the regulating pistons and the springs 11.
Remove the check valves 14 and the 2-way valves 17
Check the condition and wear of all parts.

3.2 Installation of control unit

Assembly of lower section

see Fig. 6
The same procedure applies for installation of left-hand and right-hand parts:
Insert the check valves 14 and the 2-way valves 17
Insert all tappets 8 with a regulating piston 10.1 and a spring 11 in the housing of the servo control
Insert the reset springs 13 and the seals 12.2 in the housing. Mount the plate 7.1 and secure with
the locking screw 7.4
Mount plate 6 onto plate 7.1
Fit the axle 7.3 in the plate 6 and lock it with the threaded pin 7.2
Mount the bellow 5

Installation of lower section

see Fig. 5

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Service Manual Hydraulic pilot control device with 2 pedals and damp-
Dismantling and installing the control unit

The same procedure applies for installation of left-hand and right-hand parts:
Mount the base 20 / 21 onto the control unit and fix it with the screws 11 / 21.
Fasten the pedal covering 15 / 25 onto the corresponding base 20 / 21.
.

Fig. 5 Exploded view of servo control (upper section)

5 Control unit
10 Base 20 Base
11 Fixing screw 21 Fixing screw
12 Washer 22 Washer
15 Pedal covering 25 Pedal covering

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Hydraulic pilot control device with 2 pedals and damp- Service Manual
Dismantling and installing the control unit

Fig. 6 Exploded view of servo control (lower section)

5 Bellow 10.1 Regulating piston

6 Plate 11 Spring
6.1 Threaded pin (5 Nm) 12.1 Hollow tappet
7.1 Plate 12.2 Seal
7.2 Threaded pin (2,3 Nm) 13 Reset spring
7.3 Axle 14 Check valve (5 Nm)
7.4 Screw 15 Threaded pin (4 Nm)
8 Tappet 17 2-way valves (3-5 Nm + loctite 262)
21 Threaded pin

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Service Manual Control valve complete
Tasks in general

7.61: Control valve complete

1 Tasks in general

Designation Valve support VT5 5 directional control valves

Description, see 7.62 7.63

Group

Control piston Unit 220 240 260 160 180

Hoist Stick Bucket Travel left Travel right
cylinder cylinder cylinder
Ext. Retr. Ext. Retr. Ext. Retr. For. Rev. For. Rev.
Valve nominal mm (“) 25 (1“) 25 (1“) 18 (3/4“) 18 (3/4“) 18 (3/4“)
width
Ø piston rod mm 32 32 25 25 25
Desc. see page 7.63.3 7.63.3 7.63.3 7.63.5 7.63.5
Piston stroke mm 12,1 12,1 12,3 12,3 10,5 10,2 10,5 10,5 10,5 10,5
Setting dimension mm 48,1 48,1 48,3 48,3 41,5 41,2 41,5 41,5 41,5 41,5
X
Setting dimension mm / / / / / / 9,2 9,2 9,2 9,2
Y*
D (shim rings) mm 2,1 1,6 1,9 2,3 2 2,3 3,5 3,5 3,5 3,5
p1bar ± 0.5 mm** bar 8,4 9,3 8,6 8,1 9,3 8,3 7,0 7,0 7,0 7,0
p2bar ± 0.5 mm*** bar
Qn (A)/Qn(B)° l/min
Throttle check
valve mm
to stop x mm
to stop y
Max. leak oil cm3/min
with load pressure bar
°C
with oil tempera-
ture

Tab. 1 Technical data

* The setting dimension Y applies as a reference value for the travel control pistons only.
** p1 = Control pressure for control begin
*** p2 = Control pressure for final position
° QnA/ QnB = Nominal throughflow rate at outlet A / B with p = nominal value
Shim ring thickness «D» : 2.0 mm; 1.0 mm; 0.5 mm; 0.3 mm

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Control valve complete Service Manual
Tasks in general

1.1 Circuit diagram - control valve block

Positions Positions
100 Control plate 180 Directional control valve travel gear
left
101 Pressure cut off (Ls-pressure) 180.1 Stroke limitation stick travel gear left
forwards
102 Pump valve 180.2 Stroke limitation stick travel gear left
reverse.
104 Control piston travel speed 180.3 Throttle check valve stick travel
gear left reverse.
105 Control valve travel movements 180.4 Throttle check valve stick travel
gear left forwards
106 Valve / LS-cut off grapple 180.7 Pressure relief bleed valve
107 Pressure control valve / return flow 180.8 Pressure relief bleed valve
T
108 Pressure control valve / return flow 181 Suction valve / travel left
P
182 Suction valve / travel left
110 Valve return oil utilisation 183 Control piston travel gear motor left
hoist+stick
110.1 2-way check valves 185 Pressure balance load compensa-
tor
110.2 Control valve 186 Pressure balance load compensa-
tor
110.5 Pressure reduction valve 187 Toggle switch
112 2-way check valve 188 Toggle switch
113 Piston
114 Piston 220 Control piston / hoist cylinder
115 Lowering throttle hoist cylinder 220.1 Stroke limitation stick hoist cylinder
116 Lowering throttle stick cylinder 220.2 Stroke limitation stick hoist cylinder
220.3 Throttle check valve control pres-
sure
160 Directional control valve travel 220.7 Pressure relief bleed valve
motor right
160.1 Stroke limitation stick travel gear 220.8 Pressure relief bleed valve
motor right forwards
160.2 Stroke limitation stick travel gear 221 Extend secondary pressure relief
motor right forwards valve

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Service Manual Control valve complete
Tasks in general

Positions Positions
160.3 Throttle check valve stick travel 222 Retract secondary pressure relief
gear motor right forwards valve
160.4 Throttle check valve stick travel 223 Control piston hoist cylinder
gear motor right forwards
160.7 Pressure relief bleed valve 225 Pressure balance load compensa-
tor
160.8 Pressure relief bleed valve 226 Pressure balance load compensa-
tor
161 Suction valve / travel gear motor 227 Toggle switch
right
162 Suction valve / travel gear motor 228 Toggle switch
right
163 Control piston travel gear motor
right
165 Pressure balance load compensa-
tor
166 Pressure balance load compensa-
tor
167 Toggle switch
168 Toggle switch

240 Control piston / stick cylinder 260 Control piston / bucket cylinder
240.1 Stroke limitation stick - stick cylinder 260.1 Stroke limitation stick bucket cylin-
der
240.2 Stroke limitation stick - stick cylinder 260.2 Stroke limitation stick bucket cylin-
der
240.3 Throttle check valve control pres- 260.7 Pressure relief bleed valve
sure
240.7 Pressure relief bleed valve 260.8 Pressure relief bleed valve
240.8 Pressure relief bleed valve 261 Extend secondary pressure relief
valve
241 Extend secondary pressure relief 262 Retract secondary pressure relief
valve valve
242 Retract secondary pressure relief 263 Control piston bucket cylinder
valve
243 Control piston stick cylinder 265 Pressure balance load compensa-
tor
245 Pressure balance load compensa- 266 Pressure balance load compensa-
tor tor
246 Pressure balance load compensa- 267 Toggle switch
tor
247 Toggle switch 268 Toggle switch
248 Toggle switch
Y53 Cooler precharge valve

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Control valve complete Service Manual
Tasks in general

Fig. 1 Hydraulic circuit diagram for control valve block

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Service Manual Control valve complete
Tasks in general

1.2 Control valve block - directional control valves for standard equipment

Fig. 2 Control valve block - directional control valves for standard equipment

100 Control plate 220 Control piston / hoist cylinder

101 Pressure cut off (Ls-pressure) 221 Extend secondary pressure relief valve
102 Pump valve 222 Retract secondary pressure relief valve
115 Lowering throttle hoist cylinder
116 Lowering throttle stick cylinder 240 Control piston / stick cylinder
241 Extend secondary pressure relief valve
160 Directional control valve travel motor right 242 Retract secondary pressure relief valve
161 Suction valve / travel right forwards
162 Suction valve / travel right reverse 260 Control piston / bucket cylinder
261 Extend secondary pressure relief valve
180 Directional control valve travel motor left 262 Retract secondary pressure relief valve
181 Suction valve / travel left reverse
182 Suction valve / travel left forwards

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Control valve complete Service Manual
Specifications for auxiliary equipment

2 Specifications for auxiliary equipment

Control piston Unit 500 520

Hoist Stick
cylinder cylinder
Ext. Retr. Ext. Retr.
Valve nominal mm (“)
width
Ø piston rod mm
Desc. see page
Piston stroke mm
Setting dimension mm
X
Setting dimension mm / / / /
Y*
D (shim rings) mm
p1bar ± 0.5 mm** bar
p2bar ± 0.5 mm*** bar
Qn (A)/Qn(B)° l/min
Throttle check
valve mm
to stop x mm
to stop y
Max. leak oil cm3/min
with load pressure bar
°C
with oil tempera-
ture

Tab. 2 Technical data

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Service Manual Control valve complete
Specifications for auxiliary equipment

2.1 Circuit diagram - control valve block auxiliary equipment

Positions Positions
100 Control plate 180 Directional control valve travel gear left
101 Pressure cut off (Ls-pressure) 180.1 Stroke limitation stick travel gear left for-
wards
102 Pump valve 180.2 Stroke limitation stick travel gear left
reverse.
104 Control piston travel speed 180.3 Throttle check valve stick travel gear left
reverse.
105 Control valve travel movements 180.4 Throttle check valve stick travel gear left
forwards
106 Valve / LS-cut off grapple 180.7 Pressure relief bleed valve
107 Pressure control valve / return flow T 180.8 Pressure relief bleed valve
108 Pressure control valve / return flow P 181 Suction valve / travel left
182 Suction valve / travel left
110 Valve return oil utilisation hoist+stick 183 Control piston travel gear motor left
110.1 2-way check valves 185 Pressure balance load compensator
110.2 Control valve 186 Pressure balance load compensator
110.5 Pressure reduction valve 187 Toggle switch
112 2-way check valve 188 Toggle switch
113 Piston
114 Piston 220 Control piston / hoist cylinder
115 Lowering throttle hoist cylinder 220.1 Stroke limitation stick hoist cylinder
116 Lowering throttle stick cylinder 220.2 Stroke limitation stick hoist cylinder
220.3 Throttle check valve control pressure
160 Directional control valve travel motor 220.7 Pressure relief bleed valve
right
160.1 Stroke limitation stick travel gear motor 220.8 Pressure relief bleed valve
right forwards
160.2 Stroke limitation stick travel gear motor 221 Extend secondary pressure relief valve
right forwards
160.3 Throttle check valve stick travel gear 222 Retract secondary pressure relief valve
motor right forwards
160.4 Throttle check valve stick travel gear 223 Control piston hoist cylinder
motor right forwards
160.7 Pressure relief bleed valve 225 Pressure balance load compensator
160.8 Pressure relief bleed valve 226 Pressure balance load compensator
161 Suction valve / travel gear motor right 227 Toggle switch
162 Suction valve / travel gear motor right 228 Toggle switch
163 Control piston travel gear motor right
165 Pressure balance load compensator
166 Pressure balance load compensator
167 Toggle switch
168 Toggle switch

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Control valve complete Service Manual
Specifications for auxiliary equipment

Positions Positions
240 Control piston / stick cylinder 260 Control piston / bucket cylinder
240.1 Stroke limitation stick - stick cylinder 260.1 Stroke limitation stick bucket cylinder
240.2 Stroke limitation stick - stick cylinder 260.2 Stroke limitation stick bucket cylinder
240.3 Throttle check valve control pressure 260.7 Pressure relief bleed valve
240.7 Pressure relief bleed valve 260.8 Pressure relief bleed valve
240.8 Pressure relief bleed valve 261 Extend secondary pressure relief valve
241 Extend secondary pressure relief valve 262 Retract secondary pressure relief valve
242 Retract secondary pressure relief valve 263 Control piston bucket cylinder
243 Control piston stick cylinder 265 Pressure balance load compensator
245 Pressure balance load compensator 266 Pressure balance load compensator
246 Pressure balance load compensator 267 Toggle switch
247 Toggle switch 268 Toggle switch
248 Toggle switch
Y53 Cooler precharge valve
Directional control valves / auxiliary equipment
500 Directional control valve / AHS11 (ham-
mer / cylinder)
500.7 Retract pressure relief bleed valve / aux-
iliary cylinder
500.8 Extend pressure relief bleed valve / aux-
iliary cylinder
501 Extend secondary pressure relief valve /
actuate hammer or extend auxiliary cyl-
inder
502 Extend secondary pressure relief valve /
actuate hammer or retract auxiliary cyl-
inder
503 Control piston for hammer / auxiliary cyl-
inder

520 Directional control valve / AHS12 (auxil-

iary cylinder)
520.7 Extend pressure relief bleed valve / aux-
iliary cylinder
520.8 Retract pressure relief bleed valve / aux-
iliary cylinder
521 Extend pressure relief bleed valve /
extend auxiliary cylinder
522 Extend secondary pressure relief valve /
retract auxiliary cylinder
523 Control piston for auxiliary cylinder
525 Pressure balance
526 Pressure balance
527 Toggle switch
528 Toggle switch

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Service Manual Control valve complete
Specifications for auxiliary equipment

Fig. 3 Hydraulic circuit diagram for control valve block - special equipment

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Control valve complete Service Manual
Specifications for auxiliary equipment

2.2 Control valve block - directional control valves for standard equipment

Fig. 4 Control valve block - directional control valves for standard equipment

100 Control plate Directional control valves / auxiliary equipment

Directional control valves / standard equipment 500 Directional control valve / AHS11 (ham-
mer / cylinder)
160 Directional control valve travel motor right 501 Extend secondary pressure relief valve /
actuate hammer or extend auxiliary cylin-
der
180 Directional control valve travel motor left 502 Extend secondary pressure relief valve /
actuate hammer or retract auxiliary cylin-
der
220 Control piston / hoist cylinder 520 Directional control valve / AHS12 (auxil-
iary cylinder)
240 Control piston / stick cylinder 521 Extend pressure relief bleed valve /
extend auxiliary cylinder
260 Control piston / bucket cylinder 522 Extend secondary pressure relief valve /
retract auxiliary cylinder

7.61.10 R 914 C / R 924 C

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Service Manual Control plate
Layout

7.62: Control plate

1 Layout
All directional control valves for activation of working and travel movements are flange-mounted on
control plate 100.
The control plate is supplied with oil from both working pumps via connections P1 and P2, combining
both delivery flows into a collective pressure channel and redistributing the pressure oil to all direc-
tional control valves.
On the return-flow side, the control plate collects the oil flowing back from the T channel of the direc-
tional control valves and allows it to flow back to the hydraulic tank via pressure control valves 107
and 108 and then through connections "T" (directly to the tank) and "K" (first to the cooler and then
to the hydraulic tank).
Furthermore, the control plate builds up the highest LS pressure from the pressures of the load-sens-
ing channels of the individual directional control valves where it is distributed to the pump controller
via connection "LS".
The control plate is also connected with the directional control valves integrated in the swing motor
drive for slewing movements via connections "LSS, PS and T1".
The cooler control valve Y53 integrated in the regenerator plate 110 serves to improve oil cooling.

Fig. 1 Control plate 100

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Control plate Service Manual
Layout

Fig. 2 Hydraulic circuit diagram for control plate 100

41 Test point -xP 108 Pressure control valve / return flow K

45 Test point -xLS 110 Valve / return oil valuation
100 Control plate 110.1 2-way check valve
101 Pressure cut-off 110.2 Control valve
102 Pump valve 110.3 Piston
104 Control piston travel speed 110.4 Piston
105 Control valve travel movements 110.5 Pressure reduction valve
105.3 Throttle 110.6 2-way check valve
105.4 Check valve 115 Lowering throttle hoist cylinder
106 Valve / LS cut-off 116 Lowering throttle stick cylinder
106.4 Check valve Y53 Proportional valve / cooling
107 Pressure control valve / return-flow T

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Service Manual Control plate
Layout

Fig. 3 View from below

Fig. 4 View from the rear

Fig. 5 View from above

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Control plate Service Manual
Layout

Control plate 100 also features the following valves for pressure limitation or for the execution of var-
ious procedures which are dependent on working phases:

101 Pressure cut-off (LS pressure relief valve) 108 Pressure control valve / return flow K
102 Pump valve (pressure limitation for pump 110 Valve / return oil valuation boom + stick
pressure > LS pressure
104 Control piston travel motor adjustment 110.1 2-way check valve
105 Control valve travel movements 110.2 Control valve
105.3 Throttle 110.3 Piston
105.4 Check valve 110.4 Piston
106 Valve / LS cut-off during grapple operation 110.5 Pressure reduction valve
106.4 Check valve 110.6 2-way check valve
107 Pressure control valve / return-flow T 115 Lowering throttle hoist cylinder
116 Lowering throttle stick cylinder

Fig. 6 Valves 101

1 Valve cartridge 1 Valve cartridge

2 Grommet nut 2 Adjusting shim
3 Adjusting screw 3 Pressure spring
4 Spring retainer 4 Spring retainer
5 Pressure spring 5 Valve insert
6 Valve insert 6 Valve cone
7 Valve cone

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Service Manual Control plate
Function of the valves in control plate 100

2 Function of the valves in control plate 100

2.1 Pressure cut-off valve 101 see Fig. 6

This valve restricts the maximum LS pressure to a pre-set value, internally in the control plate.
The maximum pump high pressure is thus also restricted by the pump controller to a maximum pres-
sure which is increased by P(LS).
If for example a consumer is manoeuvred against the stop, the working pump is swung back by its
LS controller until only leak oil continues to be channelled and the maximum pressure is retained (the
secondary pressure relief valves which are set higher will not respond).

2.2 Pump valve 102 see Fig. 6

The valve 102 limits the pressure difference between pump high pressure and LS pressure to a value
above that of the P(LS) set at the pump.
The valve serves to restrict the pressure peaks which can occur in the dynamic behaviour of the pump
without them being dissipated by the P-controller (e.g. should a control piston close abruptly during
start-up of the drive motor, etc.).
The valve has been pre-set at the factory.

2.3 Control valve 104 for travel motor adjustment see Fig. 7
This valve controls adjustment of the travel motors between maximum and reduced displacement
The piston actuator of the valve 104 connects:
– either connection "M" (connected with the control connection of the travel motors) and connection
"P4" of the control plate where the servo pressure originates. In this case, the hydraulic travel mo-
tors are set reduced toward the displacement (thus maximum travel speed).
– or connection "M" with the tank. In this case the travel motors are set to maximum displacement.

Note!
The servo pressure only originates at connection "P4" if fast travel has been preselected via push-
button S21 (hare symbol).

The piston actuator of the valve is controlled via the pressure for "LS travel".
If the pressure in the LS-channel increases to the extent that it pushes the piston against the pre-
stressing force of the pressure spring, the piston constitutes the connection "M - tank".
The pressure "LS travel" must drop considerably in order that the piston is reset into the rest position
(connection "M -P4").

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Control plate Service Manual
Function of the valves in control plate 100

Fig. 7 Control plate 100 - view from the rear with regenerator plate 110

101 Pressure cut-off 107 Pressure control valve / return-flow T

102 Pump valve 108 Pressure control valve / return flow K
104 Control piston travel motor adjustment 110 Valve / return oil valuation boom + stick
105 Control valve travel movements 110.1 2-way check valve
105.3 Throttle 110.2 Control valve
105.4 Check valve 110.3 Piston
106 Valve / LS cut-off 110.4 Piston
106.4 Check valve

2.4 Control valve 105 for travel movements see Fig. 7

If any travel movement is initiated, connection "Z2" of control plate 100 is charged with servo pressure
and the valve 105 closes the direct connection between "LS-travel" and "LS-working movements".
If a movement of the attachment is then initiated (e.g. raise boom) with the travel gear active, an in-
crease of "LS travel" pressure can only be attenuated via throttle 105.3.
An abrupt reduction of travel speed will thus be prevented.
A sudden increase of "LS travel" pressure on the other hand, effects an instantaneous increase of

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Service Manual Control plate
Function of the valves in control plate 100

"LS-working movements" pressure (via check valve 105.4)

2.5 Control valve 106 for grapple operation see Fig. 7

With preselected grapple operation (push-button S19 of the switchgear unit) and simultaneous acti-
vation of the "Extend stick" movement, connection "Z1" of the control plate is charged with servo pres-
sure and the piston actuator of valve 106 is actuated into a closed position.
The prevalent pressure in the "Close grapple" working circuit can thus no longer build up in the main
LS channel.
This will prevent the high pressure in the "Close grapple "circuit causing a reduction of the stick ex-
tension speed. It is therefore still possible to use the grapple to toss a load, even if the operator is
simultaneously holding the grapple tongs closed tightly.

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Control plate Service Manual
Function of the valves in control plate 100

Fig. 8 Control plate 100 - exploded view

101 Pressure cut-off 108 Pressure control valve / return flow K

102 Pump valve 110 Valve / return oil valuation boom + stick
104 Control piston travel motor adjustment 110.1 2-way check valve
105 Control valve travel movements 110.2 Control valve
105.3 Throttle 110.3 Piston
105.4 Check valve 110.4 Piston
106 Valve / LS cut-off 115 Lowering throttle hoist cylinder
106.4 Check valve 116 Lowering throttle stick cylinder
107 Pressure control valve / return-flow T

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Service Manual Control plate
Function of the valves in control plate 100

2.6 Pressure control valves 107 and 108 see Fig. 7

These valves serve to maintain a light counterpressure in the return flow circuit of the directional con-
trol valves (preventing cavitation).
At normal operating temperatures, the oil flows back through the pressure control valve 108 to the
hydraulic oil cooler. If the hydraulic oil is cold, the counterpressure increases in the return flow circuit.
Valve 107, set somewhat higher, opens and allows some of the oil to flow directly back to the tank.
This safeguards the hydraulic oil cooler against pressure peaks.
The pistons 110.3 and 110.4 in the valve 110 can increase the actuation pressure of the valves 107
and 108 for specific working procedures.

2.7 Valve 110 for yielding return oil for boom and stick see Fig. 7
The servo pressures at connection "y1" of directional control valve 220 (retract hoist cylinder ), as well
as at connection "x2" of directional control valve 240 (extend stick cylinder) are connected with the
valve 110 via internal bores in the valves and in the control plate 100.
Upon initiation of one of the aforementioned movements, the control valve 110.2 is actuated via the
2-way valve 110.1. The servo pressure available at connection "P3" of the control plate 100 builds up
on the outer working surfaces of the pistons 110.3 and 110.4.
This pistons then charge the cones of valves 107 and 108 with a force which is effective in the same
direction as the preload spring of the valves.
The increase of counterpressure resulted in the tank channel of the control plate eases suction of the
oil in the rod side of the hoist cylinder (or in the piston crown side of the stick cylinder). The occurrence
of cavitation is thus prevented when yielding return oil between both sides of the cylinder.
Temperature-dependent hydraulic oil cooling, see also Group 6.
Additionally, the pressure reduction valve 110.5 (with proportional solenoid Y53) and 2-way check
valve 110.6 are installed in the regenerator plate / valve 110.
No oil cooling (up to 40°C oil temperature):
– Valve Y53 is supplied with power (740 mA). The flow path for the control oil from connection P3
to the piston 110.4 is open through valves 110.5 and 110.6.
– The cone of the pressure relief valve 108 is charged on the spring side thus blocking the flow of
return oil to the oil cooler.
Oil cooling (above 40°C oil temperature):
– Valve 110.5 closes the flow path for the control oil to the piston 110.4 proportional to the current
to Y53 (740 mA - 100 mA); valve 108 thus becomes free.
– Increasing oil flow (return oil) in accordance with the opening position of the valve 110.5 via valve
108 (3 bar opening pressure), connection K and oil cooler.
Lowering throttle for hoist cylinder 115 see Fig. 4
This throttle is inserted in the return flow channel from the piston crown side of the hoist cylinder and
restricts the retraction speed of the hoist cylinder.
Lowering throttle for stick cylinder 116 see Fig. 4
This throttle is inserted in the return flow channel from the piston rod side of the stick cylinder and
restricts the extension speed of the stick cylinder.

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Control plate Service Manual
Function of the valves in control plate 100

Fig. 9 Valve 110 - exploded view

100 Control plate 110.2 Control valve

107 Pressure control valve / return-flow T 110.3 Piston
108 Pressure control valve / return flow K 110.4 Piston
110 Valve / return oil valuation boom + stick 110.5 Pressure reduction valve
110.1 2-way check valve 110.6 2-way check valve
Y53 Proportional valve / cooling

7.62.10 R 914 C / R 924 C

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Service Manual Inspecting the control valve blocks for leak oil
Job definition and function

7.64: Inspecting the control valve blocks for leak oil

1 Job definition and function

Measuring of leak oil for a control piston is resulted via the retraction and extension speed of the pres-
surised hydraulic cylinder connected with this control piston in the neutral position.
The amount of leak oil in the control valve block should be measured with a load pressure of 150 bar
and a test temperature of 50°C (in the hydraulic tank).
Before checking the leak oil of the control valve block, a separate check of the sealing for the sec-
ondary valves (visual inspection and replace if necessary) and actuating cylinder (blanking off) must
be undertaken as the specified values only relate to the leakage of the control piston in the control
valve block.
To carry out this check, a pressure transducer must be installed in the respective pressure line be-
tween the actuating cylinder and the control valve block (use a measuring device where necessary).
Heat the machine to operating temperature
Extend the attachment (if necessary with load)
until the pressure transducer is indicating a pressure of 150 bar
Make a marking (marker pen) on the piston rod of the cylinder and ascertain the stroke of the pis-
ton rod over one minute
The maximum permissible extension and retraction speed of the piston rod (or the permissible leak
oil quantity of the piston rod) can be obtained from the diagram, (see “Leak oil diagram” on page 2).
The maximum permissible leak oil quantity is specified in the “Technical data“ for the respective con-
trol valve block.

Note!
The values in the diagram are valid for a single actuating cylinder being supplied with oil by only one
control piston.
If, however, two actuating cylinders are being supplied with oil by a single control piston, the maxi-
mum permissible speed is to be halved (e.g. hoist cylinder).

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Inspecting the control valve blocks for leak oil Service Manual
Job definition and function

Fig. 1 Leak oil diagram

– Va: extension speed of the piston rod
– Ve: retraction speed of the piston rod
Example:
For the machine R 904 C the bucket cylinder (1x) featuring a piston diameter of D = 120 mm and a
rod diameter of d = 80 mm is supplied via piston rod 260 (1x) with NW 22.
For this control valve block (NW 22) the maximum permissible leak oil quantity per control piston to-
tals Q= 60 cm3 /min.
A maximum permissible retraction speed of 5.2 mm/min is yielded from the diagram. The maximum
permissible extension speed totals 9.5 mm/min.

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Service Manual 1-way rotary connection
System description

7.75: 1-way rotary connection

1 System description
The rotary connection is positioned at the centre of rotation for uppercarriage and undercarriage. It
connects the hydraulic system of the uppercarriage with aggregates of the undercarriage.
The stator 2 is fixed by the stator of the 1-way rotary connection (high-pressure) on the undercarriage.
The rotor 1 is connected with the uppercarriage via the rotor of the 1-way rotary connection (high-
pressure)
The upper connection is joined directly via radial and axial bore in stator 2 and the line running down-
ward.
The V-seals 12 seal the rotary connection to prevent outward leakages.

Fig. 1 Rotary connection

2 Connections and hydraulic fastenings

Connection A Variable displacement travel motors
Supply from solenoid valve Y24 to connection X for variable displacement
travel motors

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1-way rotary connection Service Manual
Dismantling and installation

3 Dismantling and installation

Caution!
Before dismantling the respective rotary connection, the following special measures are to be taken
to prevent any risk of injury to the mechanic and his assistants:
Position the vehicle on flat ground and place the attachment or the supports on the ground.
Switch off the diesel engine. With the ignition and servo control switched on, relieve the hydraulic
pressure lines of pressure by repeatedly deflecting the servo control as far as it will go.
Lower pressure of hydraulic tank by loosening the ventilation filter in the maintenance cover.

3.1 Dismantling the 1-way rotary connection to carry out sealing work, see Fig. 2

The rotary connection 30 can remain installed in rotary connection 20

Disconnect the hydraulic line 40 to the rotary connection 30
Unscrew the cylinder head screws 26, remove the lock washers 27 and actuator 25
Unscrew the nut 4 (secured with Loctite)
Remove the rotor 1 from the stator 2
Remove the V-seals 12 from the nut 4 and stator
Remove the thrust washers 3 and quad rings 11 from the rotor

3.2 Installing the 1-way rotary connection following the sealing work, see Fig. 2
Carefully remove all dust, dirt, swarf and any other foreign bodies
Check all parts meticulously for reusability
If the rotary connection sustains any damage, it is imperative that the rotary connection is re-
placed immediately by a specialist mechanic
Apply hydraulic oil to the stator outer thread 2, components and sealing elements prior to assem-
bly
Fit the quad rings 11 and thrust washers 3 in the rotor 1
Fit the V-seals 12 to stator 2 and nut 4
.

Note!
It is imperative that correct installation position and direction of V-seals 12 is observed.

Fit the rotor 1 on the stator 2

Carefully clean the thread of the stator 2 and nut 4 of oil, apply a coating of Loctite 270 and tighten
the nut 4 (tightening torque 30 Nm)
Secure the actuator 25 to the rotary connection 20 via the cylinder head screws 26 (with lock
washers 27).
Connect the hydraulic line 40 to the top of the rotary connection 30.

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Service Manual 1-way rotary connection
Dismantling and installation

Fig. 2 Installation position of the rotary connection

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1-way rotary connection Service Manual
Exploded view

4 Exploded view

Fig. 3 Exploded view of the rotary connection

1 Rotor 20 1-way rotary connection complete

2 Stator 25 Actuator
3 Thrust washer 26 Cylinder head screw
4 Nut 27 Lock washer
11 Quad ring 30 1-way rotary connection complete.
12 V-seal 40 Connection support with stabilisers
999 Sealing kit

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Service Manual 1-way rotary connection
Sectional drawing

5 Sectional drawing

Fig. 4 Sectional drawing of rotary connection

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1-way rotary connection Service Manual
Sectional drawing

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Service Manual 5-way rotary connection
System description

7.77: 5-way rotary connection

1 System description
The rotary connection is positioned at the centre of rotation for uppercarriage and undercarriage. It
connects the hydraulic system of the uppercarriage with aggregates of the undercarriage.
The stator is fastened to the undercarriage. The rotor is axially retained by the cover, which also
serves as a guard to prevent dirt from entering. The rotor is locked with the uppercarriage via the
catch pin.
Cast ports in the rotor run from the line connections 0 - 6 to the ring chambers which are sealed
against each other by special sealing rings (sealing kit). Each ring chamber is connected with the re-
spective connection 0 - 6 in the stator via a radial and axial bore.
Both outer sealing rings (sealing kit) seal the rotor against outward leakages.
The rotary connection is maintenance-free.

Fig. 1 Rotary connection

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5-way rotary connection Service Manual
Connections and hydraulic fastenings

2 Connections and hydraulic fastenings

2.1 R 900 C-Litronic and R 904 C-Litronic

Connection Leak oil

0 Return flow of leak oil from travel gear motors to the tank
Connection Right-hand travel gear motor
1 Supply from control valve block connection B1 to travel gear motor (right reverse)
Connection Travel gear motor left
2 Supply from control valve block connection B2 to travel gear motor (left reverse)
Connection Travel gear motor left
3 Supply from control valve block connection A2 to travel gear motor (left forwards)
Connection Right-hand travel gear motor
4 Supply from control valve block connection A1 to travel gear motor (right forwards)

2.2 R 924 Compact - type 911

Connection Leak oil

0 Return flow of leak oil from travel gear motors to the tank
Connection Right-hand travel gear motor
1 Supply from control valve block connection B4 to travel gear motor (right reverse)
Connection Travel gear motor left
2 Supply from control valve block connection A5 to travel gear motor (left reverse)
Connection Travel gear motor left
3 Supply from control valve block connection B5 to travel gear motor (left reverse)
Connection Right-hand travel gear motor
4 Supply from control valve block connection A4 to travel gear motor (right forwards)

3 Dismantling and installation

3.1 Dismantling the 5-way rotary connection to carry out sealing work, see Fig. 2
Mark the hydraulic lines to the rotary connections 1 and 20 at the bottom and disconnect them.
Unscrew the L-support 25 from the rotary connection 20 at the bottom.
Mark the hydraulic lines at the top and disconnect them from the rotary connections 1 and 20.
Unscrew the hexagon head screw 42 and pull the rotary connection 20 from the rotary connection
1.
Unscrew the hexagon head screw 16 and lift the complete rotary connection 1 from the undercar-
riage.

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Service Manual 5-way rotary connection
Dismantling and installation

3.2 Installing the 5-way rotary connection following the sealing work, see Fig. 2
Carefully remove all dust, dirt, swarf and any other foreign bodies
Check all parts meticulously for reusability
If the rotary connection sustains any damage, it is imperative that the rotary connection is re-
placed immediately by a specialist mechanic
Apply a coating of hydraulic oil to all parts and sealing elements before fitting
.

Note!
Observe the installation direction of the complete rotary connection 1.

Insert the complete rotary connection 1 into the correct position in the undercarriage and screw in
the screws 16 with spring washers 17.
Fit the actuator 19 onto the actuator flange of the rotary connection 1 and secure it with the screws
18 and washers.
Secure the actuator 40 with the screw 41 to the rotary connection 1.
Fit the rotary connection 20 in the correct position in the rotary connection 1 and secure it with the
screw 42.
Connect the hydraulic lines at the top (observe the markings).
Screw the L-support 25 at the bottom to the standpipe of the rotary connection 20.
Connect the hydraulic lines at the bottom (observe the markings).

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5-way rotary connection Service Manual
Dismantling and installation

Fig. 2 Installation position and direction of rotary connection

1 Rotary connection 25 L-support

16 Hexagon head screw 40 Actuator
17 Lock washer 41 Hexagon head screw
18 Hexagon head screw 42 Hexagon head screw
19 Actuator
20 Rotary connection a Travel direction

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Service Manual 5-way rotary connection
Exploded view

4 Exploded view

Fig. 3 Exploded view of the rotary connection

1 Rotary connection complete 7 Screw plug

3 Cover 8 Screw plug
5 Washer 10 Stator
6 Hexagon head screw 11 Rotor
98 Sealing kit comprising of 7 sealing rings:
2 outer seals top and bottom and 5 inner
seals

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5-way rotary connection Service Manual
Sectional drawing

5 Sectional drawing

Fig. 4 Sectional drawing of rotary connection

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Service Manual 7-way rotary connection
System description

7.79: 7-way rotary connection

1 System description
The rotary connection is positioned at the centre of rotation for uppercarriage and undercarriage. It
connects the hydraulic system of the uppercarriage with aggregates of the undercarriage.
The stator is fastened to the undercarriage. The rotor is axially retained by the cover, which also
serves as a guard to prevent dirt from entering. The rotor is locked with the uppercarriage via the
catch pin.
Cast ports in the rotor run from the line connections 0 - 6 to the ring chambers which are sealed
against each other by special sealing rings (sealing kit). Each ring chamber is connected with the re-
spective connection 0 - 6 in the stator via a radial and axial bore.
Both outer sealing rings (sealing kit) seal the rotor against outward leakages.
The rotary connection is maintenance-free.

Fig. 1 Rotary connection

2 Connections and hydraulic fastenings

2.1 R 904 C-Litronic

Connection Leak oil

0 Return flow of leak oil from travel motor and transfer case

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7-way rotary connection Service Manual
Dismantling and installation

Connection Right-hand travel gear motor

1 Supply from control valve block connection B1 to travel gear motor (right reverse)
Connection Travel gear motor left
2 Supply from control valve block connection B2 to travel gear motor (left reverse)
Connection Travel gear motor left
3 Supply from control valve block connection A2 to travel gear motor (left forwards)
Connection Right-hand travel gear motor
4 Supply from control valve block connection A1 to travel gear motor (right forwards)
Connection Extend hydraulic cylinder for levelling blade (levelling blade down)
5 Supply from control valve block connection B to levelling blade hydraulic cylinder
Connection Retract hydraulic cylinder for levelling blade (levelling blade up)
6 Supply from control valve block connection A to levelling blade hydraulic cylinder

2.2 R 924 Compact - type 198

Connection Leak oil

0 Return flow of leak oil from travel motor and transfer case
Connection Right-hand travel gear motor
1 Supply from control valve block connection B4 to travel gear motor (right reverse)
Connection Travel gear motor left
2 Supply from control valve block connection A5 to travel gear motor (left reverse)
Connection Travel gear motor left
3 Supply from control valve block connection B5 to travel gear motor (left reverse)
Connection Right-hand travel gear motor
4 Supply from control valve block connection A4 to travel gear motor (right forwards)
Connection Extend hydraulic cylinder for levelling blade (levelling blade down)
5 Supply from control valve block connection A to levelling blade hydraulic cylinder
Connection Retract hydraulic cylinder for levelling blade (levelling blade up)
6 Supply from control valve block connection B to levelling blade hydraulic cylinder

3 Dismantling and installation

3.1 Dismantling the 7-way rotary connection to carry out sealing work, see Fig. 2
Mark the hydraulic lines to the rotary connections 1 and 2 at the bottom and disconnect them.
Unscrew the L-support 25 from the rotary connection 2 at the bottom.
Mark the hydraulic lines to the intermediate flanges 20 and disconnect them.
Unscrew the cylinder head screws 22 and remove the intermediate flanges 20. Respect the rec-
tangular rings 21.

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Service Manual 7-way rotary connection
Dismantling and installation

Mark the hydraulic lines at the top and disconnect them from the rotary connections 1 and 2.
Mark the hydraulic lines to the intermediate flanges 15 and disconnect them.
Unscrew the cylinder head screws 17 and remove the intermediate flanges 15. Respect the rec-
tangular rings 16.
Unscrew the hexagon head screw 4, and washer 3, and pull rotary connection 2 out of rotary con-
nection 1.
Unscrew the hexagon head screws 12 and lock washers 13 and lift the complete rotary connection
1 from the undercarriage.

3.2 Installing the 7-way rotary connection following the sealing work, see Fig. 2
Carefully remove all dust, dirt, swarf and any other foreign bodies
Check all parts meticulously for reusability
If the rotary connection sustains any damage, it is imperative that the rotary connection is re-
placed immediately by a specialist mechanic
Apply a coating of hydraulic oil to all parts and sealing elements before fitting
.

Note!
Observe the installation direction of the complete rotary connection 1.

Insert the complete rotary connection 1 in the correct position in the undercarriage and screw in
the screws 12 with lock washers 13.
Fit the actuator 19 onto the actuator flange of the rotary connection 1 and secure it with the screws
18 and washers.
Secure the actuator 7 with the screw 9 and washer 8 to the rotary connection 1.
Secure the intermediate flanges 20 and rectangular rings 21 using the cylinder head screws 22.
Secure the intermediate flanges 15 and rectangular rings 16 using the cylinder head screws 17.
Fit the rotary connection 2 in the correct position in the rotary connection 1 and secure it with the
screw 4 and washer 3.
Connect the hydraulic lines at the top (observe the markings).
Screw the L-support 25 at the bottom to the standpipe of the rotary connection 2.
Connect the hydraulic lines at the bottom (observe the markings).

1 Rotary connection 16 Rectangular ring

2 Rotary connection 17 Cylinder screw
3 Washer 18 Hexagon head screw
4 Hexagon head screw 19 Actuator
7 Actuator 20 Intermediate flange
8 Washer 21 Rectangular ring
9 Cylinder head screw 22 Cylinder head screw
12 Cylinder head screw 25 L-support
13 Washer
15 Intermediate flange a Travel direction

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7-way rotary connection Service Manual
Dismantling and installation

Fig. 2 Installation position of the rotary connection

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Service Manual 7-way rotary connection
Exploded view

4 Exploded view

Fig. 3 Exploded view of the rotary connection

1 Rotary connection 11 Rotor

3 Cover 13 Stator
4 Screw plug 15 Felt ring
5 Screw plug 16 Screw plug
6 Lock washer 98 Sealing kit comprising of 9 seals:
1 felt ring, 2 outer seals top and bottom, 7
inner seals
7 Hexagon head screw

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7-way rotary connection Service Manual
Sectional drawing

5 Sectional drawing

Fig. 4 Sectional drawing of rotary connection

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Service Manual Brake valve for hydraulic travel gear motor
Purpose of the brake valve

7.97: Brake valve for hydraulic travel gear motor

(Brake valve of construction line «-3/2 WV»)

1 Purpose of the brake valve

The brake valve 205 flange-mounted on each travel gear motor has 3 functions:
– The brake piston 206 prevents the oil motor from overwinding when travelling downhill.
– The 2-way check valve 207 as well as the pressure reduction valve 208 generate the opening
pressure for the multi-disc brake integrated in the travel gear transmission. This opening pressure
(control pressure) is supplied to the brake when the travel pressure has reached approx. 30 bar.
– A small quantity of hydraulic oil is supplied from the low-pressure circuit into the engine housing,
keeping the temperature in the travel motor to a minimum.

Fig. 1 Hydraulic circuit diagram of brake valve

2 Pressure spring 6a Check valve

3.1a Start-up and throttle bore 6b Check valve
3.1b Start-up and throttle bore 205 Brake valve complete
3.2a Throttle bore 206 Brake piston
3.2b Throttle bore 207 2-way check valve
4a Check valve 208 Pressure reduction valve / brake control
pressure
4b Check valve 218b Cooling nozzle
5a Check valve
5b Check valve

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Brake valve for hydraulic travel gear motor Service Manual
Functional description

2 Functional description

2.1 Functioning of the hydraulic brake piston 206

Note:
The following description applies to the build-up or dissipation of pressure at connection A of the
brake valve. Changes in pressure at connection B will lead to a symmetrical reaction at the brake
valve.

Fig. 2 Sectional drawing - brake piston 206.

2.1.1 Opening of the brake piston for the travel gear.

The pressure oil «A» flows through check valve 5a and connection «A’» to the travel motor.
At the same time, pressure is built up progressively at the control surface of the piston 206 by the
control edge «da» and throttle bore 3.1a. The piston 206 is pushed against the initial tension of the
spring 2 until a conjunction between connection «B» and the S channel occurs, whereby the oil flows
back into the low-pressure connection «B» via valve cone 6b.

2.1.2 Closing the brake piston - hydraulic brake.

If the pressure drops at connection «A» (e.g. when travelling downhill), the spring 2 pushes the brake
piston 206 towards the middle position. This will restrict the oil flow between connection «B'» and «S»
via the piston 206 to maintain a specific level of pressure or to prevent cavitation or overwinding of
the oil motor.

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Service Manual Brake valve for hydraulic travel gear motor
Functional description

Upon completion of a travel actuation the higher pressure at surface «a» is released more quickly via
throttle bore 3.2a and check valve 4a to connection «A».
Piston 206 is moved immediately into the neutral position and closes the connection «B'» - «S».

2.2 Functioning of the hydraulic brake piston 206

During travel, the high pressure is supplied from connection «A» or «B» via the 2-way check valve
207 and pressure reduction valve 208 (restricted to approx. 35 bar) to the control connection «Br».
The multi-disc brake integrated in the gear and connected with connection «Br» via a hose is thus
aerated.
If connection «A» or «B» is relieved of pressure, the control pressure / air pressure at connection
«Br» is released to the hydraulic tank via valve 208 and connection «L», whereby the multi-disc brake
in the travel gear transmission is closed.
The valve 207 is implemented via the piston actuator 11 which is pushed against the spring resist-
ance 12 as soon as the difference in pressure between «A» and «B», 9 bar is reached and the high
pressure in «A» or «B» connects with the pressure reduction valve 208 (see Fig. 3 on page3).
If a pressure peak occurs in the travel motor circuit without a travel movement being initiated, this
valve will prevent a reduction of brake torque or an undesired aeration of the multi-disc brake / travel
gear.

Fig. 3 Sectional drawing - 2-way check valve 207 - pressure reduction valve 208.

2.3 Output in the travel motor

As the pressure in channel «S» is slightly higher than the pressure than the pressure in the hydraulic
tank during travel, a small quantity of hydraulic oil flows from the return flow channel «S» via the bore
«r» in the brake valve housing to connection «L».
This connection «L» is connected with the leak oil line of the travel motor, see also Description of the
travel motor in group 7.
The oil flow is determined by the overpressure in channel «S» and the diameter of the bore «r», as
well as by the nozzle 218a screwed into the connection plate of the travel motor.

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Brake valve for hydraulic travel gear motor Service Manual
Functional description

Fig. 4 Sectional drawing - nozzle 218b - channel «r».

Nozzle 218b installed in the housing of the brake valve.

Fig. 5 Sectional drawing - nozzle 218b

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Service Manual

Group 8: Electrical System

Construction of the electrical system ..................................................................................8.10

1 Cab area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.10.1
1.1 Operating and control elements in the cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.10.1
1.2 The control unit S2 (BBT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.10.3
1.3 The monitoring display H1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.10.4
1.4 Left control console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.10.5
1.5 Right control console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.10.5
1.6 The print plate A1001 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.10.6
1.7 The print plate A1010 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.10.8
2 Diesel engine D 934 S A6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.10.10
3 Electrical power box E50 with main fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.10.12
4 Various electrical components on the uppercarriage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.10.13
5 Servo oil unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.10.14
6 Electrical components of the heater and air conditioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.10.15
7 Uploading PRS software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.10.16

Monitoring display..................................................................................................................8.30
1 Indicator lights and menu control buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.30.1
1.1 Area A : Display of analog-values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.30.2
1.2 Area B: Indicator lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.30.2
1.3 Area D : Menu control keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.30.3
1.4 Area C: LCD Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.30.3
2 Main screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.30.4
2.1 Constitution of the main screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.30.4
3 Error code list. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.30.11
4 Display on the screen of the information provided in menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.30.17
4.1 Menu selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.30.18
4.2 Access to the various menus of the LCD screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.30.18
4.3 Menus accessible at level 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.30.20
4.4 Menus accessible at level 2 and 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.30.32

Control unit S2........................................................................................................................8.40

1 Function of the codage plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.40.1
1.1 Codage function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.40.1
1.2 Memory function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.40.1
2 Replacing the control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.40.3
2.1 Preparing for replacement: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.40.3
2.2 Securing the data in the codage plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.40.3
2.3 Replacing the control unit S2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.40.4
2.4 Automatic return transfer of data from the codage plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.40.4
2.5 Examination of data returned to control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.40.4
3 Replacement of bulbs for keyboard backlighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.40.5

Component list - Electrical diagrams ...................................................................................8.80

List of electrical diagrams - Standard execution.................................................................8.90

1 Electrical diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.90.1

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Service Manual Construction of the electrical system
Cab area

Group 8: Electrical System

8.10: Construction of the electrical system

1 Cab area

1.1 Operating and control elements in the cab

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Cab area

1 Safety lever- Servo control S5L Push button for rotating device
left (grapple, shear, ...),
±® «²´±½µ·²¹ ±º ½§´·²¼»® ½«¬ó±ºº øÒß÷
3 Right joystick S5M Horn
4 Left joystick S5R Push button for rotating device
right (grapple, shear, ...)
±® ¬®¿ª»´ ¿´¿®³ ±²ñ±ºº øÒß÷
5 Pedal for left travel gear S6L Push button for lifting magnet
±® ®±¬¿¬·²¹ ¼»ª·½» ´»º¬ øÒß÷
6 Pedal for right travel gear S6M Push button - reserve
9 Pedal for special attachment con- S6R Push button –travel alarm on/off
trol * ±® ®±¬¿¬·²¹ ¼»ª·½» ®·¹¸¬ øÒß÷
10 Positioning swing brake * S55 Switch – unlocking of cylinder cut-
off
±® ´·º¬·²¹ ³¿¹²»¬ øÒß÷
15 Controls for optional equiments * S57 Switch / Preselection of swing
brake operating mode
S71 Diesel engine emergency start
A3 Radio * S72 RPM adjustment during emer-
gency operation
E8 Cigarette lighter S73 Safety mode of the servo circuits
H1 Monitoring display S84-1 Push button / Central lubrication
H10 Buzzer
P5 Hourmeter U38 Control unit - air conditioner
S1 Ignition key
S2 Control unit

* Optional equiments
øÒß÷ Ì¸· ´±½¿¬·±² ±²´§ º±® Ò±®¬¸ ß³»®·½¿

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1.2 The control unit S2 (BBT)

P4 Indicator gauge / engine RPM

S10 Touch / uppercarriage floodlights S11 Touch / windshield washer
S14 Touch / windshield wiper S17 Touch / swing brake
S18 Touch / overload warning device S19 Touch / activation of rotating device
S20 Touch / low idle automatic S21 Touch / travel motors speed selection
S22 Touch / additional floodlights S36 Touch / special function (not active)
S41 Touch / beacon S56 Touch / pressure cut-in
S85 Touch / grapple operation S86 Touch / engine RPM mode selection
S228 Touch / engine RPM increase S229 Touch / engine RPM decrease
S354 Touch / Special function (not used)

Further information, see sub-group 8.74.

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1.3 The monitoring display H1

Area A: Engine monitoring

P2 Gauge / engine coolant temperature P2.1 Red LEDs - coolant overheating
P3 Gauge / Fuel level P3.1 Red LEDs - Fuel level low
Area B: Indicator lights
H2 Indicator light / low engine oil pressure H12 Indicator light / battery charge
H19* Indicicator light / blinker H20* Indicator light / parking brake
H23* Indicator light / accumulator pressure H24* Indicator light / steering oil
* Lights are not used on R excavators
Area C: LCD screen
Area D: Control buttons for LCD screen menus
S349 Touch / RETURN S350 Touch / DOWN
S351 Touch / UP S352 Touch / MENU

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1.4 Left control console

A1010 Print plate / fuses A1011 Platine / Versorgung Bausätze

A1016 Print plate / - interface to S2 S7 Safety switch / servo cut off

1.5 Right control console

A1001 Print plate ESP 01 A1009 Print plate / optional equipments

E52 Circuit / safety control for Diesel engine H1 Monitoring display
K34 Relay /cab roof windshield wiper S2 Control unit
T1 Voltage transformer U16 Regulation unit BST

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1.6 The print plate A1001

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1.6.1 Relays on the print plate A 1001

K1 Relay / windshield wiper K2 Relay / battery charge

K3 Relay / reserve K4 Relay / reserve
K5 Relay / safety operation of servo circuit

1.6.2 Final stages and control light diodes on print plate A 1001

Endstufe LED LED LED

V2 End stage / pressure cut in H1 LED green H2 LED red H3 LED yellow
Input signal Default Output signal
V3 End stage / servo pressure H4 LED green H5 LED red H6 LED yellow
Y3 Input signal Default Output signal
V4 End stage / swing brake Y7 H7 LED green H8 LED red H9 LED yellow
Input signal Default Output signal
V5 End stage / outlet flow mini H10 LED green H11 LED yellow H12 LED red
Y78 Input signal Output signal Default
V6 End stage / travel speed H13 LED green H14 LED yellow H15 LED red
control Y24 Input signal Output signal Default
V7 End stage / windshield H16 LED green H17 LED yellow H18 LED red
washer Input signal Output signal Default
V8 Reserve for special func- H19 LED green H20 LED yellow H21 LED red
tion -solenoid valve for flow Input signal Output signal Default
reparttion on R934C
V12 Reserve for special func- H22 LED green H23 LED yellow H24 LED red
tion Input signal Output signal Default
V21 End stage / floodlights on H25 LED green H26 LED yellow H27 LED red
cab Input signal Output signal Default
V24 End stage / floodlights on H28 LED green H29 LED yellow H30 LED red
attachment Input signal Output signal Default
V26 End stage / beacon H31 LED green H32 LED yellow H33 LED red
Input signal Output signal Default
V32 Special function. - Sol. H34 LED green H35 LED red H36 LED yellow
valve for pressureless low- Input signal Default Output signal
ering on R944C & R954C)
V37 End stage / Rotating de- H40 LED green H41 LED yellow H43 LED red
vice right Y23 Input signal Output signal Default (R+L)
V44 End stage / grapple swing H37 LED green H38 LED red H39 LED yellow
Y78 Input signal Default Output signal
V57 End stage / windshield wip- H42 LED green
er Input signal
V83 End stage / Rotating de- H44 LED green H45 LED green
vice left Y22 Input signal Output signal
V92 +24V for transmitters and H46 LED green
switches Input signal

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1.7 The print plate A1010

1.7.1 Fuses on print plate A1010

Pos. Description
F1 15 A Central lubrication system
F2 15 A Reserve
F3 15 A Reserve - windshield wiper and washer on cab roof
F4 15 A Windshield washer, control circuit of windshield wiper, preheating system
control circuit, 24 Volt stabilized for transmitters and switches, Qmin com-
mutation, pressureless lowering beacon*, rotating grab*
F5 15 A Windshield wiper motor (power circuit)
F6 7,5 A Circuit for “MANU” control of RPM adjustment
F7 7,5 A Control unit and display
F8 7,5 A Safety lever, solenoid valve for servo control, swing brake, travel speed in-
crease, pressure increase
F9 15 A power supply for BSt regulator
F10 25 A Headlights on working attachment and uppercarriage
F11 15 A Reserve

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Pos. Description
F12 15 A Reserve
F13 15 A Ignition key, starting circuit, voltage transformer*, Radio*, loudspeaker*
F14 15 A Dome light, cigarette lighter, signal horn
F15 15 A Reserve

1.7.2 Light diodes on print plate A1010

Pos. Description
H1 Voltage + 24V at output secured by fuse F1
H2 Voltage + 24V at output secured by fuse F2
H3 Voltage + 24V at output secured by fuse F3
H4 Voltage + 24V at output secured by fuse F4
H5 Voltage + 24V at output secured by fuse F5
H6 Voltage + 24V at output secured by fuse F6
H7 Voltage + 24V at output secured by fuse F7
H8 Voltage + 24V at output secured by fuse F8
H9 Voltage + 24V at output secured by fuse F9

1.7.3 Relays on print plate A1010

Pos. Description
K5 Relay / engine stop
K6 Relay / horn
K7 Relay / additional floodlights on the cab
K8 Relay / float position
K9 Relay / safety operation (not used))

1.7.4 Connection points and earthing points on print plate A1010

Pos. Description
KL15 Connection for voltage +24V terminal 15
KL30 Connection for voltage +24V terminal 30
MP1 Electronic earthing of print plate A 1010 in left control console
MP61-1 Earthing of print plate A1010 in left control console
MP61-2 Earthing of print plate A1010 in left control console

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Diesel engine D 934 S A6

2 Diesel engine D 934 S A6

8.10.10 R 914 C / R 924 C

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Diesel engine D 934 S A6

B12-1 Transmitter 1 / engine speed (flywheel) B182 Transmitter / fuel temperature

B12-2 Transmitter 2 / engine speed (flywheel) B46 Transmitter / boost air temperature
B12-3 Transmitter / engine speed (cam shaft) B98 Transmitter / boost air pressure
B5 Transmitter / engine oil pressure
B99-2 Transmitter / water level in fuel filter

U32 Control unit / Diesel engine and fuel B2 Transmitter / engine coolant temperature
injection
G1 Alternator B12Engine RPM transmitter for BST
Y20 Solenoid val. / magnetic clutch air conditioner

R 914 C / R 924 C 8.10.11

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Electrical power box E50 with main fuses

3 Electrical power box E50 with main fuses

The electrical power box E50 with main fuses is situated behind the left side door, above the batteries.

E50 Electrical power box with main fuses

F19 100 A Circuit breaker on Kl30 - preheating
F20 50 A Circuit breaker on Kl30 - main circuit
F22 7,5 A Fuse on Kl30 - reserve (hazard warning system on wheel excavat.)
F31 7,5 A Fuse on Kl15 - heater and air conditioning system
F33 7,5 A Fuse on Kl15 - control circuit for refuelling pump (optional extra)
F34 15 A Fuse on Kl30 - reserve for options
F35 15 A Fuse on Kl30 - reserve for options
F36 20 A Fuse on Kl30 - power circuit for refuelling pump (optional extra)
F36-2 15 A Fuse on Kl15 - cut off of cylinder movements (option)
F37 20 A Fuse on Kl30 - heater and air conditioning system
F109 50 A Circuit breaker on Kl30 - special equipments and headlights
F110 50 A Circuit breaker on Kl30 - power supply of PLD system
F115 7,5 A Fuse on Kl15 for safety mode
F116 7,5 A Fuse on Kl30 - controller of PLD system
F117 7,5 A Fuse on Kl15 - PLD system
F122 7,5 A Fuse on Kl30 - preheating signal for PLD system
F133 7,5 A Fuse on Kl30 for hydraulic adjustable cab (option)
F253 25 A Fuse on Kl30 for additional headlights on attachment (option)
K10-1 Relay / additional floodlights on counterweight
K56 Relay / fuel preheating
K66-1 Relay / cut off of cylinder movements (option)
K66-2 Relay / cut off of cylinder movements (option)
K127 Relay / engine RPM adjustment in safety mode
K128 Relay / engine start in safety mode
K288 Relay / terminal 15
K302 Relay / engine preglow
K359 Relay / additional standstill heater

8.10.12 R 914 C / R 924 C

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Various electrical components on the uppercarriage

K415 Relay / additional headlights on attachment (option)

4 Various electrical components on the uppercarriage

B8 Transmitter / hydraulic oil temperature B19L Sensor joystick left

B14 Switch / hydraulic oil level B19R Sensor joystick right
B39 Transmitter / fuel level

B40 Pressure switch / Travel pedal B33-2 Pressure switch / flow reduction AHS

R 914 C / R 924 C 8.10.13

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Servo oil unit

Y347 Solenoid valve / Cooler fan RPM

U4 Control unit / central lubrication system B51 Pulse transmitter / central lubrication

5 Servo oil unit

50 Servo oil unit

Y3 Solenoid valve / servo-pressure Y7 Solenoid valve / swing brake
Y24 Solenoid valve / Travel speed increase Y50 Reg. solenoid valve LR / Pump power

8.10.14 R 914 C / R 924 C

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Electrical components of the heater and air conditioner

Y51 Reg. solenoid valve EV1 / flow limitation Y414 Reg. solenoid valve / AHS (option)

6 Electrical components of the heater and air conditioner

B43 Temperature transmitter / air conditioning B44 Pressure switch / air conditioning
B255 Transmitter / air temperature in cab B257 Transmitter / temperature at airco exit
M13 Motor / Evaporator fan M75 Motor / air flap - outside air
M76 Motor / air flap at rear wall M77 Motor / air flap - control console right
M78 Motor / air flap - feet & front window area U37 Regul. unit / heater and air-conditioner
U38 Control unit / heater and air-conditioner Y20 Sol. valve / clutch air conditioner compressor

R 914 C / R 924 C 8.10.15

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Uploading PRS software

Y46 Regulation solenoid valve / heating power

7 Uploading PRS software

Function
The UEC (A180 print plate) is the electronic control module for proportional controls.
The «PRSxxx.HEX» software must be uploaded into the UEC to ensure proper operation of the pro-
portional controls.

NOTE: "xxx" stands for the software version. Example: «PRS014.HEX» for software version v1.4.

System requirements
PRS software can be installed starting with the following EPROM versions:
– UEC : v1.4
– Display : v4.6.9
– BBT : v4.6.9
– BST : v4.6.9

Hardware requirements
The following hardware is necessary to upload the PRS software into the UEC:
– Diagnostic cable (9596352); the cable is fitted with a "bootstrap" switch for initiating software
upload.
– A PC with a valid version of LIDIS (LIebherr Diagnosis System).
LIDIS software can be downloaded from LIEBHERR Service Documentation intranet page:
General \ Service Software \ General \ LIDIS

Software upload
Connect the PC to the UEC (A180 print plate) using RS232 serial cable.

Fig. 1 LIDIS starting screen

Start LIDIS software.
To upload the PRS software, select "UEC-Steuerung" in the "Programmieren" tab.
Confirm the "Bootstrap" is activated when the UEC is switched on: message "Bootstrap betätigen
und Steuerung einschalten" should be displayed in the "Meldungen" window.

8.10.16 R 914 C / R 924 C

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Uploading PRS software

Fig. 2 PRS software uploading screen

Select «PRSxxx.HEX»: click «Durchsuchen» button and browse for «PRSxxx.HEX» file.
The recommended upload speed is 19200 Bit/s.
Click on «Start» button to initiate the upload procedure.
When the program is successfully uploaded, click on «Beenden» button to close the window.

R 914 C / R 924 C 8.10.17

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Uploading PRS software

8.10.18 R 914 C / R 924 C

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Service Manual Monitoring display
Indicator lights and menu control buttons

8.30: Monitoring display

1 Indicator lights and menu control buttons

Fig. 1 Monitoring display

A Analog-value gauges B Indicator lights

C LCD screen D Menu control keys
H2 Indicator light, engine oil pressure H12 Indicator light, battery charge
H19 Function not used H20 Function not used
H23 Function not used H24 Function not used
P2 Coolant temperature gauge P2.1 Coolant temp. gauge - red area
P3 Fuel level gauge P3.1 Fuel level gauge - red area

S349 Back key S350 Down key

S351 Up key S352 Menu key

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Indicator lights and menu control buttons

1.1 Area A : Display of analog-values

P2 – Diesel engine coolant temperature gauge

During the operation of the machine the gauge must be in the green area.

In the event of an overheating, i. e. if the coolant temperature is above 100 °C / 212 ºF :

the red LEDs P2.1 at the end of indicator P2 start blinking,
the buzzer in the cab sounds,
the error is memorized under error code E 503,
the engine power is automatically reduced.
Stop working as soon as possible.
Keep the engine running at high idle.

If the overheating exceeds 60 seconds:

bring the engine to low idle and keep it running at low idle for another 3 to 5 minutes.
Turn the engine off.

If the temperatur increases some more (above 104 °C / 219 ºF )

the corresponding symbol is displayed on the main screen after 7 seconds
the error is memorized under error code E 523.
Turn the engine off immediately.
Find out and remedy the cause of the trouble.
P3 – Fuel level display
The number of lighting LEDs on this gauge indicate the amount of fuel remaining in the tank.
When the red LEDs P3.1 illuminate, a reserve allowing to operate the machine for approx. one or two
hours is still in the tank.

1.2 Area B: Indicator lights

H2 – Indicator light, low engine oil pressure

The indicator light illuminates if, during machine operation, the engine oil pressure drops below a val-
ue depending on the engine RPM for more than 3 seconds.
The buzzer in the cab also sounds.
When this indicator light illuminates, the error will be saved as error code E 501..
Bring the engine to a low idle immediately.
Allow the engine to idle for a short moment and switch it off.

If the pressure remains too low for 5 other seconds:

the corresponding symbol is displayed on the main screen,
the error is memorized under error code E 522.
the engine is turned off automatically.
Find and correct the cause of the problem (oil level, oil viscisity,,...)

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Indicator lights and menu control buttons

H12 – Indicator light, battery charge

The indicator light illuminates if the ignition key is placed in the contact position.
The indicator light goes out as soon as the engine is started.
When the machine is operating, this indicator light illuminates if the alternator belt or the electrical
charging system is defective.
Bring the engine to low idle immediately.
Allow the engine to idle for approximately 5 seconds.
Switch off the engine.
Find out and remedy the cause of the problem.
H19 – No function

H20 – No function

H23 – No function

H24 – No function

1.3 Area D : Menu control keys

Fig. 2 Menu control keys

The screen can be operated using the following four keys:
– S349: Back key
– S350: Down key
– S351: Up key
– S352: Menu key
These keys are used to jump from the main menu to the submenus or to move from page to page,
to scroll inside a menu, ....

1.4 Area C: LCD Screen

To change the contrast of the LCD screen:

Press the Menu key and the arrow key Up (higher contrast) or Down (lower contrast) simultane-
ously.
The contrast will be changed.
When releasing the both keys the set value of the contrast is memorized.

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Main screen

To change the brightness of the LCD screen:

Press at the same time the Back key and the arrow key Up (brighter) or Down (darker).
The brightness will be changed.
When releasing the both keys the set value of the brightness is memorized.

Note
A light sensor built in to the top left of the monitoring screen adapts the illumination on the main
screen to the brightness of the environment. The adaptation takes place from the saved brightness
value. Illumination will be automatically reduced in conditions of low environmental brightness and
inversely.

To change the brightness and the contrast setting to the initial setting:
Turn off the ignition.
Press and hold the Up and Down keys simultaneously.
Turn on the ignition again.
After completion of the automatic display check release the both keys.:
the settings for the brightness and for the contrast of the LCD screen retrieve their initial values
set at machine delivery.

2 Main screen
The main screen appears when the machine has been switched on and remains on display until the
screen is changed over to the menu selection screen using the Menu key.

Fig. 3 Main screen - Division into four fields

EC Error codes of electrical errors SY Symbols of operating faults, clock

INF Information symbols TI Display of hour meters, flow limitations, ...

2.1 Constitution of the main screen

2.1.1 SY field
The upper field of the screen shows the warning symbols for the actual operating faults and also the
clock.
Should more than two symbols be shown, so the clock is not displayed any more and up to four sym-
bols can be shown at the same time in the field SY.
If more than 4 symbols must be shown, then every 10 seconds, the symbols move to the left by one
symbol.

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See the list of the possible symbols in section "Warning symbols in the SY field", further in this chap-
ter.

2.1.2 EC field
The EC window displays the error codes for electrical faults which occur in the excavator's electronics
system (line errors, sensor errors etc.). A maximum of 7 error codes are displayed simultaneously. If
there are more than these 7 errors present, an arrow which points to where the other error codes are
located will be displayed next to the error code window.
Press the Up or Down button.
The error code list is shifted in the selected direction.

2.1.3 INF field

The INF field displays temporary information in graphic form.
If more than 3 symbols are to be displayed, the symbols will shift one symbol to the left approx. every
10 seconds.
The information is displayed in graphic or text form and indicates specific operating states on the ma-
chine (also see the section "Information symbols in the INF field", further in this chapter).

2.1.4 TI field
The machine operating hours and the daily operating hours counter are displayed in this field at the
bottom right of the screen. During the start-up phase, the operator will be alerted about a possible up-
coming service time, by a graphic symbol and an hour indication displayed instead of the machine
hour-meter during about 8 seconds.
The symbol ® is displayed when an external flow limitation is activated, (see the description of the
menu "Info In/Outputs", further in this chapter).
The symbol " " indicates that no external flow limitation is actually activated. But an internal flow
limitation (travel, swing,...) may be activated
In this field can also be indicated the denomination (for example HM2000) of the option which is ac-
tually assigned to the external flow limitation input I1 (see the description of the menu "Set option",
further in this chapter).

2.1.5 Control of the screen at error recognition

In case a new operating fault displayed in the field SY is recognized, the presentation will return to
the main screen, and the relevant symbol is displayed.
Depending on the fault (level of urgency), the buzzer will sound either continuously or in short con-
secutive bursts. At the same time the symbol "acknowledge error" will be displayed in the INF field.

Danger!
If the displayed fault is not remedied immediately, this could lead to persons sustaining injury or the
machine being damaged.
Immediately remedy the occured error or get it remedied.
Press the Back key.
The error will be acknowledged, this means that the buzzer signal alerting to the upcoming of
this fault is stopped.

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2.1.6 Warning symbols in the SY field

A) Warning symbols for operating faults

Each of the following symbols will be assigned an error code in the form “E 5xx”. When the trouble
is occuring, the corresponding symbol is displayed in the field SY of the screen. The error code will
not be displayed in the field EC too, but the occured error will be memorized under this error code in
the error list.

E 502 – Low coolant level

This symbol appears if the coolant level drops below the water sensor level.
The buzzer sounds simultaneously.
Bring the engine to a low idle immediately.
Switch the engine off as quickly as possible.
Localise the leak and carry out repairs.

Caution!
This coolant level monitoring device achieves an increased security for the engine in case of larger
amounts of water loss (e.g. hose rupture). It does not relieve the operator or maintenance
personnel from the responsibility of regularly checking the coolant level in the expansion reservoir.
E 503 – Coolant overheat - Warning stage
This symbol appears simultaneously with the two red leds on the coolant temperature gauge P2
if the coolant temperature exceeds 100°C during at least 3 seconds. The buzzer sounds
simultaneously and the engine power is reduced.
If the temperature increases some more, the symbol E523 will also be displayed.
E 504 – Low hydraulic oil level
This symbol appears if the oil level in the hydraulic tank drops below the minimum level.
The buzzer sounds simultaneously.
Bring the engine to a low idle immediately.
Switch the engine off as quickly as possible.
Find the leak.
Depressurize the hydraulic tank.
Carry out repairs.
Only refill the hydraulic oil using the return-line filter.
E 505 – Hydraulic oil overheat
This symbol appears if the hydraulic oil temperature in the tank exceeds 99 °C.
Bring the engine to a low idle immediately.
Switch the engine off after a few seconds.
Find out and remedy the trouble (radiator dirty etc.).

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Main screen

E 506 – Splitterbox oil overheat

This symbol appears if the oil temperature in the splitterbox exceeds 100 °C.
Bring the engine to a low idle immediately.
Switch the engine off after a few seconds.
Localise and rectify the error.
E 511 – High voltage of batteries
This symbol appears if the momentaneous voltage of the batteries exceeds 30 volts for at least
0.5 seconds.

E 512 – Under voltage for the Diesel control system

This symbol appears if the operating voltage for the Diesel control system is lower than
the minimum permissible value.

E 513 – Over voltage for the Diesel control system

This symbol appears if the operating voltage for the Diesel control system exceeds the
maximum permissible value.

E 516 – Safety shut off for EDC default

This symbol appears if an EDC default is detected. The engine shuts off automatically.

E 517 – Safety shut off for injector default

This symbol appears if an injector default is detected. The engine shuts off automatically.

E 518 – Safety shut off for starting synchronisation default

This symbol appears if a starting synchronisation default is detected. The engine shuts off
automatically.

E 519 – Overspeed of Diesel engine - Warning stage

This symbol appears if the RPM of the Diesel engine is above the preprogrammed warning stage.

E 520 – Overspeed of Diesel engine - Safety stage

This symbol appears if the RPM of the Diesel engine is above the preprogrammed safety stage.
The engine stops automatically.

E 521 – Both engine RPM sensors defective

This symbol appears if both engine RPM sensors are simultaneously defective. The engine shuts
off automatically.
For machine equipped with a lifting magnet, the symbol appears if one only of the both sensor is
defective. In this case, the engine does not shut off automatically.

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Monitoring display Service Manual
Main screen

E 522 – Low engine oil pressure - Safety stage

This symbol appears if the engine oil pressure is, during at least 7 seconds, below a programmed
value depending on the engine RPM. The buzzer sounds simultaneously.

E 523 – Coolant overheat - Safety stage

This symbol appears if the coolant temperature exceeds 104°C during at least 7 seconds. The
buzzer sounds simultaneously and the engine power is reduced.

E 524 – Boost air overheat - Safety stage

This symbol appears if the boost air temperature exceeds 80°C during at least 7 seconds.
The buzzer sounds simultaneously and the engine power is reduced.

E 525 – Engine in safety mode

This symbol appears if, when the engine is in safety mode, one of the following engine er-
ror is detected: E501, E503, E597, E522, E523 or E524.
Simultaneously the buzzer sounds and the LED H60 lights up
Bring the engine to a low idle and turn it off as soon as possible.
E 526 – Fuel overheat - Warning stage
This symbol appears if the fuel temperature is above the warning limit.

E 527 – Fuel overheat - Safety stage

This symbol appears if the fuel temperature is above the safety limit.

E 528 – High water level in the fuel filter

This symbol appears if a high water level is detected in the fuel filter.

E 530 – Centralized symbol - safety limit exceeded

This symbol appears simultaneously with the one of the safety stage errors : E522, E523, E524,
E527, E533, E535, E537 or E539.

E 532 – Low fuel pressure - Warning stage

This symbol appears if the fuel pressure is under the warning limit.

E 533 – Low fuel pressure - Safety stage

This symbol appears if the fuel pressure is under the safety limit.

E 534 – High fuel pressure - Warning stage

This symbol appears if the fuel pressure is above the warning limit.

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Service Manual Monitoring display
Main screen

E 535 – High fuel pressure - Safety stage

This symbol appears if the fuel pressure is above the safety limit.

E 536 – Low fuel pressure in Rail 1 - Warning stage

This symbol appears if the fuel pressure in the Rail 1 of the injection system passes below the
warning limit.

E 537 – Low fuel pressure in Rail 1 - Safety stage

This symbol appears if the fuel pressure in the Rail 1 of the injection system passes below
the safety limit.

E 538 – Low fuel pressure in Rail 2 - Warning stage

This symbol appears if the fuel pressure in the Rail 2 of the injection system passes below the
warning limit.

E 539 – Low fuel pressure in Rail 2 - Safety stage

This symbol appears if the fuel pressure in the Rail 2 of the injection system passes below
the safety limit.

E 597 – Boost air overheat - Warning stage

This symbol appears if the boost air temperature exceeds 75°C during at least 3 seconds.
The buzzer sounds simultaneously and the engine power is reduced.
If the temperature increases some more, the symbol E524 will also be displayed.

B) Warning symbols for special operating states und system errors

In addition to the above mentioned operating faults, also the symbols of the list below may appear in
the SY field of the screen to warn the operator of the occurence of particular operating sequences or
of some particular system errors.

Quick change adapter (optional equipment)

This symbol appears during the unlocking procedure or when the locking pins of the quick change
adapter are not completely out.
No error code is corresponding to this symbol.
Quick change adapter (optional equipment)
This symbol appears when no tool is detected.
No error code is corresponding to this symbol.

2.1.7 Information symbols in the INF field

Preheating
This symbol appears as long as the preheating of the air in the intake manifold is activated (preglow
process).

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Monitoring display Service Manual
Main screen

End of preheating
Preheating will stop automatically after about 20 seconds and the symbol End of preheating is dis-
played for approx. 2 seconds on the main screen.

Manual Diesel speed adjustment

This symbol informs the excavator's operator that the Diesel engine is actually operated in safety
mode, either after starting the engine using the switch S71, or due to an automatic commutation con-
secutive to a communication default in the control system.

Service due
This symbol indicates that the moment for carrying out the next recurring service work is due. When
the electrical system of the machine is turned on, this symbol and the hours for the next service falling
due are displayed for approx. 10 seconds in place of the current operating hours.
Get the the service work carried out within the prescribed delay,or report the falling due to your
supervisor.
The symbol will go out after the execution of the programmed service work has been confirmed, see
the menu "set service" thereafter.
Acknowledge error
This symbol appears if an operating fault of the machine (E5xx type error code) has occurred and
the buzzer sounds simultaneously.
It informs the operator that he can, after having recognised the occured fault, press the back key to
stop the buzzer.
“Increased care required” - servo-control circuit in safety mode
This symbol alerts the operator that the servo-pressure circuits have been turned into safety mode
(switch S73 is tilted in safety position).

Swing brake not operative

This symbol alerts the operator that the swing brake control circuit is out of function due to
the turning into safety mode of the servo-control via switch S73.

Servo control operation changed

This symbol appears if switch S73 is tilted into the safety mode position.

Overload warning device (optional equipment)

For a machine fitted with the optional equipment "overload warning device", and if this equipment has
been turned on via the switch S18, this symbol alerts the operator that the load limit of the machine
has been reached
At the same time the buzzer sounds to alert the operator to this fact.
No overload warning device recognized
This symbol appears if switching on the overload warning device via switch S18 though no overload
warning device has been installed and/or correctly initialised on the machine.

8.30.10 R 914 C / R 924 C

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Service Manual Monitoring display
Error code list

Warm up procedure
This symbol appears during a warm up procedure of the Diesel engine or of the hydraulic oil.

3 Error code list

Danger!
When switching over to emergency operation, the speed can no longer be changed
using the arrow keys on the monitoring screen. The servo control, parking brake
and swing gear brake can no longer be activated.
Please also note the subheading “Emergency operations” in the chapter “Oper-
ating the machine” in this regard.

The error codes of warning symbols will not be displayed in the EC field of the operator’s menu. They
can only be read off the S-Exxx menu list. See Chapter 3 "Main screen".

Error
Effect Cause Measure / remedy
code
E 002 Engine oil not being monitored. Short circuit + 24 V Check engine oil level, consult
E 003 Short circuit to earth LIEBHERR customer service.
or Cable break
E 004 Coolant level not being moni- Short circuit to earth Check coolant level, consult
E 005 tored. Short circuit + 24 V LIEBHERR customer service.

E 006 Cable break

E 007 Coolant temperature not being Short circuit to earth Check that the radiator is not
E 009 monitored. Short circuit + 24 V or Cable dirty, consult LIEBHERR cus-
break tomer service.

E 010 Hydraulic oil level not being Short circuit to earth Check hydraulic oil level, con-
E 011 monitored. Short circuit + 24 V sult LIEBHERR customer serv-
ice.
E 012 Cable break
E 013 Hydraulic oil temperature not Short circuit to earth Check that the radiator is not
E 014 being monitored. Short circuit + 24 V dirty, consult LIEBHERR cus-
tomer service.
E 015 Cable break
E 016 Splitterbox oil temperature not Short circuit to earth Check oil level, consult LIEB-
E 017 being monitored. (from R954) Short circuit + 24 V HERR customer service.

E 018 Cable break

E 022 Diesel engine speed not being Short circuit to earth Switch to emergency control
E 023 monitored, diesel engine speed Short circuit + 24 V speed adjustment S71 and S72
cannot be adjusted using key- and emergency operation work
E 024 pad, reduced hydraulic power. Cable break pumps Y50, consult LIEBHERR
customer service.

R 914 C / R 924 C 8.30.11

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Monitoring display Service Manual
Error code list

Error
Effect Cause Measure / remedy
code
E 027 Faulty hydraulic power LR cable error at output stage Switch to emergency control
for power control of hydraulic speed adjustment S71 and S72
pump and emergency operation work
pumps Y50, consult LIEBHERR
customer service.
E 033 Maximum fan speed EV 5 cable error at output stage Consult LIEBHERR customer
of electric valve for hydraulic fan service.
control
E 036 Flow reduction for hydraulic EV 1 cable error at the output Do not operate flow reduced
equipment not being carried out. stage for flow regulation of hy- equipment, consult LIEBHERR
draulic pump customer service.
E 039 Flow reduction for hydraulic EV 2 cable error at the output Do not operate flow reduced
equipment not being carried out. stage for flow regulation of sec- equipment, consult LIEBHERR
ond hydraulic pump customer service.
E 042 Power reduction for swing EV 3 cable error at the output Consult LIEBHERR customer
movement not being carried out stage for power reduction for service.
(for R934C and R944C). swing movement
Attachment movements are
slowed down.
E 045 Pressure reduction for hydraulic EV6 cable error at the output Do not operate pressure re-
equipment not being carried out. stage for pressure regulation of duced equipment, consult LIEB-
the hydraulic circuit. HERR customer service.
E 063 Turbocharged air temperature Short circuit to earth Check that the radiator is not
E 065 not being monitored. Short circuit + 24 V or Cable dirty, consult LIEBHERR cus-
break tomer service.
E 070 Engine RPM not being moni- Transmitter output default Switch to emergency control
tored. speed adjustment S71 and S72
and emergency operation work
pumps Y50, consult LIEBHERR
customer service.
E 072 Turbocharged air pressure not Short circuit + 24 V Check the turbocharged air cir-
E 073 being monitored. Short circuit to earth cuit, consult LIEBHERR cus-
or Cable break tomer service.

E 074 Engine does not start Start time out Consult LIEBHERR customer
E 075 Starter default service.

E 078 Défaut hardware Consult LIEBHERR customer

E 079 Défaut software service.

E 081 Engine RPM not being moni- Transmitter B12-1 default Switch to emergency control
E 082 tored. Transmitter B12-2 default speed adjustment S71 and S72
and emergency operation work
pumps Y50, consult LIEBHERR
customer service.
E 084 Cold start command default Unit 1 of cold start command Consult LIEBHERR customer
over current service.
E 085 Unit 1 of cold start command de-
fault
E 086 Open load for Unit 1 of cold start
command

8.30.12 R 914 C / R 924 C

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Service Manual Monitoring display
Error code list

Error
Effect Cause Measure / remedy
code
E 087 Engine RPM not being moni- The values registered by the Switch to emergency control
tored. transmitters B12-1 and B12-2 speed adjustment S71 and S72
are different. and emergency operation work
pumps Y50, consult LIEBHERR
customer service.
E 088 Atmospheric pressure not being Short circuit + 24 V or short cir- Consult LIEBHERR customer
monitored. cuit to earth or cable break service.
E 089 Water in fuel filter not being Short circuit + 24 V or short cir- Consult LIEBHERR customer
monitored. cuit to earth or cable break service.
Engine does not start
E 090 Fuel temperature not being Short circuit to earth Consult LIEBHERR customer
E 091 monitored. Short circuit + 24 V or cable service.
break
E 092 Fuel pressure not being moni- Short circuit + 24 V Consult LIEBHERR customer
E 093 tored. Short circuit to earth or cable service.
break
E 094 Fuel pressure in rail 1 not being Short circuit + 24 V Consult LIEBHERR customer
E 095 monitored. Short circuit to earth or cable service.
break
E 096 Fuel pressure in rail 2 not being Short circuit + 24 V Consult LIEBHERR customer
E 097 monitored. Short circuit to earth or cable service.
break
E 098 D+ default on the alternator Consult LIEBHERR customer
E 099 Alternator default service.

E 100 Engine RPM not being moni- The value registered by the Switch to emergency control
tored. transmitter B12-1 is impossible. speed adjustment S71 and S72
and emergency operation work
pumps Y50, consult LIEBHERR
customer service.
E 101 Engine RPM not being moni- The value registered by the Switch to emergency control
tored. transmitter B12-2 is impossible. speed adjustment S71 and S72
and emergency operation work
pumps Y50, consult LIEBHERR
customer service.
E 102 Engine can not be started. Cranckshaft synchronisation Consult LIEBHERR customer
default service.
E 103 Camshaft transmitter default Consult LIEBHERR customer
service.
E 104 The value registered by the Consult LIEBHERR customer
camshaft transmitter is impossi- service.
ble.
E 105 Engine can not be started. Camshaft synchronisation Consult LIEBHERR customer
service.

R 914 C / R 924 C 8.30.13

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Monitoring display Service Manual
Error code list

Error
Effect Cause Measure / remedy
code
E 106 Cold start command default Unit 2 of cold start command Consult LIEBHERR customer
over current service.
E 107 Unit 2 of cold start command de-
fault
E 108 Open load for Unit 2 of cold start
command
E 109 Hardware CAN1 default Consult LIEBHERR customer
E 110 CAN1 data impossible or time service.
out
E 111 Injector A1 default Consult LIEBHERR customer
E 112 Injector A1 error BIP / FZM service.

E 113 Injector A2 default Consult LIEBHERR customer

E 114 Injector A2 error BIP / FZM service.

E 115 Injector A3 default Consult LIEBHERR customer

E 116 Injector A3 error BIP / FZM service.

E 117 Injector A4 default Consult LIEBHERR customer

E 118 Injector A4 error BIP / FZM service.

E 119 Injector B1 default Consult LIEBHERR customer

E 120 Injector B1 error BIP / FZM service.

E 121 Injector B2 default Consult LIEBHERR customer

E 122 Injector B2 error BIP / FZM service.
E 123 Injector B3 default Consult LIEBHERR customer
E 124 Injector B3 error BIP / FZM service.

E 125 Injector B4 default Consult LIEBHERR customer

E 126 Injector B4 error BIP / FZM service.

E 127 Parameter default bank A Consult LIEBHERR customer

E 128 Parameter default bank B service.

E 129 Fuel pressure in rail 1 not being Short circuit to earth or cable Consult LIEBHERR customer
monitored. break service.
E 130 Short circuit + 24 V
E 131 Incoherent signal
E 132 Fuel pressure in rail 2 not being Short circuit to earth or cable Consult LIEBHERR customer
monitored. break service.
E 133 Short circuit + 24 V
E 134 Incoherent signal
E 135 Circuit 5 Volt - REF1 Consult LIEBHERR customer
E 136 Circuit 5 Volt - REF2 service.

E 137 Circuit 5 Volt - REF3

E 138 Circuit 5 Volt - REF4
E 139 Circuit 5 Volt - REF5
E 170 The pressureles stick retraction Short cicruit to earth or cable Consult LIEBHERR customer
not being monitored (shovel at- break service.
E 171 tachment). Short circuit + 24 V

8.30.14 R 914 C / R 924 C

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Service Manual Monitoring display
Error code list

Error
Effect Cause Measure / remedy
code
E 302 No entry possible using keypad No coding plug Consult LIEBHERR customer
service.
E 303 Diesel engine speed cannot be No CAN bus connection be- Switch to emergency control
adjusted using keypad, hydrau- tween keypad and BST plate speed adjustment S71 and S72
lic power is reduced. (message also appears if bus and emergency operation work
arbiter not operating, e g. if no pumps Y50, consult LIEBHERR
power supply is present). customer service.
E 305 Malfunctions, e g. swing gear No CAN bus connection be- Switch to emergency switching
brake, servo control tween keypad and ESP01 board of servo pressure circuits S73,
(message also appears if consult LIEBHERR customer
ESP01 not operating). service.
E 307 No CAN bus connection be- Switch to emergency control
tween keypad and engine con- speed adjustment S71 and S72
trol system PLD and emergency operation work
pumps Y50, consult LIEBHERR
customer service.
E 308 No display or incorrect display No connection keypad / screen Consult LIEBHERR customer
on screen or keypad not operating service.
E 309 No Software compatibility be-
tween screen and keypad
E 310 For boring excavators, Hard- Consult LIEBHERR customer
ware coding and software cod- service.
ing are not in concordance.
E 314 Time out for CAN bus connec- Consult LIEBHERR customer
tion between keypad and en- service.
gine control system PLD
E 318 The error codes of the UEC (pl- No CAN bus connection be- Consult LIEBHERR customer
atine A180) are not displayed on tween keypad and UEC (platine service.
screen A180)
E 319 Diesel engine speed cannot be Hardware coding not suited to Switch to emergency control
adjusted using keypad, reduced software coding speed adjustment S71 and S72
E 321 hydraulic power. Keypad has not received a rec- and emergency operation work
ognised machine type. pumps Y50, consult LIEBHERR
customer service.
E 322 Unknown hardware coding
E 442 Automatic idling on left joystick Short circuit + 24 V Deactivate automatic idling S20,
E 443 does not function, i.e. the engine Short circuit to earth or cable consult LIEBHERR customer
remains at low speed. break service.

E 445 Automatic idling on right joystick Short circuit + 24 V Deactivate automatic idling S20,
E 446 does not function, i.e. the engine Short circuit to earth or cable consult LIEBHERR customer
remains at low speed. break service.

E 447 No more monitoring of the trans- B144 pressostat wiring default. Consult LIEBHERR customer
lation motor regulation pres- Courant < 3mA ou > 21 mA service.
sure.
E 450 The pressure for pressureless Wiring default B145; Consult LIEBHERR customer
boom down movement not be- Current < 3mA or > 21 mA service.
ing monitored.
E 454 The hydraulic power of the Short circuit + 24 V Consult LIEBHERR customer
E 455 swing is no more controled. Short circuit to earth or cable service.
Possible slappings in the valves break

R 914 C / R 924 C 8.30.15

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Monitoring display Service Manual
Error code list

Error
Effect Cause Measure / remedy
code
E 456 Incorrect fuel gauge. Short circuit to earth Check fuel level visually, consult
E 458 Short circuit+ 24 V or cable LIEBHERR customer service.
break
E 601 Connection default for plate Consult LIEBHERR customer
ESP01 service.
E 860 Cable break or short circuit of Consult LIEBHERR customer
the transmitter of the X axle (sig- service.
nal 1) of the left joystick.
E 861 Cable break or short circuit of Consult LIEBHERR customer
the transmitter of the X axle (sig- service.
nal 2) of the left joystick.
E 862 Cable break or short circuit of Consult LIEBHERR customer
the transmitter of the Y axle (sig- service.
nal 1) of the left joystick.
E 863 Cable break or short circuit of Consult LIEBHERR customer
the transmitter of the Y axle (sig- service.
nal 2) of the left joystick.
E 864 Cable break or short circuit of Consult LIEBHERR customer
the transmitter of the X axle (sig- service.
nal 1) of the right joystick.
E 865 Cable break or short circuit of Consult LIEBHERR customer
the transmitter of the X axle (sig- service.
nal 2) of the right joystick.
E 866 Cable break or short circuit of Consult LIEBHERR customer
the transmitter of the Y axle (sig- service.
nal 1) of the right joystick.
E 867 Cable break or short circuit of Consult LIEBHERR customer
the transmitter of the Y axle (sig- service.
nal 2) of the right joystick.
E 870 EEPROM memory contents are Consult LIEBHERR customer
damaged. service.
E 872 Signals of the X axle of the left Contact problem or faulty trans- Consult LIEBHERR customer
joystick not logical mitter service.
E 873 Signals of the Y axle of the left Contact problem or faulty trans- Consult LIEBHERR customer
joystick not logical mitter service.
E 874 Signals of the X axle of the right Contact problem or faulty trans- Consult LIEBHERR customer
joystick not logical mitter service.
E 875 Signals of the Y axle of the right Contact problem or faulty trans- Consult LIEBHERR customer
joystick not logical mitter service.
E 876 Faulty rotator turn A Cable break of the valve on the Consult LIEBHERR customer
PWM1 output. service.
E 877 Faulty rotator turn B Cable break of the valve on the Consult LIEBHERR customer
PWM2 output. service.
E 878 Faulty rotator swivel A Cable break of the valve on the Consult LIEBHERR customer
PWM3 output. service.
E 879 Faulty rotator swivel B Cable break of the valve on the Consult LIEBHERR customer
PWM4 output. service.

8.30.16 R 914 C / R 924 C

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Service Manual Monitoring display
Display on the screen of the information provided in menus

Error
Effect Cause Measure / remedy
code
E 880 Faulty proportional grab Cable break of the valve on the Consult LIEBHERR customer
PWM5 output. service.
E 881 Faulty additional and propor- Cable break of the valve on the Consult LIEBHERR customer
tionnal attachment PWM6 output. service.
E 883 Faulty proportional adjustable Cable break of the valve on the Consult LIEBHERR customer
boom PWM8 output. service.
E 884 Faulty adjustable boom A Cable break of the valve on the Consult LIEBHERR customer
PWM9 output. service.
E 885 Faulty adjustable boom B Cable break of the valve on the Consult LIEBHERR customer
PWM10 output. service.
E 886 Faulty grab rotation A Cable break of the valve on the Consult LIEBHERR customer
OUT11 output. service.
E 887 Faulty grab rotation B Cable break of the valve on the Consult LIEBHERR customer
OUT12 output. service.
E 888 Faulty additional attachment Cable break of the valve on the Consult LIEBHERR customer
side A OUT13 output. service.
E 889 Faulty additional attachment Cable break of the valve on the Consult LIEBHERR customer
side B OUT14 output. service.
E 890 Short circuit to earth of the Consult LIEBHERR customer
transmitter supply service.
E 891 Error on UB1 supply Consult LIEBHERR customer
service.
E 892 Error on UB2 supply Consult LIEBHERR customer
service.
E 893 Error on UB3 supply Consult LIEBHERR customer
service.
E 894 Error on UB4 supply Consult LIEBHERR customer
service.

4 Display on the screen of the information provided in menus

The following description is available for the machines equipped with the following components:

Display DISP 02 R5.2 Software V4.5.X

Keypad BBT-01/R5.1 Software V4.5.X
Control system BST-EHR 5.8 Software V4.5.X

R 914 C / R 924 C 8.30.17

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Monitoring display Service Manual
Display on the screen of the information provided in menus

4.1 Menu selection

Fig. 4 Selection of the menu at operator’s level

Menu selection:
With the main screen visible, press the Menu key of the display.
The list of accessible menus is displayed. see Fig. 4
Press arrow key Down or Up.
The following or previous menu will be displayed on the screen with a black background.
If the desired menu is displayed with a black background, as an example here the Reset daily
operating hours menu.
Press the Menu key again.
The sub-menu for the function selected is displayed.
Press the Back key again.
The sub-menu will be aborted.

4.2 Access to the various menus of the LCD screen

Fig. 5 Plugs X30 and X31 for coded plug

The completion of the various functions is divided into various service levels. This division makes it
possible to make functions, which require certain knowledge about various components on the
excavator, only accessible to those who have been well informed about the effects.

8.30.18 R 914 C / R 924 C

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Service Manual Monitoring display
Display on the screen of the information provided in menus

The division is separated in three levels.

The first level is generally accessible. The 2nd. and 3rd. level requires a coded plug on "X30" or
"X31" of the final stage circuit board.

4.2.1 Level 1: Operator (access without coded plug)

Symbol of Denomination Role of the menu

menu of menu

Reset Data Reset of daily operating hours counter

Set SF Adjustment of the rotation speed of the tool

Set Service Confirmation of the execution of a

recurring service work

Set Option Selection of the flow and pressure

limitations relating to the mounted working
tool (e.g. hammer)

Info - Hours Display of the operating hours of the

machine components and general
machine data.

Info - In/Outputs Information about the status of the

hydraulic pumps and of the electrical
inputs and outputs

Info - Errors Memory of the stored operating faults and

electrical system errors

Set Clock Setting of the clock

Purge Bleeding of the high pressure fuel system

from version 4.4

4.2.2 Level 2: Monteur, access with green plug N° 9684328

R 914 C / R 924 C 8.30.19

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Monitoring display Service Manual
Display on the screen of the information provided in menus

– All functions of 1st. level

– Information about Diesel engine
– Output of hourmeters, adjustment values and
error statistic via the serial port of the control
unit
– Adjustment of nominal values for hydraulic
pumps for external users (hammer, grapple,
...)
– Output of pump control values (power test of
Diesel engine)
– Setting values for power test
– Deactivation of the monitoring of chosen in-
puts (ignore error codes or functions of the
machine)
– Deletion of test error memory
– Determination of the pumps’ flow (support to
set up the pumps)
– Adjustment of the rotation speed of the tool

4.2.3 Level 3: Inspector, access with red plug

– All functions of 2nd level.

– Adjustment of nominal values for hydraulic
pumps of system users (swing drive, travel
drive, ...).
– Adjustment of hourmeter.

4.3 Menus accessible at level 1

4.3.1 Menu: (“reset data“)

Reset of daily operating hours counter

The daily operating hours counter can be reset to 0 using this menu.
.

8.30.20 R 914 C / R 924 C

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Service Manual Monitoring display
Display on the screen of the information provided in menus

Fig. 6 Resetting the daily operating hours counter

Reset procedure
Press the Up or Down arrow key.
The OK which is not crossed out will be displayed with a black background.
Press the Menu key.
The operating hours will be reset to 0.
The arrow key symbols Up and Down and the Menu symbol will no longer be displayed.
Press the Back key.
The sub-menu will be aborted.

4.3.2 Menu: (“Set SF“)

Rotation speed of the tool

This menu enables to adjust the rotation speed of the tool.
This menu is only available when joyticks with proportional function are mounted on the excavator.
The parameter PRS control in the menu set data / set config must be activated (ON).
.

Press the Up or Down key.

The rotation speed of the tool can be adjusted.
.

Note!
The push button SF S354 has no function.

R 914 C / R 924 C 8.30.21

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Monitoring display Service Manual
Display on the screen of the information provided in menus

4.3.3 Menu: (“set service“)

confirmation of the execution of a recurring service work

This menu gives information about the falling due of the next service work and allows to confirm the
execution of the service work after it just has been carried out.

Fig. 7 Menu «set service»

The operating hours of the next service due (in this example, “500 Hrs”) and the current operating
hours (“478 Hrs”) are displayed in the menu.
An upcoming service work can be confirmed a maximum of 50 operating hours before the service
interval is due.
When this time period has been reached a query will appear to ask whether the service work has
been carried out.
If the service work has been carried out.
Press the Up arrow key.
The choice "OK not crossed out" will be displayed with a black background.
Press the Menu key.
The current operating hour will be stored as the time for the last carrying out of a recurring
service work.
The operating hours indicating the next service due will be increased by the duration of a
service interval (as an example they augment from 500 to 1000 working hours).
If the service work has not been carried out.
Press the Back key.
The sub-menu will be aborted.

4.3.4 Menu: (“set option“)

Selection of the flow and pressure limitations for external input I1

This menu allows to allocate flow and pressure limitation options to external input I1 (choice of the
maximum oil flows and system pressure depending on the mounted working tool).

In this menu, the operator can choose between 10 predefined options. For each option a pressure
limitation and a flow limitation is assigned. When an option is chosen, the limitation values assigned
to this option are effective as soon as the command of the optional tool is actuated (actuation of the
foot pedal for hammer or grapple for example)
The arrow near the Symbol gives the actual allocation for the input I1.
In the left example, the option 1 named «BRV55» is allocated to the external output I1. The flow
limitation valves EV1 and EV2 limit the flow available for the option at 55% of the maximal flow. The

8.30.22 R 914 C / R 924 C

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pressure limitation valve EV6 limits the pressure available for the option at 55% of the maximal
pressure.
In the left example, the option 10 named «BHm2000» is allocated to the external output I1. The flow
limitation valves EV1 and EV2 limit the flow available for the option at 70% of the maximal flow. The
pressure limitation valve EV6 limits the pressure available for the option at 70% of the maximal
pressure.

Fig. 8 Menu «Set option»

Press the Up or Down key.
Another predefined option (1-10) can be assigned (e g. when work equipment is changed).
Press the Menu key.
The selection is confirmed

To exit the menu:

Press the Back key.
The sub-menu will be aborted.
In the main screen the denomination of the chosen option (HM200) is also displayed.
The tool will be supplied with the reduced pressure and the reduced flow predefined for the
option 10.

Fig. 9 Main screen, the chosen option is displayed

1 Denomination of the active option 2 The symbol "R" indicates that an external
flow limitation is active

R 914 C / R 924 C 8.30.23

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4.3.5 Menu: (“i - hours“)

Operating hours of machine components

In this menu the screens 1/4 to 3/4 provide an overview of the operating hours of specific
components, of duration of processes and operating types.

Fig. 10 Menu "Info Hours" - operating hours of Diesel engine

The screen 1 indicates the operating hours for:
– Diesel engine in P mode
– Diesel engine in E mode
– Diesel engine in F mode
– Diesel engine in L mode
– Diesel engine at maximum RPM
– Diesel engine at low idle
– Diesel engine with RPM adjustment in manual control

Fig. 11 Menu "Info Hours" - duration of the various movements

The screen 2 indicates the operating hours for:
– Working attachment movements using the joystick
– Slow travelling motion
– Fast travelling motion
The screen 3 indicates the operating hours for:
– the swing movements.
– the movements of the optional equipment (operated via the foot pedals)

8.30.24 R 914 C / R 924 C

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Fig. 12 General Data

The screen 4 provides information on:
– The model of the excavator
– "Typ": the type of the excavator
– "serie": the serial number of the excavator
– "ver": the installed Software-Versions for, respectively, the monitoring display, the control unit
BBT, the pump regulator BST, and, on the second line, the SPF nb. (specification number) of the
engine regulator unit and the engine type.
• 1: 6 cylinders PLD engine (Pump line nozzle injection system)
• 2: 4 cylinders PLD engine (Pump line nozzle injection system)
• 3: 6 cylinders common rail engine
• 4: 8 cylinders common rail engine
– Example: 6/2: SPF 06 / 4 cylinders engine with pump line nozzle injection system
– "nom": the both indications beside "nom" are not used
– "volt": indication for the momentary operating voltage.
– "hours": this last line indicates respectively:
• the operation with the input X2.8 activated (special equipment – not used actually),
• the operation with the input X2.14 activated (special equipment – not used actually),
• the operation with the input X2.13 activated (special equipment – not used actually),

4.3.6 Menu: Information Input / Output

Status of hydraulic pumps and of electrical inputs and outputs

The screens 1 to 3 provide information on the regulation parameters for the hydraulic pumps.

Fig. 13 Menu "Info In/outputs" - flow and pressure limitations

The screen 1 displays
– for each of the both working pumps the active flow limitation option and which percentage of the
maximum flow is set (solenoid valves EV1 and EV2).

R 914 C / R 924 C 8.30.25

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– which is the active pressure limitation for the hydraulic system and which percentage of the
maximum pressure is set (solenoid valve EV6).
– graphic bars indicating the momentary electric current flowing to the different regulation solenoid
valves..
On the left picture, an external limitation (Hardware input I1, option 2) is activated. The currents
supplying the flow limitation solenoid valves limit these flows to 55% of their maximal values. The
current supplying the pressure limitation solenoid valve limits the pressure to 80% of its maximal
value.
On the right picture, an internal limitation (Pressure increase ) and an internal limitation (Hard-
ware input I1, option 1) are activated at the same time.
Due to the internal limitation, the flow of the pump P1 is limited to 50% of its maximum value via the
solenoid valve EV1.
Due to the external limitation, the flow of the pump P2 is limited to 70% of its maximum value via the
solenoid valve EV2 and the pressure in the hydraulic system to 60% of its maximal value via the so-
lenoid valve EV6.
When several limitations are activated at the same time, only the one with the smallest percentage
value is decisive for each regulating solenoid valve.
.

Note!
An external limitation is activated as soon as the option pedals are actuated.
The three internal limitations which are the most currently used are the followings:
– The internal limitation M1 is activated when travelling.
– The internal limitation M2 is activated when the pressure increase is actuated (button S56 on the
control unit).
– The internal limitation M3 is activated when actuating the shovel flap on machines with shovel
attachment.

The screen 2 shows the instantaneous LR current (current flowing to the solenoid valve for power
regulation).
The screen 3 hows the instantaneous current flowing to the regulation solenoid valve EV5 which
determines the RPMs of the hydrostatic driven cooler fan.

Fig. 14 Menu "Info In/Outputs"- Currents to the solenoid valves LR and EV5

8.30.26 R 914 C / R 924 C

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Fig. 15 Menu "Info In/outputs" - Etat des entrées et sorties électriques

The screens 4/8 to 8/8 provide an overview of the status of the different electrical inputs and outputs.
A“ ” means "Input not active".
A“ ”means "Input active".
An “NC” beneath the terminal designation means that the corresponding input has been deactivated
in the software.
The durations indicated in the last line of the screen 4/8, under M4/Time repectively B19/Time
correspond to the pause time for the windshield wiper in intermittent mode, respectively to the delay
time for the engine low idle automatic system.

Fig. 16 Menu "Info In/Outputs"- Status of electrical inputs and outputs

The screens 7 and 8 give information concerning the PLD control system of the Diesel engine (Pump
line nozzle injection system):
– Input K16 controls the starter operation.
– Input D+ indicates if the generator delivers current.
– Input X2/13 refers to operation of the Diesel engine with standard power curve.
– Input X2/15 refers to external commutation of hydraulic power.

R 914 C / R 924 C 8.30.27

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– Input DC/Error indicates if an error is detected in the function of the Diesel engine monitoring
system.
– Input X2/24 indicates if the engine control is in safety mode.
– Input X2/12 indicates if an operating fault is detected in the engine monitoring circuit when the
engine is in safety mode.
– Input DC/cold1 controls the function of the preglow of the Diesel engine.
– Input DC/cold2 controls the function of the postglow of the Diesel engine.
– PWRred refers to power reduction of the diesel engine in case of an intake air, engine coolant or
fuel overheating.
– Input PWRalt controls the Diesel engine power limitation in accordance with the atmosphéric
pressure.
– Input A/9 indicates if the servo-pressure measurement for the stick movement is greater than 7
bar (sensor B159).
– Input A/18 indicates if the servo-pressure measurement for the hoist movement is greater than 7
bar (sensor B160).
– Input A/20 indicates if the servo-pressure measurement for the left swing movement is greater
than 7 bar (sensor B167).
– Input A/21 indicates if the servo-pressure measurement for the translation movement is greater
than 7 bar (sensor B162).
– Input A/23 indicates if the servo-pressure measurement for the bucket movement is greater than
7 bar (sensor B163).
– Input A/24 indicates if the servo-pressure measurement for the right swing movement is greater
than 7 bar (sensor B168).
– Input B/12 indicates if the servo-pressure measurement for the dozer blade movement is greater
than 7 bar (sensor B85).

4.3.7 Menu: (“i-errors“)

Operating faults and electrical system errors

Fig. 17 Operating faults and electrical system errors

There are 3 possible choices in this menu:
– By selecting list Exxx, all the operating faults detected by the switches and sensors monitoring
the machine parameters are listed.
– By selecting list E-elec, all the electrical system errors (cable errors, sensor errors, ...) detected
during the operation of the machine are listed.
– With list S-Exxx, all the operating faults are listed, just as with the selection list Exxx, but this
time only faults which appeared when the service connector was connected .

8.30.28 R 914 C / R 924 C

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To select the desired error type:

Press the Down or Up arrow key to preselect desired type
Press the Menu key.
The sub-menu on a black background will be displayed.
If more than 6 error codes are listed, use the arrow keys Down or Up to scroll in the list.

"list Exxx" - Operating faults:

Fig. 18 List of the operating faults (fig. left) and occurrences of a fault (fig. right)
Select list Exxx.
Press the Menu button.
The first page of the sub-menu appears.
All the operating faults are listed with their error code and number of occurences.
Select the desired error code using the Down or Up arrow key and press the Menu key.
A screen appears with the operating hours and the duration for the ten first and the ten last
occurrences of the selected error.
The asterisk "*" shows that the error was also indicated by the buzzer and then acknowledged using
the Back key. .
– s*: signals that the duration is given in seconds.
– m*: signals that the duration is given in minutes.

Fig. 19 Detail faults at levels 2 and 3

At level 2 and 3 (monteur / inspector), «Sum» gives the total duration for type of error.

Note !
Only operating faults with an error code E 5xx are displayed in the list Exxx menu.

R 914 C / R 924 C 8.30.29

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"list E-elec.": Errors of the electrical system

Fig. 20 Errors of the electrical system

Select list E-elec. and press the «MENU» key to display the sub-menu
all the system errors with their error code are displayed
The column "Test" shows the number of errors occurred since the last deletion of this test error mem-
ory listing.
The operating hours above the test column show the operating hour when the last test memory was
deleted (reset).

Fig. 21 Errors of the electrical system for level 2 and 3

At the levels 2 and 3 (monteur / inspector), the column "Sum" shows the number of all errors which
were ever noted..

"list S-Exxx": Errors during «service operation»

Fig. 22 Errors during «service operation»

When a coded plug is connected:

8.30.30 R 914 C / R 924 C

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Select list S-Exxx and press the «MENU» key to display the sub-menu
all the operating faults detected by the switches and sensors monitoring the machine param-
eters are listed, like in the sub-menu list Exxx. But here only the errors which occured during
the service operation are liste, it means when a coded plug is connected.
This sub-menu allows to isolate the errors, which occured during the maintenance and particularly
the erros provocated by a trouble shooting.
For each error, an overview can be shown and paged in just like for the "list Exxx".
When disconnecting the coded plug, the memory "list S-Exxx" is erased, the errors are not
memorised.

Note !
Only operating faults with an error code E 5xx are displayed in the list S-Exxx menu.

4.3.8 Menu: “set clock“

Clock setting
This menu permits to set the time displayed in the upper section of the screen.

Fig. 23 Clock setting

After selection of the function the digit completely right is inversely displayed.
Press key UP or DOWN to adjust the selected digit.
Press MENU key to select the next digit.
Press the Enter key to store the set number.
The message "update xx: xx" appears shortly on screen to confirm the new setting and the
display automatically returns to main screen.

4.3.9 Menu: “Purge“

Bleeding of the high pressure fuel system

When starting the machine, the operator can activate the bleeding mode.
To start in bleeding mode allows to bleed the high pressure fuel system (see the chapter concerning
the maintenance of fuel system).

R 914 C / R 924 C 8.30.31

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Fig. 24 Menu "Purge"

Note !
To start in bleeding mode is preconised only in case of running with fuel tank empty
or in case of emptying of the fuel system.
When starting in mode "Purge", the engine will emit black smoke.
As soon as the engine rpm reaches 800 rpm, the menu "purge" is not accessible
any more.

4.4 Menus accessible at level 2 and 3

4.4.1 Menu “i-engine“

Information about diesel engine

Fig. 25 Information about diesel engine

This information screen displays data coming from the BST plate and from the engine control
system PLD.
On the screen 1, the following informations are displayed:
– Coolant temperature measured by PLD system
– Hydraulic oil temperature measured by the BST
– Rpm of the diesel engine measured by the BST
– Engine oil pressure measured by PLD system
– LR current measured by the BST
On the screen 1, the following informations are displayed:
– act. engine speed: instantaneous rpm of the diesel engine measured by the PLD system
– intake manifold pres.: intake manifold pressure measured by the PLD system
– coolant temperature: coolant temperature measured by PLD system
– intake manifold temp.: intake manifold temperature measured by the PLD system

8.30.32 R 914 C / R 924 C

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– oil pressure: engine oil pressure measured by PLD system

– battery potential: supply voltage measured by PLD system

4.4.2 Menu “i-data“

Printing of machine data

Fig. 26 Printing of machine data

This menu allows to activate the printing of the operating hours list, resp. of the memorized system
parameters and of both error lists. The data are transmitted to the serial port of the control unit.
The function "print error" transmits both error lists to the serial port of the control unit.

4.4.3 Menu “set pumps“

Setting the external flow and pressure limitation values

Fig. 27 Setting the external flow and pressure limitation values

In the "set pumps" function, the maximum nominal values for the hydraulic pumps (flow and pressure)
are defined. These values are effective after activation of an external limitation. This external limita-
tion can be activated by the operation of a special attachment, the activation of a given movement, ...
To set the nominal pump values, certain conditions must be entered, under which the pump value is
valid in operation.
In the first step, the electrical input is determined, whose activation result in the desired flow and pres-
sure limitation. For track excavators, only the input I1 is available.

Electrical input I1:

In the next step, it is possible to choose between 10 options (equipment) for the input I1.

R 914 C / R 924 C 8.30.33

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Fig. 28 Choice between 10 options

In the third step, the flow and pressure limitation values and the name for each option are defined

Fig. 29 Definition of the name and limiatations for the option

When a solenoid valve is chosen, the current values are shown. The nominal values are the momen-
tary set values for the conditions determined by the first two selection criteria.
The value behind the selected pump is highlighted. Use the arrow key to change this value.
The indicated values are forwarded directly to the pumps during adjustment.
A value change is effective immediately.
– The values EV1 and EV2 determine the initiated working pump flow limitation while additional at-
tachment operating.
– The value EV6 determines the permitted maximal pressure level for the additional attachment
feeding.
– With the function « Info », it is possible to change the name affected to this option. Use the arrow
key to modify the inversely displayed position. Use the „MENU“ key to change the inversely dis-
played number to the next higher number (more left digit). Once all the digits have been set, press
the „RETURN“ key to leave the function and to store the set time.

Incidence on the main screen

After having chosen the attachment (function set option), the option name (for example BRV55) is
displayed in the lower section of the main.
When an external limitation is activated, the symbol is displayed on the main screen.

8.30.34 R 914 C / R 924 C

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Fig. 30 Main screen with use of the option BRV55

4.4.4 Menu “power test“

Setting a defined hydraulic pump output

Fig. 31 Menu “power test“

This function is used to set the power regulator of the hydraulic pumps to a defined value.
The screen displays the value for the current I(LR) in percent.
The value is the currently valid nominal value for the horsepower regulators of the pumps.
Use the arrow key to change the value on the selected horsepower regulator.
When entering the menu, the value is set to 100%.
The changed value will return to 100% after leaving the menu.
In addition, the screen shows the actual RPM of the Diesel engine, the coolant temperature, the hy-
draulic oil temperature, the intake air manifold temperature and the intake air manifold pressure.
Usually the menu "power test" is used to check the maximum hydraulic output allowed by the Diesel
engine (test for engine output).
For the test, I(LR) is set to 100%, this ensure that the pumps will remain in maximum angle, even at
pressures above the expected regulation begin pressure.

4.4.5 Menu “set hour“

Adjustment of the hourmeters

R 914 C / R 924 C 8.30.35

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Fig. 32 Menu “set hours“

All the hourmeters mentioned in the menu "i-hours" can be set separately in this function.
Use the arrow keys to select the component, whose operating hours must be displayed or changed.
Confirm the choice using the "MENU" key
The screen will appear with the indication of the desired operating hours.

Fig. 33 Modification of the hours number of a component

Press one of the arrow key
The operating hours are increased or decreased by one digit
Press one of the arrow key simultaneously with the menu key
The operating hours are increased or decreased by 10 digits at a time
SIf trying to change the hours for "engine" to a value smaller than the last service interval, then the
question will appear on the screen if you really want to do this.

If the question is answered with "OK"

The hour meter remains at the present setting.The operating hours can be let as they are or
changed upward.

If the question is answered with "OK"

The operating hours can be changed backward
At the same time, the next to last stored confirmed service interval will be entered as the last
confirmed service interval.

Components concerned by the modification of the operating hours

– «engine»: Diesel engine
– «swing»: swing movements
– «travel slow»: travel movements at low speed
– «travel fast»: travel movements at high speed
– «mode P»: Diesel engine in mode "P"
– «mode E»: Diesel engine in mode “E“

8.30.36 R 914 C / R 924 C

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– «mode F»: Diesel engine in mode “F“

– «mode L»: Diesel engine in mode “L“
– «high idle»: Diesel engine at high idle
– «low idle»: Diesel engine at low idle
– «input selected»: movement for external input I1 (optional equipment)
– «engine speed manu»: Diesel engine rpm adjusted in manual mode
– «sensor activ»: activation joysticks sensors
– «X2/14»: activation of electrical input X2/14 (not connected)
– «X2/8»: activation of electrical input X2/8 (not connected except for R944 C: stick movement sen-
sor)
– «high power»: activation of electrical input X2/13 (not connected

4.4.6 Menu “set data“

setting machine specific data

Fig. 34 setting machine specific data

Le menu «set data» is divided in 11 functions:
– set E-code
– set info
– set config

R 914 C / R 924 C 8.30.37

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– engine stop
– set pump
– set values
– set type
– set serie
– set clock
– engine pump
– set ctrl1.1 / set ctrl2.1

Function «set E-code»:

The function "set E-code" allows to switch off the monitoring of chosen inputs ( = to deactivate the
inputs).
"OFF" means that the corresponding input is deactivated. "ON" means that it is monitored and that
the corresponding error code is active.
The selection of the input to be modified is made using the arrow keys, the change of the status ON
/ OFF using the key "MENU".

Fig. 35 Function «set E-code»

List of the possible settings (SD= State at machine Delivery)
– B19 - X2/32: Monitoring of the connection wire to the sensor plate in the left joystick.
• SD = ON
– B19 - X2/33: Monitoring of the connection wire to the sensor plate in the right joystick.
• SD = ON
– EV1 - X135/7: Monitoring of the connection wire to the solenoid valve EV1.
• SD = ON
– EV2 - X135/6: Monitoring of the connection wire to the solenoid valve EV2.
• SD = ON
– EV3 - X135/25: Monitoring of the connection wire to the solenoid valve EV3.
• SD = OFF

Function «set info»:

8.30.38 R 914 C / R 924 C

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The function "Set info" allows to eliminate the display of the symbols allocated to the different
electrical inputs.

Fig. 36 Sous-menu «set info»

List of symbols that can be eliminated: (SD= State at machine Delivery)
– K5 - X2 / 27: Symbol "Engine Stop"
• SD = OFF
– Y78 - X6.1 / 6: Symbol Qmin : "Pump to flow min"
• SD = OFF

Function «Set config»

The function "set config", permits to activate or deactivate some specific function in the control of
the machine.

Fig. 37 Function «set config»

List of the possible settings (SD= State at machine Delivery)
– B208 – V159: Does not concern the track excavators
• SD = allways OFF
– UL - X2/19: Disable the lighting of the control light inside the overload warning device control
switch S18.
• SD = ON only if an overload warning device is installed
– SW B26 LOW–X17/3: Allows to adapt the monitoring of the quick change coupler to the type of
the proximity switch B26 at the locking pin (make contact or break contact switch).
• SD = ON, only if the contact is of breaker type (i.e. contact opens when the bolt leaves the end
locked position).
– Oil warm up: Activates or deactivates the warm up procedure of the hydraulic oil (SD = ON).
When activated, this warm up procedure is effective for an hydraulic oil temperature lower than
8°C. During this procedure, the current supplying the solenoid valves when working in mode E
and P are the same as the current when working in mode L and F (low value)
• SD = ON

R 914 C / R 924 C 8.30.39

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Fig. 38 Function «set config»

– Immobilizer: This setting concerns an immobilizer that should not be used on track excavators
• SD = allways OFF
– Traeger:Activates or deactivates the functions for traeger excavators. If this setting does not cor-
respond to the hardware input X50.15, the error code E310 is displayed.
• SD = OFF
– clock 12h: Activates the american hour system (ON) or the european hour system (OFF)
• SD = OFF
– multi function: Activates or deactivates the monitoring of the wire to the solenoid valve EV6 to
allow generation of error code E045.
• SD = OFF for standard excavators, SD = ON if option Tool control

Fig. 39 Function «set config»

– new gear box: Does not concern the track excavators.
• SD = allways OFF
– B144 - X50/18: Activates or deactives the monitoring of the fast travel
• SD = OFF
– B145 - X50/19: Activates or deactives the monitoring of the sensor for the pressureless boom
down movement.
• SD = OFF
– cold oil reg: Activates or deactives the specific hydraulic regulation for cold regions.
• SD = OFF

8.30.40 R 914 C / R 924 C

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Fig. 40 Function «set config»

– purge: Activates or deactivates the bleeding of the high pressure fuel system of the diesel engine
(see “Menu: “Purge“” on page 31).
• SD = OFF
– B177/B178/B179: Activates or deactives a flow limatation in case of grading work.
• SD = OFF
– tropic: Optimizates the fan rpm in areas with tropical climat.
• SD = OFF
– fan revers: Notifies the BST that a reversible fan controled by the keypad is mounted on the ex-
cavator.
• SD = OFF

Fig. 41 Function «set config»

– S7 - E9 : When this option is activated, the rotating beacon functions as soon as the security lever
is pushed down and as the engine is running. As long as the rotating beacon is working, the LED
in the touch S41 remains switched on. The touch S41 is inactive.
• SD = OFF
– stop engine - B19: Activates or desactivates the function "automatic motorstop after low idle"
(oversee the sensors B19L, B19R and B40). The time lag before the automatic stop is adjustable
in the menu set data / set values / time eng. stop.
• SD = OFF
– PRS control: When this option is activated, the errors codes of the UEC (A180 plate) are dis-
played on the screen. The communication between the UEC and the BST is overseen (error code
E318) and the menu "Set SF" is available.
• SD = ON only when one or two joysticks with proportional function are mounted on the excava-
tor.
– SW - X17/1: This parameter is set to ON when the excavotor has a quick-change adapter with a
second sensor for tool detection. A symbol lights up on the display if no tool is detected
• SD = OFF

R 914 C / R 924 C 8.30.41

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Function «engine stop»

This function is only accessible at level 3 (inspector) with the red coded plug.

The function "engine stop", permits to activate or deactivate the automatic stop of the engine in
case of warning.
"OFF" means that the automatic stop is deactivated.
"ON" means that the automatic stop is activated.

The selection of the input to be modified is made using the arrow keys, the change of the status ON
/ OFF using the key "MENU".

Fig. 42 Function «engine stop»

– stop eng. water temp.: Activates or deactivates the automatic stop of the engine in case of coo-
lant overheating.
• SD = OFF
– stop eng. oil pressure: Activates or deactivates the automatic stop of the engine in case of low
engine oil pressure.
• SD = OFF
– stop eng. over speed.: Activates or deactivates the automatic stop of the engine in case of ex-
cessive engine speed.
• SD = OFF
– stop eng. air temp.: Activates or deactivates the automatic stop of the engine in case of intake
air overheating.
• SD = OFF

Fig. 43 Function «engine stop»

– stop eng. water level: Activates or deactivates the automatic stop of the engine in case of low
coolant level.
• SD = OFF
– stop eng. fuel temp.: Activates or deactivates the automatic stop of the engine in case of fuel
overheating.
• SD = OFF

8.30.42 R 914 C / R 924 C

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Function «set pump»

This function is only accessible at level 3 (inspector) with the red coded plug.

In the function « Set pump » the values for the internal flow limitations specific to the machine, are
defined. These flow limitations are active for travel motions, bottom dump bucket, pressure cut in, ...

Fig. 44 Function «set pump»

The parameter selection is made by selecting the flow limit function (M1 to M8) and by selecting the
pump.
The pump values adjustment is the same way as for the external flow limit values (I1, I2, ...), in
menu ((see “Menu “set pumps“” on page 33).
After activating an internal flow limitation no symbol appears at the main display.

Function «set values»

In the function "set values" some time lags can be displayed and adjusted.

Fig. 45 Function «set values»

– sensor B19: Setting of the time lag for low idle automatic between 2 s and 10s. f no low idle
automatic system is installed on the machine, the screen for adjustment of the time lag will not
appear.
• SD = 5 s
– wiper M4: Setting of the time lag for intermittent mode of the windshield wiper between 2 s and
10s.
• SD = 3.2 s

Note!
Both above mentioned time lags can also be adjusted using the push buttons controlling the low idle
automatic and the windshield wiper, also see the description of the control unit.

R 914 C / R 924 C 8.30.43

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Fig. 46 Function «set values»

– magnet (step): Setting of the RPM stage in mode magnet only accessible at level 3 (inspector).
This stage will be automatically selected when operating the lifting. The step can be changed ei-
ther using the switches S228, S229 and S86, or by the low idle automatic system.
• SD = 8

Fig. 47 Function «set values»

– fan rev. time: Setting of the time during which the fan turns in reverse direction (between 50 an
600 seconds).
• SD = 140 sec
– fan rev. per.: Setting of the time interval (between 0.5 and 300 hours) until the fan automatically
start to turn in reverse direction. When this value is set to its maximal value (300 hours), the au-
tomatic transition to reverse mode is desactivated.
• SD = 300 hours

Fig. 48 Function «set values»

– time eng.stop: Setting of the time lag for automatic engine stop between 60 seconds and 1000
seconds. The parameter stop engine - B19 in the menu set data / set config must be activated
(ON).
• SD = 300 sec

8.30.44 R 914 C / R 924 C

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Function «set type»

This function is only accessible at level 3 (inspector) with the red coded plug.
In the function "Set type", the excavator's type number can be changed.

Fig. 49 Function «set type»

Press the menu key
the first digit is inversely displayed.
Press key UP or DOWN to adjust the selected digit.
Press the menu key
the second digit is inversely displayed.
Press key UP or DOWN to adjust the selected digit.
Adjust the other digits in the same way.
When all digits are adjusted, leave the function by pressing the return key.
Press the Enter key to store the set number.
The message "update xx: xx" appears shortly on screen to confirm the type number and the
display automatically returns to main screen.

Function «set serie»

This function is only accessible at level 3 (inspector) with the red coded plug.
In the function "Set serie", the excavator's serial number can be changed.
serie

Fig. 50 Function «set serie»

Press the menu key
the first digit is inversely displayed.
Press key UP or DOWN to adjust the selected digit.
Press the menu key
the second digit is inversely displayed.

R 914 C / R 924 C 8.30.45

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Press key UP or DOWN to adjust the selected digit.

Adjust the other digits in the same way.
When all digits are adjusted, leave the function by pressing the return key.
Press the Enter key to store the set number.
The message "update xx: xx" appears shortly on screen to confirm the serial number and the
display automatically returns to main screen.

Function «set clock»

The function "Set clock" allows to set the time displayed in the upper section of the main. The setting
is done in the same way as in the menu accessible in level I ((see “Menu: “set clock“” on page 31).

Function «engine pump»

This function is only accessible at level 3 (inspector) with red coded plug.
The function "engine pump" permits to register the code of the pump injectors mounted on the en-
gine. The codes must be registered when starting the machine for the first time or when changing the
pump injectors.
serie

Fig. 51 Function «engine pump»

Press the menu key
in the column «engine pump nr.» the cylinder number of the selected pump injector is inversely
displayed.
in the column «actual code» the actual code of the selected pump injector is displayed.
Press key UP or DOWN to select the pump injector.
Press the menu key
in the column «new code» the first digit of the new code is inversely displayed.
Press key UP or DOWN to adjust the selected digit.
Press the menu key
the first digit is registered
in the column «new code» the second digit of the new code is inversely displayed.
Press key UP or DOWN to adjust the selected digit.
Adjust the two last digits in the same way.
Press the return key
The code entered in the column «new code» is registered
The entered code disappear from the column «new code» and is displayed in the column «ac-
tual code»
In the column «engine pump nr.», the cylinder number of the selected pump injector is inverse-
ly displayed.
Press key UP or DOWN to select the pump injector and proceed as before to adjust the codes.

8.30.46 R 914 C / R 924 C

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Display on the screen of the information provided in menus

Function «set ctrl1.1 / set ctrl2.1»

The menu «set ctrl1.1 / set ctrl2.1» easily enables the set up of the hydraulic parameters. They are
then transmitted to the BST and to the keypad.
This set up aid is able via the menus set data / set ctrl1.1 ou set ctrl2.1:
– The menu set ctrl1.1 is only accessible at level 3 (inspector).
– The menu set ctrl2.1 is only accessible at level 2 (monteur).
The contents is the same in both menus.

"OFF" means that the corresponding function is desactivated.

"ON" means that the corresponding function is activated.
The selection of the input to be modified is made using the arrow keys, the change of the status ON
/ OFF using the key "MENU".
When the keybord starts, all the values are set on OFF.
When one activate (ON) a new parameter in set data / set ctrl1.1 or set ctrl2.1, the previous param-
eter is automatically desactivated (OFF).
When one quit the menu set data / set ctrl1.1 or set ctrl2.1, the parameters are not reset at their
initial values.
When the red or green plug is disconnected, then all the parameters are reset to OFF.

Fig. 52 Function «set ctrl1.1» or «set ctrl2.1»

– test diesel engine: Setting of the Diesel engine from speed level 1 to speed level 10 with an in-
terval of 2 seconds between each change and then setting of the Diesel engine on speed level 1.
– engine speed max: Setting of the Diesel engine on speed level 10.
– fan min: Setting of the fan current on its maximal value (= fan rpm on its minimal value) and of
the Diesel engine on speed level 10.
– fan emergency: Setting of the fan current on 0 mA (= fan rpm in emergency mode) and of the
Diesel engine on speed level 10.

Fig. 53 Function «set ctrl1.1» or «set ctrl2.1»

R 914 C / R 924 C 8.30.47

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– fan max: Setting of the fan current on its minimal value (= fan rpm on its maximal value) and of
the Diesel engine on speed level 10.
– fan ramp: Progressive increase of the fan current from its minimal value to its maximal value. After
awhile, progressive decrease from its maximal value to its minimal value. Meanwhile, setting of
the Diesel engine on speed level 10.
– fan + A/C: Setting of the fan current on a given value (= value when the AC is activated) and of
the Diesel engine on speed level 10.
– fan revers: Setting of the fan current on a given value (= value when the fan rotates in reverse
direction) and of the Diesel engine on speed level 10.

Fig. 54 Function «set ctrl1.1» or «set ctrl2.1»

– reg. valve min: Setting of the current on solenoid valve LR (Y50) on 200 mA and of the Diesel
engine on speed level 10.
– reg. valve 50%: Setting of the current on solenoid valve LR (Y50) on 500 mA and of the Diesel
engine on speed level 10.
– reg. valve max: Setting of the current on solenoid valve LR (Y50) on 800 mA and of the Diesel
engine on speed level 10.
– reg. valve emergency: Setting of the current on solenoid valve LR (Y50) on 0 mA and of the Die-
sel engine on speed level 10.

Fig. 55 Function «set ctrl1.1» or «set ctrl2.1»

– begin of reg. P1/P2: Setting of the current on solenoid valves EV1 (Y51), EV2 (Y52) on 560 mA
(= maximal value) and on LR (Y50) on 800 mA (= maximal value). Meanwhile, setting of the Diesel
engine on speed level 1.
– delta P1/P2: Setting of the current on solenoid valve LR (Y50) on 300 mA (= value in mode P) and
of the Diesel engine on speed level 10.
– test secondary: not used
– swing 100%: not used

8.30.48 R 914 C / R 924 C

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Fig. 56 Function «set ctrl1.1» or «set ctrl2.1»

– swing 0%: not used

– swing 50%: not used
– swing ramp: not used
– option pressure min: Setting of the current on solenoid valve Y414 on its minimal value and of
the Diesel engine on speed level 10.

Fig. 57 Function «set ctrl1.1» or «set ctrl2.1»

– option pressure max: Setting of the current on solenoid valve Y414 on its maximal value and of
the Diesel engine on speed level 10.
– option pressure ramp: Progressive increase of the current on solenoid valve Y414 from its min-
imal value to its maximal value. After awhile, progressive decrease from its maximal value to its
minimal value. Meanwhile, setting of the Diesel engine on speed level 10.
– option flow ramp: not used
– power control P1: Setting of the current on solenoid valve EV1 (Y51) on its minimal value, on
solenoid valve EV2 (Y52) on its maximal value and on solenoid valve LR (Y50) on 460 mA. Mean-
while, setting of the Diesel engine on speed level 10.

Fig. 58 Function «set ctrl1.1» or «set ctrl2.1»

R 914 C / R 924 C 8.30.49

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– power control P2: Setting of the current on solenoid valve EV1 (Y51) on its maximal value, on
solenoid valve EV2 (Y52) on its minimal value and on solenoid valve LR (Y50) on 460 mA. Mean-
while, setting of the Diesel engine on speed level 10.
– reg. valve ramp: Progressive decrease of the current on solenoid valve LR (Y50) from its maximal
value to its minimal value. After awhile, progressive increase from its minimal value to its maximal
value. Meanwhile, setting of the Diesel engine on speed level 10.

4.4.7 Menu: “reset data“

Function «reset day hours»

Fig. 59 Function «reset day hours»

This function is accessible at level 1 and permits to reset the daily operating hours counter to 0. ((see
“Menu: (“reset data“)” on page 20).

Sous-menu «reset elec. test errors»

Fig. 60 Function «reset elec. test errors»

The function «reset elec. test errors» permits to delete the column "Test" of electrical errors ((see “"list
E-elec.": Errors of the electrical system” on page 30).

Reset procedure
Press key UP or DOWN
The answer «OK» is selected (inversly displayed)
Press the menu key
The number of hours is reset toà 0
the symbols «UP», «DOWN» and «MENU» are not displayed anymore
Press the return key
The function is closed

8.30.50 R 914 C / R 924 C

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Function «reset elec. wire errors»

Fig. 61 Function «reset elec. wire errors»

This function is only accessible at level 3 (inspector) with the red coded plug.
The function«reset elec. wire errors» permits to delete the electrical error list.

Function «reset service data»

Fig. 62 Function «reset service data»

The function "reset service data" permits to reset the errors occuring during service operation ((see
“"list S-Exxx": Errors during «service operation»” on page 30).

Function «reset machine data»

Fig. 63 Function «reset machine data»

This function is only accessible at level 3 (inspector) with the red coded plug.
The function "reset machine data" permits to reset the memory for the operating errors detected by
the switches and the sensors for machine parameters monitoring.

R 914 C / R 924 C 8.30.51

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Function «reset machine hours»

Fig. 64 Function «reset machine hours»

This function is only accessible at level 3 (inspector) with the red coded plug.
The function "reset machine hours" permits to reset all hourmeters of the machine.

Function «reset machine param»

Fig. 65 Function «reset machine param»

This function is only accessible at level 3 (inspector) with the red coded plug.
The function «reset machine param» permits to recover the parameters that had been set at machine
delivery and reset them as the standard parameters.
The concerned parameters are those defined in the menus "set option", "set pump" and "set data"
(only the functions "set E-code", "set info" and "set pump").

Function «reset serviceinterval»

Fig. 66 Function «reset serviceinterval»

This function is only accessible at level 3 (inspector) with the red coded plug.
The function «reset serviceinterval» permits to reset the memory of the confirmed service intervals.

8.30.52 R 914 C / R 924 C

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Function «lock error display»

Fig. 67 Function «lock error display»

The function «lock error display» permits to prevent to display the electrical errors (codes type 500)
in the menu « I-Exxx » of the conductor. The error codes are nevertheless recorded.

Function «release error display»

Fig. 68 Function «release error display»

The function «release error display» permits to activate the display of the electrical errors again in the
menu « I-Exxx ».

4.4.8 Menu "Flowtest"

Setting of a given flow of the hydraulic pumps

Fig. 69 Function «Flowtest»

The function "flowtest" permits to set the flow of the pumps P1 and P2. Higher is the percentage, high-
er is the pump flow.
– pump 1: Setting of the flow of pump P1 with the arrows up and down. Meanwhile, the pump P2
stays on 0% (=minimal flow).

R 914 C / R 924 C 8.30.53

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– pump 2: Setting of the flow of pump P2 with the arrows up and down. Meanwhile, the pump P1
stays on 0% (=minimal flow).

Note!
"Current I(SD1): 0%" on display means that:
– The flow of pump P1 is minimal, but
– nevertheless the current on the solenoid valve EV1 (Y51) is on its maximal value.
"Current I(SD1): 100%" on display means that:
– The flow of pump P1 is maximal, but
– nevertheless the current on the solenoid valve EV1 (Y51) is on its minimal value.
Idem for pump P2.

8.30.54 R 914 C / R 924 C

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Service Manual Control unit S2
Function of the codage plug

8.40: Control unit S2

1 Function of the codage plug

Fig. 1 Connection between control unit and codage plug

1 Control unit S2 6 Codage plug X42

2 Micro-processor 7 EEPROM-storage of the operating data
3 Plug connector X42 8 Coding of excavator type
4 Monitoring display H1

Note!
The control unit S2 (also called BBT), is fitted on its connector X42 with a codage plug which carries
out the following functions :

1.1 Codage function

The excavator type will be recognised via a hardware-coding in the 15 pole plug X42. Of no valid cod-
age plug is inserted, operation of the control unit will be blocked.

1.2 Memory function

The actual machine data listed below is to be stored in a data storage unit (serial EEPROM) in the
codage plug.
Whethear the control unit S2 has to be replaced, this storage avoid waste of data and one can directly
transfer the data from the codage plug to the new control unit.

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Control unit S2 Service Manual
Function of the codage plug

Stored data:
– machine type, serial number and adjustments from the menu «set config»
– actual reading of the operating hour counter
– actual operating times (indicated in menu i-hours)
– actual values of the flow limitations (internal as well as external values)
– actual selection of the flow limitation option
– error storage of the low water level (E502)
– error storage of the high water temperature (E503)
– error storage of the low hydraulic oil level (E504)
– error storage of the high hydraulic oil temperature (E505)
– error storage of the low engine oil level (E501)
Storing of the data from the control unit ito the codage plug occurs:
– automatically, about every 30 minutes
Die Speicherung der Daten aus der Tastatur in den Kodierstecker erfolgt:
– automatisch, ca. alle 30 Minuten
– manually, using the key «Mode» and «SF» (see next paraghraph) in order to secure the data con-
tained in the codage plug, as an example before replacing the control unit.

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Service Manual Control unit S2
Replacing the control unit

2 Replacing the control unit

Fig. 2 Platine A1001, connector X32 and parameters on display

2.1 Preparing for replacement:

With ignition key turned off, insert the grun service plug into the connector X31 of the circuit board
A1001 (ESP01) see Fig. 2.
Before beginning the replacement, the important parameters of the control unit should be read
from the monitoring display and noticed (serial-no, operating hours, flow limitations, number of op-
erating errors E5xx in the error storage, ...). Use the menus «i-hours», «i-errors» and «set-option».

2.2 Securing the data in the codage plug

Fig. 3 Keypad

Proceed as follows :
With ignition key turned off and service plug inserted into X31, press the «Mode» and «SF» touch
and keep depressed while simultaneously switching on the ignition key to contact position.

The control unit now compares ist data with those in the codage plug:
if the data are OK, the information «X42-OK» appears on the display
if the data are not OK, storage of the data from the control unit into the codage plug will be
carried out automatically (recognisable from the moving light on the LED-Display for the speed
adjustement)
Thereafter the information «X42-OK» will appear on the display.

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Control unit S2 Service Manual
Replacing the control unit

2.3 Replacing the control unit S2

Fig. 4 Backside of the control unit BBT

Before unplugging the plug connectors, the battery’s main switch must be switched of.
Remove the plug connections from the control unit to be replaced and insert them in the new con-
trol unit (taking note of assignment) and secure with the screws see Fig. 4.

2.4 Automatic return transfer of data from the codage plug

After electronic ignition (self-check), the data contained in the EEPROM are checked and automati-
cally transferred into the new control unit.
This is shown via the moving light in the speed indicator on the control unit S2.
When this procedure is completed, all important data (as listed in paragraph 1) are available in the
new control unit.

2.5 Examination of data returned to control unit

Using the menus of the monitoring display, copare the date with the values noticed at the beginning
og the replacement.

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Service Manual Control unit S2
Replacement of bulbs for keyboard backlighting

3 Replacement of bulbs for keyboard backlighting

Fig. 5 Position of the bulbs in the keyboard

To backlight the keyboard keys, 6 bulbs (L) are installed under the upper section of the keyboard.
New keyboard contain 2 replacement bulb.

In case of defective backlighting, fix as follows:

Remove the keyboard from the right control panel.
Unscrew the 4 side screw M3 (Philipps head screws) on the keyboard housing and remove the
upper section of the keyboard.
For safety reason, do not unplug the plug connection (S) between the upper and the lower section.
Pull the defective bulb (L) from the base.
From the bulb base, pull the replacement bulb (E) and insert it into the base.
Set the upper section of the keyboard onto the lower section and screw the M3 screws.
Set the keyboard into the housing.

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Service Manual Component list - Electrical diagrams

8.80: Component list - Electrical diagrams

R 906 Classic from serial number 23145
R 916 Classic from serial number 17943
R 926 Classic from serial number 17941

Pos. Description Step Location

A3 radio (A) 3 armrest left
A 1001 print plate ESP 01 9-23 armrest right
A 1010 print plate A1010 1-4;6-23;30 armrest left
A 1011 print plate A1011 3;30 armrest left
A 1016 print plate A1016 26 armrest left

B2 transmitter diesel engine coolant temperature 5 diesel engine

B3 switch coolant level diesel engine 9 expansion tank
B5 transmitter oil pressure diesel engine 5 diesel engine
B8 transmitter hydraulic oil temperature 9 hydraulic tank
B12 transmitter engine speed 5 diesel engine
B12-1 transmitter engine speed 5 diesel engine
B12-2 transmitter engine speed 5 diesel engine
B12-3 transmitter engine speed 5 diesel engine
B14 switch oil level 9 hydraulic tank
B19L sensitiv switch joystik left 17 armrest left
B19R sensitiv switch joystik right 17 armrest right
B21 pressure switch overload 19 attachment
B33-2 flow limitation hammer 19 under driver stand
B33-4 flow limitation 16 driver stand rear
B39 transmitter fuel level 20 fuel tank
B40 pressure switch travel pedal 18 travel pedal
B43 switch / air conditioning 27 air conditioning
B44 switch / air conditioning 27 dryer unit
B46 transmitter / boost air temperature 5 diesel engine
B50 loudspeaker 3 cab
B50-2 transmitter central lubrication tank level 30 fuel tank
B51 inductiv switch control circuit of central lubrication 30 fuel tank
B53 Pulse transmitter / swing Engine 19 Uppercarriage
B55-1 inductiv switch cut-off cylinder (option) 29 attachment
B55-2 inductiv switch cut-off cylinder (option) 29 attachment
B98 transmitter / boost air pressure 5 diesel engine
B99-2 water level 5 diesel engine
B144 pressure switch 4-20mA travel engine regulation 16 distribution block
B159 pressure switch 4-20mA stick 16 cab rear
B160 pressure switch 4-20mA boom 16 cab rear
B162 pressure switch 4-20mA translation 19 under driver stand
B163 pressure switch 4-20mA bucket 17 cab rear
B167 pressure switch 4-20mA left-hand rotation 19 cab rear
B168 pressure switch 4-20mA right-hand rotation 17 cab rear
B181 transmitter oil level 5 diesel engine
B182 transmitter fuel temperature 5 diesel engine

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Component list - Electrical diagrams Service Manual

Pos. Description Step Location

B183 transmitter fuel pressure 5 diesel engine
B190 Transmitter / 4-20mA hoist pressure 19 Uppercarriage

E1-1 floodlight on working attachment left (industrial excavator) 29 attachment

E1-2 floodlight on working attachment right (industrial excava- 29 attachment
tor)
E1-3 floodlight on stick left (industrial excavator) 29 attachment
E1-4 floodlight on stick right (industrial excavator) 29 attachment
E2 floodlight 17 attachment
E4 headlight - upper carriage - right (option) 20 fuel tank
E5 additional floodlights on cab front 2x 20 cab
E7 dome light 22 cab
E8 cigarette lighter 23 right control console
E9 beacon 15 cab
E25 lightning of control unit 25 S2
E50 electrical main box / circuit breakers & relays 1 - 2;30 rear driver stand
E52 electric box / safety control for diesel engine 6 right control console

F1 fuse (15A) for option 3;30 A1010

F2 fuse (15A) for option 3 A1010
F3 fuse (15A) for option 3 A1010
F4 fuse (15A) for option 3 A1010
F5 fuse (15A) for windshield wiper motor 3 A1010
F6 fuse (7.5A) for safety mode 6 A1010
F7 fuse (7,5A) for display, control unit 3 A1010
F8 fuse (7,5 A) for Y3, Y6, Y7, Y160 3 A1010
F9 fuse (15A) for option 6 A1010
F10 fuse (25A) for E3 3 A1010
F11 fuse (15A) for option 3 A1010
F12 fuse (15A) for option 3 A1010
F13 fuse (15A) for S1, K43, K16, K288, T1 2 A1010
F14 fuse (15A) for E7, E8 3 A1010
F15 fuse (15A) reserve 3 A1010
F19 circuit breaker preheating unit R51 (100A) 2 E50
F20 circuit breaker main circuit Kl30/Kl15 (50A) 2 E50
F22 fuse for hazard warning device (wheel excavator) 2 E50
F31 fuse for Kl15 air conditioning (7,5A) 2 E50
F33 fuse for option fuel pump (7,5A) 2 E50
F34 fuse for reserve 2 E50
F35 fuse for reserve 2 E50
F36 fuse for option fuel pump (20A) 2 E50
F36-2 fuse for cut-off attachment movements (15A) (option) 1 E50
F36-3 fuse for additional heating (7,5A) (option) 29 E50
F37 fuse for Kl30 air conditioning 2 E50
F109 circuit breaker special attachments and headlights (50A) 1 E50
F110 circuit breaker for Kl30/Kl15 PLD (50A) 2 E50
F112 fuse for E50 (100A) 1 fuel tank
F115 fuse for safety mode (7,5A) 2 E50

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R 914 C / R 924 C
ADMIN
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Service Manual Component list - Electrical diagrams

Pos. Description Step Location

F116 fuse for U32 (7,5A) 2 E50
F117 fuse for Kl15 PLD 2 E50
F122 fuse for signal preheating (7,5A) 2 E50
F133 fuse for option adjustable cab (option) 2 E50
F153 fuse for starter 400A 1 fuel tank
F253 fuse for floodlight attachment (25A) (option) 2 E50

G1 alternator 1 diesel engine

G2 batteries 1 fuel tank

H1 monitoring display 24 right control console

H2 indicator light / low engine oil pressure 25 on S2
H9 horn 4 fuel tank
H10 horn - buzzer 26 right control console
H11 indicator light - diesel engine diesel on safety mode 6 safety control box
H12 indicator light battery charge 25 on S2
H19 indicator light blinker (not used) 25 on S2
H20 indicator light swing brake 25 on S2
H23 indicator light accumulator pressure (not used) 25 on S2
H24 indicator light steering oil (not used) 25 on S2
H33 travel horn 28 uppercarriage
H38-2 indicator light central lubrication tank empty 30 right control console
H57 buzzer error diagnostic 6 safety control box
H60 indicator light / engine error with safety mode on 6 safety control box

K1 relay windshield wiper 13 A1001

K2 relay reserve 22 A1001
K3 relay reserve 23 A1001
K4 relay reserve 23 A1001
K5/A1001 relay functions safety mode 18 A1001
K5/A1010 relay diesel engine stop 3 A1010
K6 relay horn 4 A1010
K7 relay additionnal floodlights on cab roof 4 A1010
K8 relay floating position 4 A1010
K9 relay flow limitation for safety mode 7;9 A1010
K66-1 relay for option «cylinder cut-off» 29 E50
K66-2 relay for option «cylinder cut-off» 29 E50
K127 relay / RPM adjustment in safety mode 1 E50
K128 relay / engine start in safety mode 1 E50
K288 relay Kl.15 2 E50
K302 relay preheating 2 E50
K415 relay 20A for floodlight attachment (option) 29 E50

M1 starter 1 diesel engine diesel

M3 windshield washer motor 16 travel pedal right
M4 windshield wiper motor 12 windshield

MP 1 electronic earthing print plate left control console 1;6;10 left control console

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R 914 C / R 924 C
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Component list - Electrical diagrams Service Manual

Pos. Description Step Location

MP10 electronic earthing on batteries main switch 1 batteries box
MP12 electronic earthing print plate A1001 23 right control console
MP50 earthing under diesel engine for starter 1 sous diesel engine
MP51 earthing for alternator 1 uppercarriage
MP53 earthing diesel engine 1 diesel engine
MP53-1 earthing on diesel engine for heating body 2 diesel engine
MP53-2 earthing on diesel engine for PLD 1 diesel engine
MP60 earthing under driver stand middle 1;4;16 under driver stand
MP61-1 earthing print plate A1010 1 left control console
MP61-2 earthing print plate A1010 1;3 left control console
MP63 earthing uppercarriage (to driver stand) 1 uppercarriage
MP65 earthing on chassis left control console 1 left control console
MP66 earthing floor plate for left control console 1;3;15;18; floor plate
20
MP81 earthing uppercarriage for solenoid valve servo control 14-19 hydraulic tank
unit
MP82 earthing trestle 15;17;19;29 on trestle uppercarria-
ge
MP87 earthing for floodlight - horn,... 4;20;21 uppercarriage
MP88 earthing batteries main switch 1 uppercarriage
MP89 earthing on batteries main switch 1 batteries main switch
MP90 earthing for electrical main box E50 1 E50
MP91 earthing for diesel engine 1;2 under diesel engine
MP92 earthing uppercarriage to electrical main box 1 uppercarriage
MP93 earthing uppercarriage for counterweight floodlight 4;29 uppercarriage

P2 indicator gauge engine coolant temperature 25 on S2

P3 indicator gauge fuel level 25 on S2
P4 indicator gauge engine rpm 25 control unit
P5 indicator gauge hours count 3 left control console

R51 flame glow plug 2;3 diesel engine

S1 starter and preglow switch 2 right control console

S2 control unit 24-26 right control console
S5L push button / grapple rotating device left 21 armrest left
S5R push button / grapple rotating device right 21 armrest left
S5M push button horn 22 armrest left
S6L push button magnetic lifting (option) 4 armrest right
S6R push button / travel alarm 4 armrest right
S6M push button / floating position (option) 4 armrest right
S7 safety switch 13* left control console
20**
S9 batteries switch 1 fuel tank
S10 touch / floodlights uppercarriage 17;20;25 control unit
S11 touch / windshield washer 16;25 control unit
S14 touch / windshield wiper 13;25 control unit
S17 touch / swing brake 18;25 control unit
S18 touch / overload 19;25 control unit

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R 914 C / R 924 C
ADMIN
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Service Manual Component list - Electrical diagrams

Pos. Description Step Location

S19 touch / activation of rotating device 20;21;25 control unit
S20 touch / low idle automatic 25 control unit
S21 touch / travel motors speed 16;25 control unit
S22 touch / additional floodlights 4;25;29 control unit
S36 touch / special function 25 control unit
S41 touch / beacon 16;25 control unit
S55 touch / pontage cut-off cylinder (option) 22 armrest left
S56 touch / pressure cut-in 16;25 control unit
S57 touch / swing brake (inactive) 11 armrest right
S71 Switch / RPM control in mode Manu 6 on E52
S72 Switch / RPM (+/-) adjustment Manu 6 on E52
S73 Switch / safety operation for servo circuit 6 on E52
S84-1 touch / central lubrication pignon swing 30 right control console
S85 touch / grapple operation 25 control unit
S86 touch / mode selection (diesel engine RPM) 25 control unit
S228 touch / increase diesel engine RPM 25 control unit
S229 touch / decrease diesel engine RPM 25 control unit
S349 touch «return» 25 on S2
S350 touch «down» 25 on S2
S351 touch «up» 25 on S2
S352 touch «enter» (menu) 25 on S2
S354 touch travel brake 19;25 control unit

T1 voltage transformer 3 right control console

U4 control unit / central lubrication 30 rear driver stand

U16 print plate - regulation unit BST 7-10 right control console
U32 print plate - regulation injectors diesel engine 5 diesel engine
U37 regulation unit air conditioning - heating 27 air conditioning
U38 control unit air conditioning - heating 27 air conditioning

V2 end stage pressure cut in 16 A1001

V3 end stage solenoid valve pression servo-commande 18 A1001
V4 end stage swing brake 19 A1001
V5 end stage solenoid valve flow regulation 15 A1001
V6 end stage travel speed control 16 A1001
V7 end stage windshield washer unit 16 A1001
V8 end stage reserve 19 A1001
V12 end stage reserve 19 A1001
V21 end stage floodlight uppercarriage 20 A1001
V24 end stage floodlight attachment 17 A1001
V26 end stage beacon 15 A1001
V32 end stage preglow 14 A1001
V37 end stage rotating device 21 A1001
V44 end stage special attachment 19 A1001
V57 end stage windshield wiper 13 A1001
V83 end stage rotating device left 21 A1001
V92 end stage 24V stabilised for transmitter 20 A1001

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Component list - Electrical diagrams Service Manual

Pos. Description Step Location

XA/U32 plug 40 poles 2;5 U32

XB/U32 plug 40 poles 2;5;6;29 U32
X1/A1001 plug 5 poles 11 right control console
X1(air plug 3 poles 27 air conditioning
cond.)
X1(diesel plug 3 poles oil pressure 5 diesel engine
engine)
X1 plug 40 poles 10 BST
X2/A1001 plug 37 poles 23 right control console
A1001
X2 (BBT) plug 37 poles 25 control unit
X2 (air plug 3 poles 27 air conditioning
cond.)
X2 (diesel plug 3 poles pression boost air 5 diesel engine
engine)
X3/A1001 plug 10-poles 14;20 right control console
A1001
X3 (air plug 3 poles 27 air conditioning
cond.)
X3 (diesel plug 3 poles transmitter oil level 5 diesel engine
engine)
X3_1 plug 9 poles 12;13;16;20 driver stand for cab
;22
X3_2 plug 9 poles 3;15 driver stand for cab
X3_3 plug 3 poles 3 left control console
X3_4 plug 2 poles 3
X4 (diesel plug 3 poles for water sensor 5 diesel engine
engine)
X4 plug 4 poles 12;22 right control console
A1001
X4 plug 2 poles 28 print plate A100
X4 (air plug 3 poles 27 air conditioning
cond.)
X5 (diesel plug 3 poles for sensor pressure boost air 5 diesel engine
engine)
X5 (air plug 2 poles 27 air conditioning
cond.)
X5-1 plug 8 poles 12;17;19;20 right control console
A1001
X5-1 plug 1 pole 4 right control console
X5-1-1 plug 1 pole 20 right control console
X5-2 plug 3 poles 19 right control console
A1001
X6 (diesel plug 3 poles for coolant temperature 5 diesel engine
engine)
X6 (air plug 6 poles 27 air conditioning
cond.)
X6-1 plug 6 poles 15-19 right control console
A1001

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ADMIN
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Service Manual Component list - Electrical diagrams

Pos. Description Step Location

X6-2 plug 8 poles 19-21 right control console
A1001
X7 (diesel plug 3 poles for fuel temperature 5 diesel engine
engine)
X7 (air plug 4 poles 27 air conditioning
cond.)
X7 plug 3 poles 17 right control console
A1001
X8 (diesel plug 4 poles for RPM sensor 2 5 diesel engine
engine)
X8 (air plug 8 poles 27 air conditioning
cond.)
X8 plug 3 poles 17 right control console
A1001
X9 (diesel plug 4 poles for RPM sensor 1 5 diesel engine
engine)
X9 plug 2 poles 18 right control console
A1001
X10 plug 2 poles 18 right control console
A1001
X10 (diesel plug 4 poles for RPM sensor 2 5 diesel engine
engine)
X11 plug 4 poles 12;13 right control console
A1001
X11 (diesel plug 2 poles for solenoid valve Y711 5 diesel engine
engine)
X11 (air plug 6 poles 27 air conditioning
cond.)
X12 plug 4 poles 21;22 right control console
A1001
X12 (air plug 6 poles 27 air conditioning
cond.)
X12 (diesel plug 2 poles for solenoid valve Y712 5 diesel engine
engine)
X13 plug 2 poles 11 right control console
A1001
X13 (air plug 6 poles 27 air conditioning
cond.)
X14 plug 3 poles 20 right control console
A1001
X14 (diesel plug 2 poles for solenoid valve Y713 5 diesel engine
engine)
X14 (air plug 6 poles 27 air conditioning
cond.)
X15 (air plug 2 poles 27 air conditioning
cond.)
X15-3 plug 3 poles 22 left control console
X15 (diesel plug 2 poles for solenoid valve Y714 5 diesel engine
engine)
X16 plug 2 poles 20 right control console
A1001

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R 914 C / R 924 C
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Component list - Electrical diagrams Service Manual

Pos. Description Step Location

X16 (air plug 2 poles 27 left control console
cond.)
X17 plug 3 poles 23 right control console
A1001
X18 plug 6 poles 16 right control console
A1001
X19 plug 6 poles 15 right control console
A1001
X20 plug 10 poles 12;13;15;16 right control console
;19;20;22 A1001
X20-1 plug 10 poles 4;12;13;16 left control console
X21 plug 3 poles 21 right control console
A1001
X22 plug 2 poles 11 right control console
A1001
X23 plug 2 poles 23 right control console
A1001
X30 plug 9 poles 11 right control console
A1001
X31 plug 9 poles 11 right control console
A1001
X32 plug 9 poles 11 right control console
A1001
X33 plug 9 poles 11 right control console
A1001
X40 plug 8 poles 25 right control console
A1001
X42 plug 15 poles 25;26 right control console
A1001
X43 plug 2 poles 14;18 right control console
A1001
X44 plug 3 poles / encoding 10 right control console
X45 plug 9 poles 1;2 sortie E50
X47 plug 6 poles diagnostic 5 diesel engine
X49 plug 3 poles 26 control unit
X50 plug 25 poles 26 control unit
X65 plug 2 poles 3 transformer 24V
X66 plug 2 poles 3 transformer 12V
X67-1 plug 8 poles 3 radio (power supply)
X67-2 plug 8 poles 3 radio (loudspeaker)
X69 plug 40 poles 1;2;3;29 sortie E50
X74 plug 3 poles floating position 4;9 right control console
X78-1 plug 4 poles (option floodlight attachment x4) 29 uppercarriage
X79 plug 1 pole (air cond.) 27 left control console
X80 plug 3 poles 17 left control console
X81 plug 3 poles 17 left control console
X84_2 plug 2 poles (air cond.) 1;27 left control console
X84_3 plug 2 poles (air cond.) 1;27 left control console
X87 plug 3 poles 27 air conditioning
X88 plug 2 poles 27 air conditioning

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R 914 C / R 924 C
ADMIN
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Service Manual Component list - Electrical diagrams

Pos. Description Step Location

X95 plug 4 poles 29 cab
X102 plug 1 pole (option additional heating) 29 E50
X107 plug 2 poles 29 attachment
X107-1 plug 2 poles 29 attachment
X120 plug 4 poles 21 uppercarriage
X121 plug 3 poles overload alarm 19 fuel tank
X122 plug 4 poles 20 fuel tank
X125 plug 12 poles 2/4/20/30 fuel tank
X129 plug 4 poles B33-2 19 under driver stand
X129-4 plug 4 poles B33-4 16 driver stand rear
X130 plug 4 poles / reserve pressure switch 16 driver stand rear
X133 plug 3 poles / B51 30 fuel tank
X134 plug 4 poles 9 hydraulic tank B8
X135 plug 40 poles U16 7/10 right control console
X136 plug 1 pole 2 fuel tank
X139 plug 3 poles 19 left control console
X142 plug 1 pole 29 cab
X143-1 plug 4 poles 30 central lubrication pi-
gnon
X143-2 plug 4 poles / transmitter central lubrication tank level 30 fuel tank
X148-1 plug 4 poles / B55-1 29 fuel tank
X148-2 plug 4 poles / B55-2 29 fuel tank
X152 plug 15 poles 6--8 left control console
A1010
X153 plug 15 poles 7--9 left control console
A1010
X154 plug 15 poles 3;4;6--9 left control console
A1010
X155 plug 15 poles 6--9;15 left control console
A1010
X156 plug 15 poles 1--4 left control console
A1010
X157 plug 15 poles 1;3;6;16;18 left control console
--21 A1010
X158 plug 15 poles 4;15--20 left control console
A1010
X159 plug 9 poles 1--3 left control console
A1010
X160 plug 15 poles 9;16;18;19 left control console
A1010
X161 plug 15 poles 4;15;17;19- left control console
-21 A1010
X163 plug 2 poles 19 left control console
A1010
X164 plug 2 poles F1 30 left control console
A1010
X164-1 plug 2 poles 30 left control console
A1011
X164-2 plug 2 poles 3 left control console
A1011

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R 914 C / R 924 C
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Component list - Electrical diagrams Service Manual

Pos. Description Step Location

X164-3 plug 2 poles 3 left control console
A1011
X164-4 plug 2 poles 3 left control console
A1011
X165 plug 2 poles F2 3 left control console
A1010
X165-1 plug 2 poles 3 left control console
A1011
X165-2 plug 2 poles 3 left control console
A1011
X165-3 plug 2 poles 3 left control console
A1011
X165-4 plug 2 poles 3 left control console
A1011
X166 plug 2 poles F3 3 left control console
A1010
X166-1 plug 2 poles 3 left control console
A1011
X166-2 plug 2 poles 3 left control console
A1011
X166-3 plug 2 poles 3 left control console
A1011
X166-4 plug 2 poles 3 left control console
A1011
X167 plug 2 poles F4 3 left control console
A1010
X168 plug 2 poles F11 3 left control console
A1010
X169 plug 2 poles F12 3 left control console
A1010
X169-1 plug 2 poles 3 left control console
A1010
X170 plug 1 pole 1 output E50
X174 plug 2 poles 9 water level B3
X179 plug 12 poles 17/29 for attachment
X180 plug 2 poles Y347 9 diesel engine
X182-1/2 plug 3/4 poles 30 left control console
X187 plug 3 poles 7 RPM engine B12
X189 plug 3 poles 6 right control console
E52
X192 plug 1 pole 3 left control console
X196 plug 3 poles 18 travel pedal g.
X197 plug 3 poles 18 travel pedal d.
X233 plug 3 poles 19 left control console
X262 plug 8 poles / quick tool adapter 28 left control console
X262-1 plug 8 poles / quick tool adapter 28 fuel tank
X319 plug 1 pole 2 E50 - fuel pump
X324-3 plug 1 pole 4 right control console
X324-4 plug 1 pole 4 right control console
X403 plug 25 poles / A1016 26 left control console
X405 plug 25 poles / A1016 26 left control console

8.80.10 R 914 C / R 924 C

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Service Manual Component list - Electrical diagrams

Pos. Description Step Location

X414 plug 2 poles / Tool-control 9 distribution block
X428 plug 2 poles for option travel alarm 4 left control console
X429 plug 2 poles / H33 28 uppercarriage
X430 plug 2 poles 29 cab
X434 plug 1 pole 3 E50
X435 plug 1 pole 27 cab
X452-1 plug 2 poles / Y387-1 Likufix 28 distribution block
X452-2 plug 2 poles / Y387-2 Likufix 28 distribution block
X456 plug 2 poles 20 under driver stand
X461 plug 12 poles 21;22 left control console
X462 plug 12 poles 4;11 right control console
X583 plug 1 pole 16 left control console
X599 plug 1 pole 14 cab
X600 plug 4 poles 2 output E50
X603 plug 12 poles 2;29 output E50
X606 plug 2 poles 6 E52
X616 plug 3 poles / CAN 10
X616-1 plug 3 poles / CAN (industrial) 5 cab rear
X655 plug 1 pole 2 output E50
X681 plug 2 poles / fan drive reversible 29 distribution block
X697 plug 12 poles 7/9/15/17/ hydraulic tank
18
X698 plug 2 poles 9 left control console
X700 plug 1 pole to earthing => commutation caracteristic pow- 15 left control console
er diesel engine
X701 plug 1 pole to earthing => commutation external hydraulic 15 left control console
power
X716 plug 12 poles 16;17;19 left control console
X717 plug 1 pole 16 left control console
X734 plug 2 poles 3 right control console
X738 plug 2 poles 19 cab
X752 plug 1 pole 29 cab
X771 plug 2 poles 16 B159 / cab rear
X772 plug 2 poles 16 B160 / cab rear
X773 plug 2 poles 19 B162 / cab rear
X774 plug 2 poles 19 B161 / cab rear
X775 plug 2 poles 17 B163 / cab rear
X776 plug 2 poles 17 B164 / cab rear
X784 plug 12 poles 16/17/19 cab rear
X787 plug 12 poles 1/7/9/29 diesel engine
X788 plug 1 pole 3 diesel engine
X789 plug 12 poles 10 right control console
X789 plug 2 poles / Y53 8 distribution block
X790 plug 2 poles / commutation cisor on pedal 29 cab rear
X791 plug 2 poles / cut-off by hammer use 29 cab rear
X856 plug 1 pole 30 right control console
X857 plug 1 pole 3 left control console
X863-1 plug 4 poles 26 fuel tank
X1027 plug 1 pole (air cond.) 27 left control console

R 914 C / R 924 C 8.80.11

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Component list - Electrical diagrams Service Manual

Pos. Description Step Location

X1063 plug 40 poles (on indus. excavator) 3/7/9/16/17/ cab rear
19/28/29
X1064 plug 1 pole (on indus. excavator) 2 cab rear
X1065 plug 1 pole (on indus. excavator) 3 cab rear
X1071 plug 70 poles (on indus. excavator) 1-3/7-9/15- cab rear
22/28-30
X1072 plug 24 poles (on indus. excavator) 29 cab rear

Y3 solenoid valve pressure servo-control 18 servo control unit

Y7 solenoid valve swing brake 18 servo control unit
Y20 solenoid valve air conditioning coupling 27 injection pump
Y21-1 solenoid valve cut-off limit sensor stick cylinder 29 distribution block
Y21-2 solenoid valve cut-off limit sensor stick cylinder 29 distribution block
Y24 solenoid valve fast travel motor 17 servo control unit
Y46 solenoid valve coolant 27 driver stand
Y50 regulation solenoid valve flow limitation LR 5 servo control unit
Y51 regulation solenoid valve flow limitation EV1 8 servo control unit
Y52 regulation solenoid valve flow limitation EV2 8 servo control unit
Y53 regulation solenoid valve flow limitation EV3 8 distribution block
Y78 solenoid valve Qmin 15 servo control unit
Y139 solenoid valve parallel travel 14 distribution block
Y347 solenoid valve fan drive 5 fan drive
Y387-1 solenoid valve Likufix 28 distribution block
Y387-2 solenoid valve Likufix 28 distribution block
Y414 solenoid valve AHS11 9 servo control unit
Y711 solenoid valve injectors 5 diesel engine
Y712 solenoid valve injectors 5 diesel engine
Y713 solenoid valve injectors 5 diesel engine
Y714 solenoid valve injectors 5 diesel engine

* R 906 Classic from serial number 23145 to 28556; R 916 Classic from serial number 17943 to
28562; R 926 Classic from serial number 17941 to 28647
** R 906 Classic from serial number 28557; R 916 Classic from serial number 28563; R 926 Classic
from serial number 28648

8.80.12 R 914 C / R 924 C

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Service Manual List of electrical diagrams - Standard execution
Electrical diagrams

8.90: List of electrical diagrams - Standard execution

1 Electrical diagrams

Valid
Machine Ident no. Diagram no.
from to
R 914 C 19527 28566 10078989 1022 9010 00 008
R 924 C 19846 28566
R 914 C 28567 ... 10820808 1022 9010 00 102
R 924 C 28567 ...

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R 914 C / R 924 C
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List of electrical diagrams - Standard execution Service Manual
Electrical diagrams

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Group 9: Swing Gear Transmission

Swing gear «SAT» ..................................................................................................................9.10

1 Construction of swing gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.10.1
2 Technical Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.10.2
3 Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.10.2
4 Function and power flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.10.3
4.1 Transmission of torque and RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.10.3
4.2 Gear lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.10.4
5 Removal and installation of swing gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.10.4
5.1 Removal of swing gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.10.4
5.2 Installation of swing gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.10.5
6 Swing gear sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.10.6
6.1 Sealing in the area of the swing motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.10.6
6.2 Sealing in the area of the multi-disc brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.10.6
7 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.10.7
7.1 Maintenance on swing gear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.10.7
7.2 Maintenance of the lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.10.7
8 Swing gear sectional drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.10.8

Swing gear brake....................................................................................................................9.20

1 System description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.20.1
1.1 Multi-disc brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.20.1
1.2 Solenoid valve Y7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.20.1
1.3 Printed circuit board A 1001 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.20.2
1.4 Functioning and control of the swing gear braking system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.20.2
1.5 Operation of the brake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.20.3
2 Hydraulic circuit diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.20.4
3 Repairing the brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.20.5
3.1 Sealing the brake and replacing the brake discs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.20.5
3.2 Removal of hydraulic motor and brake housing 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.20.5
3.3 Dismantling the brake housing 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.20.6
3.4 Assembly of brake housing 25, see Fig. 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.20.7
3.5 Mounting brake housing 25 and swing gear motor, see Fig. 6 / Fig. 7 . . . . . . . . . . . . . . . . . . . 9.20.7

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Service Manual Swing gear «SAT»
Construction of swing gear

Group 9: Swing Gear Transmission

9.10: Swing gear «SAT»

1 Construction of swing gear

The two stage planetary gear is driven by the attached HMF hydraulic oil motor.
The swing gear is attached on the uppercarriage .It moves the uppercarriage via the output shaft and
the internally geared swing ring.
The integrated disc brake acts directly on the gear drive. It is used as a spring applied brake and is
vented hydraulically, i.e. if there is no brake pressure, the discs are pressed together by springs and
the brake is mechanically closed.
A housing around the output pinion of the swing gear contains all the necessary lubrication reserve
for the lubrication of the output pinion and swing ring teeth.
Lubricating the gear partially replaces this reserve.

Fig. 1 Swing gear with grease reserve

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Swing gear «SAT» Service Manual
Technical Data

2 Technical Data

Machine R 914 C R 924 C

from serial number 19527 19846
Gear Type SAT 275 / 237 SAT 275 / 238
Max output speed U / min 86
Max output torque N.m 9000 9500
Gear ratio 1 : 31.7 1 : 36
Hydraulic motor Type HMF 75
Weight kg 204 209
Oil quantity in gear l 6,0
Oil quality in gear see sub-group 1.50
Brake Type hydraulically vented disc brake
Air pressure min. to release brake Bar 28
Air pressure max. Bar 35

Tab. 1 Technical Data

Machine R 914 C R 924 C

from serial number 19527 19846

A) Control measure for axial play of sun gear 5
(distance between top of sun gear 5 and mounting mm 9+0.5
face of oil motor)
B) Pretension of roller bearings 57 and 58
Screw in the slotted nut 47 until contact (20 N.m.)
and then turn in more by an angle of degree 54
(corresponds to an axial pretension of) mm 0.3
D) Tightening torque - screws 61 Nm 210
E) Tightening torque - screws 63 Nm 210

Tab. 2 Axial plays, adjusting values and tightening torques

3 Description
see Fig. 2
The swing gear is made of many components:
– Output shaft housing 2
– Output shaft 17
– Input housing with inner gear 20
– Grease cap around output pinion 26
– Hydraulic motor for swing drive 130
Brake discs 36 / 37 are installed in the input housing with inner gear 20, and are held into place by
the brake piston 30 ring 35.

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Service Manual Swing gear «SAT»
Function and power flow

Fig. 2 Swing gear

2 Output shaft housing 130 Hydraulic motor for swing drive

20 Input housing with inner gear 150 Ball swing ring
26 Grease cap around output pinion

4 Function and power flow

4.1 Transmission of torque and RPM

(see “Sectional drawing of swing gear” on page 8)
The output torque of the hydraulic motor 130 is transmitted via inner splines to the sun wheel 5 of the
planetary stage I.
In gear stage I the sun wheel 5 drives the sun wheel 6 via the planetary gears 10 and the planetary
carrier 15. In doing so the number of revolutions is reduced by the ratio of transmission of the plane-
tary gear I.
In gear stage II the sun gear 6 drives the output shaft 17 via the planetary gears 11 and the planetary
carrier 16. In doing so the number of revolutions is reduced by the ratio of transmission of the plane-
tary stage II.
The complete gear ratio (see “Technical Data” on page 2) results from the ratios of both planetary
gears. The output torque increases in the same ratio as the output speed is reduced.
The pinion of the output shaft engages in the swing ring inner ring with inner toothing of the swing
ring 150. This inner ring is bolted to the undercarriage central part of the machine.

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Swing gear «SAT» Service Manual
Removal and installation of swing gear

Both tapered roller bearings 57 and 58 realize the seating of the rotating output shaft 17 in the hou-
sing 2 which is steadily bolted to the uppercarriage structure.
The gear housing is filled up with lubrication oil in the area of the both planetary stages and of the
tapered roller bearing 57. The chamber situated above tapered roller bearing 58 is filled up with
grease.
The shaft sealing ring 90 provides sealing between both sides of the gear.
When there is no pressure in the hydraulic port for brake control pressure 92, brake discs 36 / 37 are
pressed together in the multidisc brake.
The braking torque between the input housing 20 and the sun gear 5, resulting from this pressure, is
at least as high as the driving torque of the hydraulic motor and sufficient to ensure the blocking of
the swing gear.

4.2 Gear lubrication

The gear is filled up with lubrication oil. The gear oil can be drained through drain valve 94 and refilled
through cap 86.
The grease cap 26, mounted on the output shaft housing, covers the pinion of the output shaft to the
connection with the swing ring 150. The cap 26 is filled with grease which is released to the toothing
of the output shaft pinion and of the swing ring every time the uppercarriage turns.
The central lubrication of the machine is connected via the lube port 62 to the grease cap 26 and
achieves an automatic and regular replacement of the grease reserve.
A charge of grease inside the output shaft housing 2 ensures the lubrication of the tapered roller bear-
ing 58 in the lower area of the output shaft.
Excess grease can escape from the gear through a draining bore in the bottom of the housing 2.

Notice!
All grease lubrications occur automatically and at regular intervalls during machine operation, wit-
hout any action from the operator.
For grease specification, refer to the lubricant chart (see sub-group 1.50).

5 Removal and installation of swing gear

Warning:
During all operation:
– Carefully clean and check all parts for wear before installation.
– Depending on use, all seals should be greased or lubricated before installation.

5.1 Removal of swing gear

Lower attachment to the ground.
Stop the Diesel engine.
Suppress all residual pressure by acting on the pedals and joysticks.
Remove cap 105 on drain valve 94.
Attach oil drain hose (delivered with the excavator) and drain gear oil into an appropriate contain-
er.
Remove the oil drain hose and install cap 105 on drain valve 94.
Disconnect hydraulic lines and remove parts which might be in the way when removing the gear.
Disconnect hydraulic, leak oil and brake lines from the oil motor and gear.
Disconnect grease cap 26 lube port 62.

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Service Manual Swing gear «SAT»
Removal and installation of swing gear

Remove screws 104 and lift the gear with a lifting device from the upper carriage.

Fig. 3 Swing motor and swing gear

5.2 Installation of swing gear

Coat the centring surface of the swing gear and its housing in the upper carriage with anticorrosive
grease (preferably use ''Optimol White T'' Ident no. 8500307).
Install the swing gear complete assembly in the uppercarriage, checking for correct location of oil
drain plug (oil drain plug should face the hole in the undercarriage).
Install screws 104 and tighten them to the recommended torque (according to Liebherr Standard
4037, see sub-group 1.20).
Install cap 105 on drain valve 94.
Connect the brake, leak oil and hydraulic lines to the oil motor and gear.
Connect grease cap 26 lube port 62.
Refill the gear with oil (for oil specifications, see lubrication chart in group 1.50). until the level
reaches the upper mark on the dipstick.
Check the swing gear pinion meshes correctly into the swing ring.
Refill the grease reserve 26 by starting several lubrication procedure (button S84, see «Operator’s
Manual»).
Check the swing ring teeth lubrication.

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Swing gear «SAT» Service Manual
Swing gear sealing

6 Swing gear sealing

Note:
The following operations can be performed with the gear installed.

Important:
– Carefully clean and check all parts for wear before installation.
– All seals should be lightly oiled or greased before installation.

6.1 Sealing in the area of the swing motor

Remove all lines which might be in the way.
Hydraulic lines, leak oil lines and control lines on the oil motor may stay connected.
Remove screws 101 (see Fig. 3) and lift oil motor 130 from the gear.
Replace the O-ring 81 (see Fig. 4) on the oil motor 130.
Install the oil motor 130 into the gear.
Install screws 101 and tighten them to the recommended torque (according to Liebherr Standard
4037, see sub-group 1.20).

6.2 Sealing in the area of the multi-disc brake

Warning:
Before removing the brake, make sure the attachment is lowered to the ground.

6.2.1 Removal
Remove the oil motor 130 from the gear (see 6.1).
Remove and plug the brake line from the gear.
Remove the screws 61.
Remove the brake housing 25 from the inner gear 20.

Warning:
The ring 31 and piston 30 are spring loaded.

Push down piston 30 with special tool No. 60 (see subgroup 2.07) and two M16X 120 screws.
Release lock ring 73.
Remove the special tool.
Remove piston assembly 30, springs 42 / 43 / 44, o-rings 82 / 83 and grooved ring 88 from brake
housing 25.
Push end ring 31 from piston 30 and pull off grooved ring 89.
Remove front ring 35, brake discs 36 / 37 and rear ring 35 from the inner gear 20.

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Service Manual Swing gear «SAT»
Maintenance

6.2.2 Assembly

Important:
Carefully clean and check all parts for wear before installation.

Set the rear ring 35 into the inner gear 20 and insert the outer and inner discs 37 / 36 in the fol-
lowing order: outer disc - inner disc - outer disc - etc...
Set the front ring 35 onto the last outer disc.

Note:
Mount the support rings to the side opposite the pressure side.
Lightly lubricate the grooved rings before installation.

Insert the grooved ring 89 into the end ring 31. Insert the grooved ring 88 and the o-rings into the
brake housing 25.
Lightly lubricate o-ring 82 and install it on the brake housing 25.
Push end ring 31 into the piston 30.
Insert springs 42 / 43 / 44 and install piston assembly 30 onto the brake housing 25.
Using special tool No. 60 (see sub-group 2.07), push the piston 30 down and insert snap ring 73
(check that it is correctly seated).
Remove the special tool.
Fit new o-rings 81 (on the oil motor) and 83 (on the brake housing).Lubricate them lightly before
installation.
Push the brake housing assembly 25 into the inner gear 20.
Install screws 61 with washers 66 and tighten them to the recommended torque D (see Tab. 2 on
page2).
Install the oil motor 130 (see 6.1).
Install the swing gear (see 5.2).

Swing gear sealing and repair

See ''Repair Instruction of Swing Gear SAT".

7 Maintenance

7.1 Maintenance on swing gear

Regularly check swing gear and motor oil level, oil leakage and fixings. Refer to Inspection chart
(Group 3)
The gear oil must be replaced at the recommended intervals.

7.2 Maintenance of the lubrication system

The grease packing in the grease cap is replaced or replenished automatically during a lubrication
procedure. Lubrications procedures must be performed at set intervals from the central lubrication
system, see maintenance instructions in Group 3 and in the «Operator’s Manual».

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Swing gear «SAT» Service Manual
Swing gear sectional drawing

8 Swing gear sectional drawing

Fig. 4 Sectional drawing of swing gear

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Service Manual Swing gear «SAT»
Swing gear sectional drawing

2 Output shaft housing 57 Tapered roller bearing

5 Sun wheel 58 Tapered roller bearing
6 Sun wheel 60 Allen head screw
10 Planetary wheel 61 Allen head screw
11 Planetary wheel 62 Lubrication port for output pinion teeth
15 Planetary carrier 63 Allen head screw
16 Planetary carrier 65 Lock washer
17 Output shaft 66 Lock washer
20 Input housing with inner gear 70 Lock ring
25 Brake housing 71 Lock ring
26 Grease cap 73 Lock ring
30 Brake piston 77 Support ring
31 End ring 81 O-ring
35 Ring 82 O-ring
36 Inner disc 83 O-ring
37 Outer disc 84 O-ring
40 Disc carrier 86 Oil fill cap
42 Spring 88 Grooved ring
43 Spring 89 Grooved ring
44 Spring 90 Shaft seal
45 Retaining disc 91 Nilos ring
46 Retaining disc 92 Hydraulic port for brake control pressure
47 Slotted nut 93 Hydraulic oil motor
49 Support ring 94 Oil drain plug

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Swing gear «SAT» Service Manual
Swing gear sectional drawing

9.10.10 R 914 C / R 924 C

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Service Manual Swing gear brake
System description

9.20: Swing gear brake

1 System description

1.1 Multi-disc brake

The brake is integrated in the swing gear and is applied at the geared drive.
It is a hydraulically-bled multi-disc brake. The brake discs 36 / 37 are pressed together mechanically
by the prestressing force of the pressure springs 43 / 44 (closed linkage) and released by way of pre-
stressing force being charged to the ring pistol 30 on the opposite side of the pressure springs.

1.2 Solenoid valve Y7

The solenoid valve Y7 is integrated in the servo oil unit 50.
In the rest position, the solenoid valve connects the chamber K with the tank via connection A3 (brake
applied).
In the working position, the solenoid valve connects the chamber K with the servo pressure via con-
nection A3 (brake released).

Fig. 1 Swing gear and servo oil unit

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Swing gear brake Service Manual
System description

1.3 Printed circuit board A 1001

This printed circuit board actuates the solenoid valve Y7 (Fig. 1) via the final power stage V4.
When the printed circuit board receives the signal “Brake released“ from the operating keyboard via
CAN-BUS 2, the final stage is actuated and voltage is supplied to the power output for the solenoid
valve Y7 (Fig. 1).
Details and arrangement of the components on the printed circuit board A 1001 (see “Aggregates of
the electrical system“).

Fig. 2 Arrangement of printed circuit board A1001

1.4 Functioning and control of the swing gear braking system

Fig. 3 Push-button S17 on the control desk

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Service Manual Swing gear brake
System description

1.5 Operation of the brake

For machines A 900 C and A 904 C the brake is controlled directly via key S17.

Fig. 4 Direct control

– Position A = brake applied = LED lit = Y7 in rest position = brake applied
– Position B = brake released = LED not lit = Y7 activated = brake released

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Swing gear brake Service Manual
Hydraulic circuit diagram

2 Hydraulic circuit diagram

Fig. 5 Hydraulic circuit diagram

30 Hydraulic pump / servo control A1001-X3 Plug connection / 10-pole

50 Servo oil unit A1001-X6.1 Plug connection / 6-pole
195 (130*) Swing motor drive A1001-V4 Final stage / swing gear brake
155 Swing gear brake A1010 Printed circuit board control
ESP02
156 Swing gear A1010-F8 Fuse 7.5 A
A1001 Printed circuit board control A1010-X232/2 Plug connection for KS control
ESP01 desk
Right
A1001-H7 LED green / input signal A1010-X246/3 Plug connection for KS Swing
platform
A1001-H8 LED red / error Y7 Solenoid valve / swing gear
A1001-H9 LED yellow / output signal
* (for R900C only)

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Service Manual Swing gear brake
Repairing the brake

3 Repairing the brake

3.1 Sealing the brake and replacing the brake discs

Intense noises or deterioration of braking action when braking.

indicates worn lining surfaces
Replace lining discs immediately

Note!
We recommend replacing the entire disc package. Repair of the brakes can be undertaken without
having to dismantle the gear.

Caution!
All necessary safety measures for machine and personnel are to be undertaken before commencing
any repair tasks on the brakes; e.g. positioning the machine on an even surface or securing the ma-
chine when working on slopes. Dissipate the oil pressure in the brake system.

Fig. 6 Excerpt from “Swing gear SAT“ subgroup for swing gear

3.2 Removal of hydraulic motor and brake housing 25

Remove the respective lines which obstruct access to the gear
Unscrew the fastening screws for the hydraulic motor and remove with flange-mounted hydraulic
lines from the gear
Unscrew the brake line from the gear
Unscrew the cylinder screws 61
Remove the complete brake housing 25 from the interior 20

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Swing gear brake Service Manual
Repairing the brake

3.3 Dismantling the brake housing 25

Caution!
The lock ring 31 and ring piston 30 are sealed with pretension.
Risk of injury
Hold the lock ring tightly when loosening the circlip 73

Push down the ring pistol 30 using the pressing fixture (special tool no. 20 - 23, see Group 2.07) and
two screws M16X120 or M16X140.
Work out the circlip 73, loosen and remove the fixture
Remove the complete brake piston 30, remove the pressure springs 43 / 44, take out the O-ring
82 and grooved ring 88 with supporting rings from the brake housing 25
Push the lock ring 31 out of the ring piston 30 and remove the grooved ring 89 with supporting ring
Remove the compression ring 35, brake discs 36 / 37 and rear compression ring 35 from the in-
ternal geared wheel 20

Fig. 7 Sectional drawing of brake housing 25 turned around 90°

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Service Manual Swing gear brake
Repairing the brake

3.4 Assembly of brake housing 25, see Fig. 7

Clean all used parts prior to assembly and check thoroughly for reusability.
Insert the compression ring 35 into the internal geared wheel 20
Insert the outer discs and inner discs 37 / 36 one after the other as follows
outer disc - inner disc - outer disc, and so on...
Fit the front compression ring 35 onto the last outer disc
Insert grooved ring 89 with supporting ring into the lock ring 31
Insert grooved ring 88 with supporting ring into the brake housing 25

Note!
Fit the supporting rings on the opposite side of the pressure.
Apply a light coating of grease onto the grooved ring prior to installing.

Apply a light coating of grease to the O-ring 82 prior to installing

Pull the O-ring 82 onto the brake housing 25
Push the lock ring 31 all the way into the ring piston 30
Insert the pressure springs 43 / 44 and push the complete ring piston 30 onto the brake housing 25
Push the ring piston 30 downwards using the pressing fixture
Work in the circlip 73 (ensure correct seating)
Remove the pressing fixture

3.5 Mounting brake housing 25 and swing gear motor, see Fig. 6 / Fig. 7
Replace the O-ring on the hydraulic motor and O-ring 84 on the brake housing and apply a light
coating of grease prior to installing
Push the complete brake housing 25 into the internal geared wheel 20 and fasten with screw 61
and washer 66
Insert the complete hydraulic motor into the gear and secure with fastening screw to the brake
housing 25
Observe the tightening torques (see “General specifications“ in the Group “Swing gear“)
Connect the brake line to the gear
Ensure sound functioning of brake (see “Functioning and control of the swing gear braking sys-
tem” on page 2)

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Swing gear brake Service Manual
Repairing the brake

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Service Manual

Group 10: Swing Ring

Ball slewing ring ...................................................................................................................10.10

1 Job definition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.10.1
2 Tasks in general . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.10.2
3 Functional description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.10.3
4 Measuring clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.10.4
4.1 Measuring tilting clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.10.4
4.2 Measuring circumferential backlash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.10.5
5 Dismantling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.10.5
6 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.10.6

R 914 C / R 924 C 10.00.1

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10.00Wednesday,
.2 R 914 C / R 924 C
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Service Manual Ball slewing ring
Job definition

Group 10: Swing Ring

10.10: Ball slewing ring

1 Job definition
The ball slewing ring which allows the uppercarriage to be swung in any direction desired, is featured
as a slewing connection with bearing element between undercarriage and uppercarriage.
The slewing ring is a single-row, large diameter axial roller bearing.
For rotary drive of the uppercarriage, the swing gear transmission engages in the internal involute
gear of the slewing ring and manoeuvres the uppercarriage.

R 914 C / R 924 C 10.10.1

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Ball slewing ring Service Manual
Tasks in general

Fig. 1 Installation position of the slewing ring in the undercarriage

2 Tasks in general

Machine R 914 C R 924 C

Type 1062 / 1063 / 1064 / 1066 / 1067 / 1068 /
1065 1069 / 1136 / 1174
from serial number 19527 19846
Ball slewing ring Type KUD 64 VJ 003-001 KUD 64 VJ 003-001
Tilting clearances
Delivery clearance mm 0.6 0.6
Maximum clearance mm 2,1 2,1
Maximum circumferential backlash mm 1,4 1,4

10.10Wednesday,
.2 R 914 C / R 924 C
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Service Manual Ball slewing ring
Functional description

Machine R 914 C R 924 C

Type 1062 / 1063 / 1064 / 1066 / 1067 / 1068 /
1065 1069 / 1136 / 1174
from serial number 19527 19846
Weight of uppercarriage
without attachment kg approx. 10000 approx. 10000 - 12000
with attachment kg approx. 21000 - 23000 approx. 21500 - 25500
Tightening values
Fastening screws large M 20 M 20
Quality 10.9 Nm 560 560

Tab. 1 Technical data

3 Functional description

Fig. 2 Segment of ball slewing ring

1 Outer ring 4 Upper sealing lip

2 Internal ring 5 Lower sealing lip
3 Ball 6 Connecting bore for lubrication line

When working with the machine, high forces and alternating torques must be absorbed by the ball
slewing ring via the uppercarriage. These excessive stresses are transferred via the external ring 1
fixed to the uppercarriage, through the ball 3 to the internal ring 2 with toothing connected to the un-
dercarriage.
The sealing lips 4 and 5 prevent dirt and dust infiltrating the ball bearing.
Lubrication of the ball track is resulted via the central lubrication system at the external ring of the
slewing ring. The toothing of the internal ring and drive pinion of the swing gear are lubricated via a
grease packing at the swing gear pinion, see also Group 9.

R 914 C / R 924 C 10.10.3

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Ball slewing ring Service Manual
Measuring clearances

Supplementation or replenishment of the lubricating grease for the ball track and grease capsule of
the swing gear is resulted automatically with regular actuation of the central lubrication system at pre-
determined intervals, see also the maintenance guidelines in Group 3.

Caution!
Ball slewing rings must always be laid down flat during transport and storage. Impacts, shocks and
twisting are to be absolutely avoided during installation. When carrying out repair tasks, it is imper-
ative that the accident-prevention guidelines regarding operation of the machine are observed.

4 Measuring clearances

Fig. 3 Measuring tilting clearance and circumferential backlashes (tooth impressions using lead
sheets)

4.1 Measuring tilting clearance

Note!
Tilting clearance - delivery clearance: Maximum clearance which could be indicated by a newly
installed bearing see Tab. 1.
Maximum tilting clearance: The max. permissible bearing clearance of the uppercarriage bearing
(wear limit). Ball slewing rings can usually be operated with up to max. tilting clearance. If stiffness
of the bearing is determined prematurely, the ball slewing ring must be replaced. Operational safety
can no longer be guaranteed if max. clearance is exceeded.
Continuous monitoring, as well as assurance of freedom-of-movement is nevertheless essential.

A dial gauge with magnetic base indicator holder is required for measuring the tilting clearance.
Ensure that the magnetic base indicator holder is fastened securely to ensure that errors do not
occur during the measuring procedure. Manoeuvre the uppercarriage into an appropriate position.
Mount the dial gauge at the front or at the rear, flush with the attachment at the ball slewing ring
see Fig. 3.
Fill the bucket of the machine, lift it above ground level and extend to maximum reach
Set the dial gauge to zero
Raise the machine slightly using the attachment (minimal ground clearance at the front wheels)
The difference of both measured values indicates the tilting clearance of the ball slewing ring. To de-
termine different sized clearance ranges, the aforementioned measuring procedures must be repeat-
ed at different swing angles of the uppercarriage.

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.4 R 914 C / R 924 C
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Service Manual Ball slewing ring
Dismantling

4.2 Measuring circumferential backlash

Note!
Circumferential backlash: The backlash which may occur when pairing a new bearing with a new
pinion, together with the coincidence of all influences which could increase clearance.

A lead sheet approx. 10 mm in width, 120 mm in length and 2 mm in thickness can be used for meas-
uring the circumferential backlash.
Position the machine on a level surface. Loosen the uppercarriage locking and swing gear brake
Extend the attachment completely and raise it approx. one meter
Place lead strips horizontally in the middle of the tooth between swing gear pinion and slewing
ring and swing the uppercarriage manually from the end of the attachment
Ascertain the circumferential backlash, as described in the following example:

Tooth flank A 1.00 mm

Tooth flank B + 0.40 mm
Circumferential back- 1.40 mm
lash

5 Dismantling
It is possible to replace the ball slewing ring after raising the uppercarriage.

Adapt the size of the crane, sufficiently dimensioned lifting gear, ropes, shackle, etc. to the respec-
tive weight of the uppercarriage (see Tab. 1 on page 3).

Ensure a corresponding length of the suspension gear

Danger!
Observe all applicable safety guidelines for the tasks listed as follows.
Standing beneath the suspended uppercarriage is strictly prohibited, and is also not necessary if the
procedure described is adhered to.

Position the machine on firm, level ground and implement any support devices featured. Secure
the undercarriage against rolling by placing chocks beneath the wheels
Extend bucket, stick, and hoist cylinder completely. Retract bucket stick and bucket completely
Continue to retract the adjusting cylinder until the lower edge of the attachment becomes aligned
with the lower edge of the uppercarriage (level position when setting down)
Mark, disconnect and seal the upper lines on the oil feeder pipes
Catch any escaping oil in a suitable oil pan
Dismantle the actuator for the oil feeder pipes
If necessary, disconnect the lubrication line
Hook the lifting gear, ropes, shackle, etc. onto the lifting eyes or attachment points provided on
the top of the pivoting arm, thus securing the uppercarriage, see Fig. 4
Unscrew the outer slewing ring fastening screws 13 with washers 14 from the ball slewing ring to
the uppercarriage
Lift the uppercarriage carefully with the crane until above the rotary connection and set it down to
one side
Unscrew the fastening screws 5 with washers 6 from the undercarriage to the ball slewing ring

R 914 C / R 924 C 10.10.5

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Ball slewing ring Service Manual
Installation

Lift the slewing ring completely and set it down on a suitable surface

Fig. 4 Recommended lifting gear for lifting of the uppercarriage

6 Installation
Cleanliness and an even seating of the ball slewing ring on the screwing surfaces are prerequisite for
sound functioning.

Carefully remove any burr formations, weld beads and other irregularities
Set the complete ball slewing ring down onto the uppercarriage, observe the prescribed direction
of installation precisely, see Fig. 4

Fig. 5 Correct installation position of the ball slewing ring

5 Hexagon head screws slewing ring- 13 Hexagon head screws slewing ring-
undercarriage uppercarriage
6 Washers 14 Washers

10.10Wednesday,
.6 R 914 C / R 924 C
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Service Manual Ball slewing ring
Installation

8 Sealing plug 40 Centring pin form A (round)

10.1 External ring 41 Centring pin form B (diamond-shaped)
10.2 Internal ring
F Travel direction and predominant direction
of operation
Sext Marking for hardness gap on the external Sint Marking for hardness gap on the internal
ring ring

Note!
The markings “S“ (hardness gap = beginning and end of raceway hardening) on external and inter-
nal rings of the slewing ring, as well as on the sealing plug in the external ring must indicate an in-
clination of 90° to the predominant direction of operation.
The hardness gap Sint on internal ring 10.2 must be located on the left-hand side of the undercar-
riage when viewed in travel direction F.
The hardness gap Sext on external ring 10.1 must be located on the right-hand side of the upper-
carriage when viewed in travel direction F.

Screw in the fastening screws 5 complete with washers 6 and tighten crosswise with the torque
wrench, displaced around 90° , (see Tab. 1 on page 3)
Ensure easy freedom-of-movement of the slewing ring
Rotate the external ring of the slewing ring into the correct position. Observe the position of hard-
ness gap point Sext on the external ring and angle between travel direction and centring pin see
Fig. 6.
Turn the diamond-shaped centring pin 41 so that the longitudinal direction is positioned crossways
to the slewing ring diameter.

R 914 C / R 924 C 10.10.7

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Ball slewing ring Service Manual
Installation

Fig. 6 Installation position of the ball slewing ring - as viewed from above

a Angle of travel direction - centring pin F Travel direction

10.1External ring of slewing ring 10.2External ring of slewing ring
40 Centring pin form A (round) 41 Centring pin form B (diamond-shaped)

Machine R 924 Compact

Type 911/198

9.6°

Lift the uppercarriage above the ball slewing ring

Caution!
First rotate the external ring of the slewing ring into the correct position see Fig. 4. The swing gear
pinion must engage in the toothing and the through bores must align with the threads of the upper-
carriage.

Lower the uppercarriage to approx. 1 cm above the ball slewing ring

Screw in the two outer fastening screws 13 with washers 14 and tighten crosswise with the torque
wrench, displaced around 90° in accordance with the table
Lower the lifting gear etc. and remove it from the machine

10.10Wednesday,
.8 R 914 C / R 924 C
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Service Manual Ball slewing ring
Installation

Connect the oil lines at the top of the rotary connection. Observe the markings
Mount the actuator for the oil feeder pipes
Remount the attachment (depending on the machine) as required
Connect the lubrication lines
Start up the diesel engine, actuate all functions in the undercarriage and check the lines for leaks
Replenish the grease packing of the lubrication device on the swing gear pinion.
Ensure proper functioning of the ball slewing ring and check measuring precision of the clearanc-
es see Fig. 3

Note!
When installing a new ball slewing ring, the lubrication cap (incorporating the housing and the swing
gear pinion) must be carefully cleaned of any existing grease. An initial filling of the lubrication cap
must then be undertaken with a grease type prescribed for the slewing ring toothing.

Start up the diesel engine, actuate all functions in the undercarriage and check the lines for leaks
Lubricate the toothing by rotating the uppercarriage or by way of the central lubrication system,
ensure correct lubrication.

Note!
If a central lubrication system is featured, the ball raceway and the toothing of the slewing ring is
automatically supplied with an optimum amount of grease with every lubrication procedure.

Ensure proper functioning of the ball slewing ring and check measuring precision of the clearanc-
es see Fig. 3

R 914 C / R 924 C 10.10.9

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Installation

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.10 R 914 C / R 924 C
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Service Manual

Group 11: Travel Gear

Gear types schedule ............................................................................................................11.10

Technical data of the travel gears.......................................................................................11.15

Travel gear FAT of construction line P(b) ..........................................................................11.25

1 Functioning of the chains drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.25.1
2 Construction and operating mode of the travel gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.25.2
3 Kinematic representation of the travel gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.25.4

Sealing the gear - construction line P(b)............................................................................11.50

1 Sealing at the centering of the travel motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.50.1
2 Replacement of the slipring seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.50.1
2.1 Removing the slipring seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.50.1
2.2 Installing the slipring seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.50.1

Travel brakes ........................................................................................................................11.71

1 Construction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.71.1
1.1 Multi-disc brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.71.1
1.2 Brake valve 205. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.71.1
2 Function of the travel gear brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.71.2
3 Repair of the multi-disc brake in the travel gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.71.3
3.1 Preliminary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.71.4
3.2 Travel gears FAT with construction line P(b). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.71.4
3.3 Travel gears FAT with construction line P(r) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.71.5
3.4 Travel gears FAT with construction line A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.71.6
3.5 Return into operation of the FAT Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.71.6

Slipring seals ........................................................................................................................11.75

1 Handling and installation instructions for slipring seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.75.1
2 Installation instructions for slipring seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.75.1

R 914 C / R 924 C 11.00.1

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11.00Wednesday,
.2 R 914 C / R 924 C
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Service Manual Gear types schedule

Group 11: Travel Gear

11.10: Gear types schedule

Machine type Gear construction Description

Machine Gear type
(Serial number) line see subgroup

1062
1063 FAT
R914 C P(b) 11.25
1064 350 P 022
1065

1066
1067 FAT
P(b) 11.25
1068 350 P 022
1136 from SN 18086

R924 C
1136 up to SN 18085 FAT
P(b) 11.25
1174 350 P 003

1069 FAT400 P 063 P(b) 11.25

R 914 C / R 924 C 11.10.1

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.2 R 914 C / R 924 C
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Service Manual Technical data of the travel gears

11.15: Technical data of the travel gears

Travel gear of construction line P(b): FAT FAT

(see subgroup 11.25) 350 P 022 400 P 063
Ident number. 968743701 968743701
( 9443210 ) ( 9443220 )
Output speed max. U / min 36 34,7
Output torque Nominal N.m 35 000 60 000
Maximum - -
Gear ratio 102,0 102,0
Driving motor Typ FMV 075 FMV 100
Torque constant Nm/bar 1,19 1,59
Dry weight approx. kg 180 305
Oil quantity in gear l 2,8 4,3
( 4,1 ) ( 6,5 )
Oil quality / viscosity SAE 90 ou SAE 80W90
Brake Type multidisc brake, spring applied, pressure re-
leased
Air pres. min. to release the brake Bar 18 18
Brake torque static N.m 53 000 90 000
Brake torque dynamic N.m - -
Adjustment values to be observed at gear assembly:
Control measure for axial play A* mm 93,5+1 111,5±0,5
Control measure B* mm 3,5+0,1 3,5+0,1
Tightening torque C* (grub screw 1.4) Nm 69 Nm 69 Nm
+ Loctite 242 + Loctite 242
Tightening torque D* (screw 51) Nm 49 Nm 49 Nm
+ Loctite 243 + Loctite 270
Tightening torque of the Plug 54* Nm 80 80

* For the measures A and B and for the tightening torques C, D and 54 see the cut view of the cor-
respondant travel gear.

R 914 C / R 924 C 11.15.1

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.2 R 914 C / R 924 C
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Service Manual Travel gear FAT of construction line P(b)
Functioning of the chains drive

11.25: Travel gear FAT of construction line P(b)

Travel gear are transformers which allow to change the mechanical power characteristics (Output
R.P.M. n and torque C) of the power supplied by the travel engine.

1 Functioning of the chains drive

Two planetary gears, which are fixed on the back side of the side frames of the undercarriage, set the
chains in motion.
Each travel gear 100 is driven by a hydraulic motor 95 and is directly bolted with one side frame 103
via its connection housing 5.
The characteristics (Output R.P.M. n and torque C) of the power change with by factor equal to the
ratio of transmission which is defined by the three gear stages of gear 100 (with the number of teeth
of each component) to adapt the RPM and the torque necessary to the chains drive.
The chain 104 is driven by the sprocket wheel 105, which is connected with the rotating output flange
5 of the gear.

Fig. 1 Components of a chain drive

1 Connection housing 5 Output flange

70 Multidisc brake 95 Hydraulic motor for travel drive
98 Travel gear mounting bolts 100 Travel gear complete
103 Side frame 104 Chain
105 Sprocket wheel 110 Hydraulic brake valve

The multidisc brake 70, which is fixed in the connection housing 1 functions as a parking brake. This
brake is spring applied and hydraulically vented by the pressure existing in the travel drive circuit.

R 914 C / R 924 C 11.25.1

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Travel gear FAT of construction line P(b) Service Manual
Construction and operating mode of the travel gear

The hydrostatic drive of the travel gears functions as a service brake.

Furthermore, the hydraulic brake valve 110, which is front flanged to the hydraulic motor 95, prevents
the travel gear from overspeeding when the excavator is driven downhill.

2 Construction and operating mode of the travel gear

The output torque of the hydraulic motor 95 is transmitted to the driving shaft 40 via the inner splines
of the discs carrier 65.

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Service Manual Travel gear FAT of construction line P(b)
Construction and operating mode of the travel gear

1 Connection housing 2 Roller cage

3 Ball roller 10 Output housing with inner teeth
16 Support ring 17 Planetary gear of planetary stage III
18 Snap ring 20 Sun gear of planetary stage III
25 Planetary carrier of planetary stage II 26 Retainer disk
27 Planetary gear of planetary stage II 28 Snap ring
30 Sun gear of planetary stage II 35 Planetary carrier of planetary stage I
36 Retainer disk 37 Planetary gear of planetary stage I
38 Snap ring 40 Driving shaft
45 Cover 46 Retainer disk
47 L-Ring 49 O-Ring
51 Hex head screw 54 Plug
57 O-Ring 58 Slipring seal
60 Receptacle ring for slipring seal 61 Snap ring
65 Discs carrier 66 Locking ring
70 Multidisc brake complete 70.3 Brake piston
70.4 Cover 70.5 Pressure ring
70.7 Brake disc with outer teeth 70.8 Brake disc with inner teeth
70.10 Locking ring 70.11 Snap ring
70.14 Piston sealing ring 70.15 Piston sealing ring
70.17 Pressure spring large 70.17 Pressure spring
72 Cylindrical screw 74 Cylindrical metal pin
81 O-ring 89 Hydraulic hoses for brake pressure
95 Hydraulic motor

The travel gear is composed of three planetary gears and the planetary carrier of the previous one is
fixed. For each stage the sun gear of stage N is fixed on the planetary carrier of the stage N-1.
In gear stage I the driving shaft 40 transmits the power to the planetary gear 37, so it turns around
itself. As this planetary gear is interlinked with the output housing 10, it turns around the travel gear
axis. So, thanks to the pivot between planetary gear 37 and the planetary carrier 35, the planetary
carrier 37 and the sun gear 30 begin to turn. That gives us a ration of transmission between the driv-
ing shaft 40 and the sun gear 30. But this ratio of transmission depends on the R.P.M. of the Output
houssing 10, and so on the next stages.
In gear stage II the sun gear 30 transmits the power to the planetary gear 27, so it turns around itself.
As this planetary gear is interlinked with the output housing 10, it turns around the travel gear axis.
So, thanks to the pivot between planetary gear 27 and the planetary carrier 25, the planetary carrier
27 and the sun gear 20 begin to turn. That gives us a ration of transmission between the sun gear 30
and the sun gear 20. But this ratio of transmission depends on the R.P.M. of the Output houssing 10,
and so on the next stage.
In gear stage III the sun gear 20 transmits the power to the planetary gear 17, so it turns around itself.
As this planetary gear can’t turns around the travel gear axis (because he is connected to the con-
nection housing 1). So thanks to the pivot between planetary gear 17 and the connection housing 1,
the output housing begin to turn. That gives us a ratio of transmission between the sun gear 20 and
the output gear 10. That all permitted us to determinate the total ratio of transmission between the
driving shaft 40 and the output housing 10 of the travel gear.
The output flange 5 bolted with the output housing 10 by the mounting bolts 11 drives the sprocket
wheel 105 and the chain. The RPM of the sprocket is the RPM of the hydraulic motor reduced by the
complete ratio of transmission of the travel gear.
In contrast to that, the torque is raised. The torque generated at the output flange 5 is modified with

R 914 C / R 924 C 11.25.3

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Travel gear FAT of construction line P(b) Service Manual
Kinematic representation of the travel gear

a ratio of transmition equal to the inverse of the RPM ratio of transmission. The ratio of transmission
is the complete transmission of the travel gear.
The rotating output flange 3 is seated on the stationary connection housing 1 by means of two rows
of bearing rollers 3, which are installed diagonally.
The slipring seal 58 is fixed between the connection housing 1 and the output flange 5. Thanks to this
seal the travel gear is sealed up from the exterior.
When there is no pressure in the hydraulic port for brake control pressure 89 the brake discs 70.7
and 70.8 are pressed together in the multidisc brake 70.
The braking torque between the connection housing 1 and the disc carrier 65, resulting from this pres-
sure, is at least as high as the driving torque of the hydraulic motor and it is sufficient to ensure the
blocking of the travel gear, even when the excavator is situated at a slope.

3 Kinematic representation of the travel gear

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.4 R 914 C / R 924 C
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Service Manual Sealing the gear - construction line P(b)
Sealing at the centering of the travel motor

11.50: Sealing the gear - construction line P(b)

Notice!
Used components have to be cleaned properly prior to mounting. Furthermore you have to check
them thoroughly in order to know if they can be used again.
Removed sealing elements have to be replaced by new ones. The new elements have to be slightly
lubricated before installation.

1 Sealing at the centering of the travel motor

Dismantle the hydraulic motor 95, (see "Removing and reinstalling the travel gears FAT" in the
subgroup 11.40).
Replace the O-ring 81. Apply a light coating of grease to the O-ring prior to installing.
Install the hydraulic motor 95,(see "Removing and reinstalling the travel gears FAT" in the sub-
group 11.40).

2 Replacement of the slipring seal

Note!
For this replacement it is necessary to remove the complete gear from the side frame.
For removal and installation see heading “Removal and installation of the travel gear FAT ” in the
subgroup 11.40.

Dismount the gear and place it on an even, clean surface with the connection housing 1 on the
upper side.

2.1 Removing the slipring seal

Press in the receptacle ring for the slipring seal 60 in order to discharge the snap ring 61 from the
axial prestress of the halfseals 58.
Therefore, three sprocket fastening screws 105, which are distributed evenly on the circumfer-
ence of the gear, have to be fixed above the thread bores in the connection housing 1 (underlay
accordingly with sleeves or washers).
Remove the snap ring 61.
Remove the screws 105 and the snap ring 61.
Lift the receptacle ring 60 and remove the O-ring 57.
Take the halfseals 58 out of the receptacle ring 60 and out of the output flange 10.

2.2 Installing the slipring seal

Mount a new halfseal into the receptacle ring 60 by the aid of the appropriate installation tool and
the respective instructions (see heading “slipring seals” in group 12).
Mount a new halfseal into the output flange 10 by the aid of the appropriate installation tool and
the respective instructions.
Put a new O-ring 57 onto the connection housing 1 (slightly lubricate the O-ring prior to mounting).
Put the receptacle ring 60 together with the slipring seal onto the gear.
Put the snap ring 61 onto the outside circumference of the connection housing 1.
Mount the screws 105. Press the halfseals together until the snap ring 61 can be inserted into its
seat.

R 914 C / R 924 C 11.50.1

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Sealing the gear - construction line P(b) Service Manual
Replacement of the slipring seal

Evenly loosen and remove the screws 105.

1 Connection housing 10 Output flange

57 O-ring 58 Slipring seal
60 Receptacle ring for slipring seal 61 Snap ring
74 Cylindrical metal pin 81 O-ring
95 Hydraulic motor 96 Mounting bolts for hydraulic motor

11.50Wednesday,
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Service Manual Travel brakes
Construction

11.71: Travel brakes

1 Construction

1.1 Multi-disc brake

A hydraulically vented wet multi-discs brake is mounted in each travel gear and acts on the gear input
shaft.
If no pressure is applied to chamber C via the brake connection, the pressure springs 70.17 / 70.19
push the ring pistons 70.3 and the brake discs 70.7 / 70.8 are pressed together with the pretension
force of the springs.
The resulting brake moment is transmitted to the drive shaft of the hydraulic motor 95 via the both
internally and externally-toothed disc carriers 65.
If chamber C is charged with pressure, the ring piston 70.3 is pushed against the force of the pressure
springs 70.17 / 70.19 as far as it will go against the end ring 70.4. The braking moment induced by
the discs is nullified.

Fig. 1 Multi-disc brake in travel gear FAT

1.2 Brake valve 205

The brake valves 205 flanged to the travel motors 95 incorporate the hydraulic brake pistons 206

R 914 C / R 924 C 11.71.1

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Travel brakes Service Manual
Function of the travel gear brake

which prevent runaway of the excavator when travelling down on slopes.

The brake valves 205 generate the brake pressure required for control of the multi-disc brake from
the respective high pressure pA or pB. This pressure is applied via connection Br of the brake valve
205 and hose line 109 into the brake chamber C of the travel gear.
For a description of the brake valves 205, see Subgroup 7.98.

Fig. 2 Hydraulic braking valve 205

2 Function of the travel gear brake

The high pressure existing at connection A (or B) of a travel motor 95 builts up via the selection valve
207 and the pressure reducing valve 208 at connection Br of the brake valve 205. As a result, the
multi-discs brakes 70 in the travel gears open automatically as soon as the high pressure occuring
at actuation of a travel movement on connection A (or B) of the travel motor 95 exceeds the venting
pressure of the multi-disc brake.
When releasing the travel pedals, the difference in pressure between connections A and B of the
brake valve is dissipated via the A - B connection existing in the travel gear control piston when in
the neutral position.
The available pressure at connection Br is decreased via a throttle and the multi-disc brakes apply
automatically.

70 Mechanical multi discs brake (209) 95 Hydraulic travel motor (200 / 201)
195 Rotary connection 196 Rotary connection for travel brakes
202 Positioning piston 203 Valve - travel motor adjustment
205 Hydraulic braking valve complete 206 Hydraulic brake valve
207 Selection valve - brake control pressure 208 Press. reducing valve - brake control pr.
211 Sec. pressure relief valve - travel left 212 Sec. pressure relief valve - travel left
213 Sec. pressure relief valve - travel right 214 Sec. pressure relief valve - travel right

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Service Manual Travel brakes
Repair of the multi-disc brake in the travel gear

Fig. 3 Basic circuit diagram - hydraulic and mechanical travel brakes

3 Repair of the multi-disc brake in the travel gear

(Sealing the brake and replacing the brake discs).
Intense noises when braking indicates worn lining surfaces. In this case, the outer discs must be re-
placed immediately. Likewise, the brakes must be replaced in case of a decrease of the braking effi-
ciency.

R 914 C / R 924 C 11.71.3

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Travel brakes Service Manual
Repair of the multi-disc brake in the travel gear

3.1 Preliminary

Note!
Repair of the brakes can be undertaken without having to dismantle the gear.

Drain the oil of the travel gear.

Remove the hydraulic motor 95 (see subgroup 11.40).
Take the discs carrier 65 off from the drive shaft 40.

3.2 Travel gears FAT with construction line P(b)

3.2.1 Removal

Fig. 4 Removal and installation of the discs brake - FAT Gear of construction line P(b)

Caution!
Spring tension is being applied to the end ring 70.4 and to the brake piston 70.3.

Push the end ring 70.4 downwards using the compression tool 129 (see subgroup 2.17) and two
screws 96 (for example fastening screws for hydraulic motor 95).
Extract the snap ring 70.10, loosen and remove the compression tool 129.
Lift out the end ring 70.4 and the brake piston piston 70.3 complete with pressure springs 70.17 /

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Service Manual Travel brakes
Repair of the multi-disc brake in the travel gear

70.19 from the gear and remove the grooved rings 70.14 and 70.15 (with supporting rings ) from
the connection housing 1.
Remove the brake discs 70.7 / 70.8 (as necessary also the upper compression ring 70.5) and the
lower compression ring 70.5 from the internal toothing of the connection housing 1.

3.2.2 Installation

Note!
Clean all used parts prior to re-assembly and check them thoroughly for reusability.

Insert the lower compression ring 70.5 in the internal toothing of the connection housing 1 and
insert the outer and inner discs 70.7 / 70.8 one after the other as follows:
Outer disc - inner disc - outer disc, and so on.
As necessary, install the front compression ring 70.5 onto the last outer disc 70.7.
Apply a light coating of grease to the the grooved rings 70.14 and 70.15 and insert them with sup-
porting rings into the connection housing 1.

Note!
Fit the supporting rings on the opposite side of the pressure.

Insert the pressure springs 70.17 / 70.19 and push the complete ring piston 70.3 into the groove
of the connection housing 1.
Push the discs carrier 65 into the toothing of the drive shaft 40 and the inner toothing of the inner
discs 70.8.
Insert the end ring 70.4 and push down the brake piston 70.3 using the compression device 129
(see subgroup no. 2.17).
Squeeze in the snap ring 70.10 (ensure correct seating) and remove the compression device 129.

3.3 Travel gears FAT with construction line P(r)

3.3.1 Removal of the multi discs brake 70 complete

R 914 C / R 924 C 11.71.5

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Travel brakes Service Manual
Repair of the multi-disc brake in the travel gear

As necessary, remove the adapting flange 80 for the hydraulic motor 95.

Remove the O-ring 81 from the adapting flange 80 and the O-ring 83 out of the chamfering at the
port for brake contol pressure in the adapting flange 1.
Extract the multi-discs brake 70 complete out of the adapting flange 1 using two threaded rods
screwed into the both extraction holes of the brake housing.

Fig. 5 Removal and installation of the discs brake - FAT Gear of construction line P(r)

3.3.2 Repair of the multi discs brake 70

3.3.3 Installation of the multi discs brake 70 complete

Insert the O-rings 71 at the outer diameter of the brake housing 70.1 and lightly oil the O-Rings.
Fit the multi-discs brake 70 with two threaded rods and insert the discs brake 70 complete into
the connection housing 1 ein. Pay attention that the opening for brake control pressure at the outer
diameter of brake housing and the one in the connection housing coincide.
Coat the socket head screws 72 with screw locking paste Loctite 243, insert the screws 72 and
tighten them to the prescribed torque.
As necessary, reinstall the adapting flange 80 for the hydraulic motor 95.
• insert the O-ring 81 in the motor flange 80 and lightly oil the O-Ring.
• coat the contact surface «S» of the connection housing 1 with surface sealing paste Loctite 573.
• lift up the adapting flange 80 using an adequate lifting device and lower it down to the adapting
flange 1.
• Insert the socket head screws 82 and tighten them to the prescribed torque.

3.4 Travel gears FAT with construction line A

3.5 Return into operation of the FAT Gear

As necessary, push the discs carrier 65 into the toothing of the drive shaft 40 and of the inner

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Service Manual Travel brakes
Repair of the multi-disc brake in the travel gear

discs 70.8.
Replace the O-ring 97 on the hydraulic motor 95. Apply a light coating of grease to the O-ring prior
to installing.
Reinstall the hydraulic motor 95 into the gear (see subgroup 11.40).
Refill the travel gear with gear oil.
Actuate the travel function and check the gear for leaks in the area of the hydraulic motor and af-
terwards ensure proper functioning of the brake.

R 914 C / R 924 C 11.71.7

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Travel brakes Service Manual
Repair of the multi-disc brake in the travel gear

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Service Manual Slipring seals
Handling and installation instructions for slipring seals

11.75: Slipring seals

1 Handling and installation instructions for slipring seals

The slipring seals have been developped to ensure a lasting tightness on components having to sup-
port very heavy loads, exposed to severe abrasive and corrosive conditions (sand, mud, water, ...)
and at relative low rotation speeds.
The slipring seals are thus particularly well adapted to guarantee the sealing of the components of
the tracks of our hydraulic excavators.

A slipring seal consists of two metallic sliding rings 4, which have the same geometric contour and
are flexibly supported in elastomeric rings 3
The seal is assembled so that one of the metallic rings is rotating and the other is mounted stationary.
The relative movement between the rotating part and the immobile part takes place at the lapped con-
tact face 1 between the both sliding rings 4.
There is no relative movement in the area of the elastomeric ring 3.
The tightness is permitted by the axial forces exerted by the elastomeric rings 3 due to their compres-
sion in the housing parts 9 at the installation.
The sliding contact face 1 is lubricated in permanence thanks to the oil contained inside the housing
of the sealed component, the inflow of oil is improved by the wedge shaped gap created by the as-
sembly of the conically designed contact faces 2 of the sliding rings 4.
Depending on constructive features, the section of the elastomeric rings 3 can be either circular (seal
with toric sealing elastomeric rings, see figure above) or have a trapezoid shape (seal with trapezoi-
dal elastomeric rings, see figure 2).

2 Installation instructions for slipring seals

Warning!
Slipring seals are precision components made out of chilled cast iron. Therefore sharp knocks and
blows should be avoided!

Do not remove slipring seals from protective packing until they are ready to be used. Protect the
polished seal faces 1 from damage and dirt.

Slipring seals are delivered wrapped per pair since the both halfseals have been lapped together.
New slipring seals must always be installed per pair, as wrapped.

The seal housings 9 (receiver parts) must be clean and free of burrs and machining residues. AlI
edges in the housing bore must be smooth and chamfered.
When ever possible, always employ a special installation tool 10 to insert slipring seals with toric
rings into their seat in the receiver parts 9.
The installation tool consists of two half shells that are closed around the sliding ring 4 and push

R 914 C / R 924 C 11.75.1

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Slipring seals Service Manual
Installation instructions for slipring seals

the elastomeric ring 3 back from the metallic ring 4.

Employing the tool allows to apply the force necessary for seal installation evenly around the cir-
cumference of the elastomeric ring 3.

Note!
For easier assembly, moisten the bore in the housing and the elastomeric ring 3 with a 1 :1 mixture
of water and spirit.

Fig. 1 Slipring seal with toric elastomeric rings

Fig. 2 Slipring seal with trapezoidal sealing rings

1 Sliding contact face 2 Conicaly designed face of the sliding ring

3 Elastomeric ring (trapezoïdal or toric) 4 Sliding ring
5 Radius of mounting chamber 6 Installation bewel
7 Diameter of the bore 8 Housing face
9 Housing parts 10 Installation tool

Press the slipring seal into the housing, taking care that the elastomeric ring 3 is inserted evenly
in the seat of the housing part 9.
Check that afterwards, the contact face 1 lies parallel with the housing surface 8 of the receiver
part. As necessary, measure the distance A at three points evenly positioned around the slipring
circumference (see fig. 3) to verify the correct installation.

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Service Manual Slipring seals
Installation instructions for slipring seals

After installation, the elastomeric rings 3 must not sit wave-like in the housing bore or bulge partially
looped out of the bore (fig. 4).

Fig. 3 Correct positionning of slipring seals

Note!
In case no special installation tool is available, it is possible, for slipring seals with toric elastomeric
rings and of smaller dimensions, to wind a thick string or a rope around the sliding ring 4 to push the
elastomeric ring 3 aside during the ring installation.
These procedure is not adapted to the slipring seals of greater dimensions, for example those
mounted inside our travel gears type FAT.

Before assembling the slipring seals, apply a thin oil film to the seal faces 1, using a soaked cham-
ois leather cloth. Take special care to do not apply oil to the elastomeric rings or to the housing
bores.

R 914 C / R 924 C 11.75.3

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Installation instructions for slipring seals

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Service Manual

Group 12: Track components

Track components of crawler excavators..........................................................................12.10

List of the track components on R 914C - R 924C ............................................................12.20

1 R 914C from serial number 19527. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.20.1
2 R 924C from serial number 19846. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.20.2

Wear on the track components ...........................................................................................12.30

1 Generalities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.30.1
2 Wear on the track chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.30.2
2.1 Chain links wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.30.2
2.2 Chain bolts and chain bushings wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.30.2
2.3 Track pads wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.30.3
3 Wear on the track rollers (running rollers) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.30.4
4 Wear on the carrier rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.30.4
5 Wear on the guide wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.30.4
6 Wear on sprockets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.30.5
6.1 Sprockets with simple teeth. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.30.5
6.2 Sprockets with double teeth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.30.5

Wear limits for chains ..........................................................................................................12.32

Wear limits for rollers...........................................................................................................12.35

Wear limits for guide & sprocket wheels ...........................................................................12.38

Dismantling and installing track components...................................................................12.40

1 Dismantling and installing the carrier roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.40.1
2 Removal & installation the guide wheel with grease tensioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.40.2
3 Dismantling and installing the track roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.40.2
4 Dismantling the complete chain. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.40.3
4.1 Relieving tension in the chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.40.3
4.2 Dismantling the chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.40.4
5 Mounting the complete chain. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.40.4
5.1 Re-tensioning the chain (see Fig. 5 on page4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.40.4
5.2 Checking chain tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.40.5
6 Replacing damaged track pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.40.5
7 Repairing a damaged chain. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.40.6
8 Dismantling the end pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.40.7
9 Mounting the end pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.40.7

Tension units - Technical data ............................................................................................12.52

1 One free spring tension unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.52.1
1.1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.52.1
1.2 Assembly drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.52.1

R 914 C / R 924 C 12.00.1

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Tension unit with single spring loose................................................................................ 12.56

1 Removal and installation of the complete unit (with tension spring) . . . . . . . . . . . . . . . . . . . . . . . . . 12.56.1
1.1 Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.56.1
1.2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.56.2

Grease tensioner and guide wheel unit ............................................................................. 12.58

1 Removal and installation of guide wheel with grease tensioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.58.1
2 Disassembly and assembly of the guide wheel unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.58.1
2.1 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.58.1
2.2 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.58.1
2.3 Refilling the guide wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.58.2
3 Disassembly and assembly of the grease tensioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.58.3
3.1 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.58.3
3.2 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.58.3

Track roller ........................................................................................................................... 12.70

1 Disassembly of the track roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.70.1
2 Assembly of the track roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.70.2
3 Refilling the track roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.70.3

Carrier roller (supported on one side) ............................................................................... 12.75

1 Dismantling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.75.1
2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.75.1
3 Refilling the carrier roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.75.1

Slipring seals........................................................................................................................ 12.80

1 Handling and installation instructions for slipring seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.80.1
2 Installation instructions for slipring seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.80.1

12.00Wednesday,
.2 R 914 C / R 924 C
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Service Manual Track components of crawler excavators

Group 12: Track components

12.10: Track components of crawler excavators

Fig. 1 Arrangement of the track components

1 Undercarriage welding structure

1.1 Undercarriage central piece 1.2 Side frame right
1.3 Side frame left
Depending on the execution of the undercarriage, the side frames 1.2 and 1.3 are either
bolted to the central piece 1.1 (i. e. removable), welded to the central piece (i. e. not remov-
able), or bedded in the central piece (i. e. adjustable).

10 Hydraulic rotary connection

20 Travel drive complete

R 914 C / R 924 C 12.10.1

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Track components of crawler excavators Service Manual

21 Travel gear 22 Sprocket wheel

23 Travel motor 24 Hydraulic travel brake valve

30 Chain complete
30.2 Track pad 30.3 Mounting bolt for track pad
30.4 Track pad nut
31 Chain complete without pads 31.1 Chain link

40 Chaine guide 41 Mounting bolt for chain guide

50 Track roller 52 Mounting bolt for track roller

55 Carrier roller 56 Mounting bolt for carrier roller

60 Chain tension unit complete

2 Guide wheel (or idler wheel) 3 Grease tensioner
6 Cover for grease tensioner 13 Grease fitting
15 Spring locking plate 16 Closing cover
63 Mounting bolt for guide wheel 67 Loose mounted spring
68 Intermediate sliding piece (spring plate)

Fig. 2 Undercarriage with removable side frames (bolted to the central part)

Fig. 3 Undercarriage with adjustable width (side frames sliding and adjustable to central piece)

12.10Wednesday,
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Service Manual List of the track components on R 914C - R 924C
R 914C from serial number 19527

12.20: List of the track components on R 914C - R 924C

1 R 914C from serial number 19527

Machine types 1062 1063 1064 1065

Chains
1 Chains with design size B60
- Chain B60L - Titan KN 461 19527 No
23398
Number of links / chain 50 -
Number of grousers per pad 3 -
Track pads bolts: ident 7369630 -
- Thread size / Quality M18 x 1,5 / 12.9 -
- Tightening torque N.m 570 -
ft.lbs 420 -
- Wrench size mm 24
- Chain B60 - Berco KM2561 23755 No
Number of links / chain 50 -
Number of grousers per pad 3 -
Track pads bolts: ident 10017415 -
- Thread size / Quality M20 x 1,5 / 12.9 -
- Tightening torque N.m 800 -
ft.lbs 590 -
- Wrench size mm 27 -
2 Chains with design size D6C
- Chain D6C - Berco LH1348 Reinforced execution by request 19527
Number of links / chain 47 44
Number of grousers per pad 3
Track pads bolts: ident 7001689

- Tightening torque N.m 675

ft.lbs 500
)
Rollers
Track rollers ident 5601369
- Type D6 - Berco KL18C
- Number of roller per chain 8 7
- Oil quantity per roller cm3 380
- Oil quality SAE 40
Carrier rollers id 10003861
- Type B60 - Berco LH1497
- Number of roller per chain 2
- Oil quantity per roller cm3 220

R 914 C / R 924 C 12.20.1

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List of the track components on R 914C - R 924C Service Manual
R 924C from serial number 19846

Machine types 1062 1063 1064 1065

- Oil quality 90% AGIP ROTRA LSX 75W90
10% AGIP ROCOL ASO/R90-140HT
Idler wheel ident 10009658
- Type B60
- Outer diameter mm 506
inch 19,9
- Oil quantity cm3 330
- Oil quality SAE 40
- Idler wheel weight kg 139
Grease tensioner unit Typ 43 409 1100
- Piston diameter mm 100
- Länge des Spanners maxi / mini mm 340 / 500
- Weight of tensioner kg 61
Spiral spring tensioner unit
execution as
- spring assembly complete -
- single spring loose B60
- dual springs loose -
Total weight of spring tensioner unit kg 109

2 R 924C from serial number 19846

1066
Machine types 1067 1069 1136 1174
1068
Chains
3 Chains with design size B60
- Chains B60L - Titan KN 461 19846 No No No
23261
Number of links / chain 51 - - -
Number of grousers per pad 3 - - -
Track pads bolts: ident 7369630 - - -
- Thread size / Quality M18 x 1,5 - - -
/ 12.9
- Tightening torque N.m 570 - - -
ft.lbs 420 - - -
- Wrench size mm 24 - - -
- Chain B60 - Berco KM2561 23836 19846 21939 No
- Chain B60 - Berco KM782 No 24187
Number of links / chain 51 54
Number of grousers per pad 3 3
Track pads bolts: ident 10017415 7366657

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Service Manual List of the track components on R 914C - R 924C
R 924C from serial number 19846

1066
Machine types 1067 1069 1136 1174
1068
- Thread size / Quality M20 x 1,5 / 12.9
- Tightening torque N.m 800
ft.lbs 590
- Wrench size mm 27
4 Chains with design size D6C
- Chains D6C - Berco LH1348 Reinforced execution No
by request
Number of links / chain 48 -
Number of grousers per pad 3 -
Track pads bolts: ident 7001689 -

- Tightening torque N.m 675 -

ft.lbs 500 -
) -
Rollers
Track rollers ident 5601369
- Type D6 - Berco KL18C
- Number of roller per chain 9 10
- Oil quantity per roller cm3 380
- Oil quality SAE 40
Carrier rollers id 10003861 5617779
- Type B60 - Berco LH1497 D6
- Number of roller per chain 2 3
3
- Oil quantity per roller cm 220
- Oil quality 90% AGIP ROTRA LSX 75W90
10% AGIP ROCOL ASO/R90-140HT
Idler wheel ident 10009658 10009659 10009658
- Type B60L B60 B60L
- diameter mm 506 570 506
inch 19,9 22,45 19,9
- Oil quantity cm3 330 330 330
- Oil quality SAE 40 SAE 40 SAE 40
- Idler wheel weight kg 139 155 139
Grease tensioner unit Typ 43 409 1100 43 404 1100
- Piston diameter mm 100
- Lenght of tensioner maxi / mini mm 340 / 500
- Weight of tensioner kg 61 59
Spiral spring tensioner unit
execution as
- spring assembly complete -
- single spring loose B60

R 914 C / R 924 C 12.20.3

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List of the track components on R 914C - R 924C Service Manual
R 924C from serial number 19846

1066
Machine types 1067 1069 1136 1174
1068
- dual springs loose -
Total weight of spring tensioner unit kg 109 111

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Service Manual Wear on the track components
Generalities

12.30: Wear on the track components

1 Generalities
Each time when track components are in movement and come each other into contact, or come into
contact with the soil, they are subject to wear, due to the important loads and stresses and to the
abrasive working environment (ground, stones, sand, ...).
Improper travelling and manoeuvring (e.g. sudden turning, uneven loads, incorrect crossing of obsta-
cles, ...) results in significantly increased wear.

Note !
Observe the following basic rules during operation of your excavator in order to minimize the
wear of the track components.

sliding surfaces.
ystem of the excavator must be at the rear.
l direction using the backhoe bucket, for exam-
ple when digging a channel, move the excavator in reverse direction and work with the digging
tool over the idler.

cket or with a front shovel, ensure that the

excavator is not elevated or tipped to extremes.

At regular intervalls perform with the required precision the thereafter described measurement at
the track components so to evaluate their exact degree of wear and to be able to determine the
economically relevant moment for the replacement of the parts.

Hinweis !
The measurements should always be, if possible, repeated at various locations, for example at the
idler wheel, or on several parts, for example on the chain links, or the bushings. Always consider
the maximum measured wear as the wear value for the part.

Worn chassis parts such as chain links, track pads, running rollers, carrier rollers, guide and sprocket
wheels, must be replaced with new parts as soon as the wear limits specified on the following pages
are reached.
The degree of wear is determined by comparing the measured dimension (actual value) with the cor-
responding dimension of the new part (nominal value) and the indicated wear limit for the part (see
the subgroups «wear limits», thereafter).

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Wear on the track components Service Manual
Wear on the track chains

2 Wear on the track chains

2.1 Chain links wear

Measure on several links HCL Height of Chain Link between track pad and wearing surface, using
a depth gauge .
Compare the maximum measured value HCL (= actual value) with
HCL(n) = Height of Chain Link in new condition, and
HCL(w) = Height of Chain Link at wear limit,
determine the resulting degree of wear of the chain links as indicated in following example:
HCL (n) =126 mm
HCL (w) =116 mm
HCL = 120 mm
Degree of wear = ( HCL (n) - HCL ) / ( HCL (n) - HCL (w) ) = (126 - 120) / (126 - 116) = 60%.

Note !
For all the measurements for track components wear described thereafter in this subgroup, the de-
gree of wear is determined as explained in the example above, this means it is calculated by inter-
polation of the measured value (actual value) between the value in new condition and the value at
wear limit.
The values in new condition and at wear limit are to be taken from the «Wear limit charts» in the
following pages.

2.2 Chain bolts and chain bushings wear

The inner wear at bushings and bolts as well the wear at the wearing surface of the chain links lead
to an increasing of the chain pitch. As a result, the sprocket wheel and the bushings fail to engage
properly, so that there is increased wear at the inner and outer surfaces of the bushings as well as at
the engaging surfaces of the sprocket wheel.
The wear of the chain can be appreciated on two different manners:
Measuring the chain pitch (inner wear):

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Service Manual Wear on the track components
Wear on the track chains

Measure L4L lenght of 4 links, at different locations of the tightly tensioned chain, and determine
the average value of the measurement.
Compare the average measured value L4L (= actual value) with
L4L(n) = lenght of 4 links in new condition, and
L4L (w) = lenght of 4 links at wear limit,
determine the resulting degree of inner wear of the track bolts and bushings.
Measuring the bushings (outer wear):
Measure DBU diameter of bushing on several bushings, using a calliper gauge and at point of
maximum wear.
Compare the measured value DBU (= actual value) with
DBU(n) = diameter of bushing in new condition, and
DDU (w) = diameter of bushing at wear limit,
determine the resulting degree of wear of the track bushings.
The effect of internal wear can be considerably reduced by turning the bolts and bushings by 180
degrees.
The right moment the bolts and bushings are to be turned is reached when:

4L - L4L(n)
BU(n) - DBU

Note !
When the wear per bolt and bore ( L4L - L4L(n) ) / 4 reaches approx. 5 mm, the bolts and bushings
must be replaced.

2.3 Track pads wear

Measure HTG height of track grousers on several track pads, using a depth gauge and evaluate
the average value of the measurement.
Compare the average measured value HTG (= actual value) with
HTG(n) = height of track grousers in new condition, and

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Wear on the track components Service Manual
Wear on the track rollers (running rollers)

HTG (w) = height of track grousers at wear limit,

and determine the resulting degree of wear of the track grousers.

3 Wear on the track rollers (running rollers)

Measure DTR diameter of track roller in the area of the wearing surface, using a calliper gauge.
Compare the measured value DTR (= actual value) with
DTR(n) = diameter of track roller in new condition, and
DTR (w) = diameter of track roller at wear limit,
and determine the resulting degree of wear of the track roller.

4 Wear on the carrier rollers

Measure DCR diameter of carrier roller in the area of the wearing surface, using a calliper gauge.
Compare the measured value DCR (= actual value) with
DCR(n) = diameter of carrier roller in new condition, and
DCR (w) = diameter of carrier roller at wear limit,
and determine the resulting degree of wear of the carrier roller.

5 Wear on the guide wheels

Measure DIW difference at guide wheel between wearing surface and outer diameter, using a
depth gauge at several points and evaluate the average value of the measurement.
Compare the average measured value DIW (= actual value) with

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Service Manual Wear on the track components
Wear on sprockets

DIW(n) = difference at guide wheel in new condition, and

DIW (w) = difference at guide wheel at wear limit,
and determine the resulting degree of wear of the idler wheel.

6 Wear on sprockets
Sprocket tooth wear results from tooth mesh and friction with chain bushings. Signs of wear on
sprockets are associated with wear at the outer surfaces of the bushings and the wear areas and im-
pact on both components are therefore similar.

6.1 Sprockets with simple teeth

For this shape of sprocket teeth, the evolution of the tooth contact pattern starting from the tooth base
is used as a reference parameter for visual wear inspection.

Fig. 1 Wear on tooth flanks

Sprockets can still be used as far as the contact area re
the tooth tips.

Fig. 2 Wear on tooth tips

Replace the sprocket as soon as possible when the wear has reached the tooth tips.

6.2 Sprockets with double teeth

For this shape of sprocket teeth, the teeth wear condition is determined through comparing the worn
teeth shape with the unused teeth shape. To do so, a template with the shape of a new sprocket is
placed on the sprocket to be checked, between two teeth, and the maximum gap between template
and worn tooth flanks is determined.

Fig. 3 Evaluation of wear condition using a template

R 914 C / R 924 C 12.30.5

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Wear on the track components Service Manual
Wear on sprockets

Center the template over two tooth tips and measure the gap GSW at different locations and for
at least two tooth flanks.
Compare the maximum measured gap GSW (= actual value) with
GSW(n) = gap between template and teeth flank in new condition, and
GSW (w) = gap between template and teeth flank at wear limit,
and determine the resulting degree of wear of the sprocket.

Note !
For most of the templates, the gap GSW(n) is equal to zero.
When the GSW(n) gap is different from zero , the GSW(n) value is indicated on the original Liebherr
template as «OFFSET X mm».

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Service Manual Wear limits for chains

12.32: Wear limits for chains

Value in
Max value Measured
Chain links Type new
at wear limit value
condition
Measure HCL - Height of chain link HCL (n) HCL (w) HCL
mm / inch mm / inch mm / inch
B60L Intertrac 105 / 4.13 97 / 3.82
......... / .........
KN 461
B60 Berco 105 / 4.13 97 / 3.82
......... / .........
KM 3807
B60 Linser 105 / 4.13 97 / 3.82
......... / .........
702076
B60 Berco
- KM 2561 106 / 4.17 98 / 3.85 ......... / .........
- KM 782
D6C Berco 121.5 / 4.78 110 / 4.33
......... / .........
LH 1348
B6 HD Intertrac 117,5 / 4.62 107 / 4.21
......... / .........
FW 2208
D7 Intertrac 117,5 / 4.62 107 / 4.21
......... / .........
E49446
D7 Berco 117,5 / 4.62 107 / 4.21
......... / .........
LH 1349
D7G Berco 126 / 114 /
......... / .........
SI 873A
D7G Berco 126 / 114 /
......... / .........
LH 1273
B7-HD Intertrac 129 / 5.08 120 / 4.72
......... / .........
83576H
D8K Berco 138 / 5.43 125 / 4.92
......... / .........
LH 1154
B9 HD-S 156 / 6.14 144.5 / 5.69
......... / .........
Intertrac
D9G Berco
- CR 4885A 155.5 / 6.12 144.5 / 5.69 ......... / .........
- LH 1352

12.32.1
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Wear limits for chains Service Manual

Value in
Max value Measured
Chain pins Type new
at wear limit value
condition
Measure L4L - Length of 4 links L4L (n) L4L (w) L4L
mm / inch mm / inch mm / inch
B60L Intertrac 760 / 29.90 780 / 30.70
......... / .........
KN 461
B60 Berco 760 / 29.90 780 / 30.70
......... / .........
KM 3807
B60 Linser 760 / 29.90 780 / 30.70
......... / .........
702076
B60 Berco
- KM 2561 760 / 29.90 774 / 30.50 ......... / .........
- KM 782
D6C Berco 814 / 32.05 827 / 32.55
......... / .........
LH 1348
B6 HD Intertrac 811 / 31.95 832 / 32.75
......... / .........
FW 2208
D7 Intertrac 811 / 31.95 832 / 32.75
......... / .........
E49446
D7 Berco 814 / 32.05 827 / 32.55
......... / .........
LH 1349
D7G Berco 4
......... / .........
SI 873A
D7G Berco 4
......... / .........
LH 1273
B7-HD Intertrac 864 / 34.0 884 / 34.80
......... / .........
83576H
D8K Berco 916 / 36.05 929 / 36.60
......... / .........
LH 1154
B9 HD-S 1042 / 41.05 1062 / 41.80
......... / .........
Intertrac
D9G Berco
- CR 4885A 1042 / 41.05 1062 / 41.80 ......... / .........
- LH 1352

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Service Manual Wear limits for chains

Value in
Max value Measured
Chain bushings Type new
at wear limit value
condition
Measure DBU - Diameter of bushing DBU (n) DBU (w) DBU
mm / inch mm / inch mm / inch
B60L Intertrac 58.8 / 2.31 48.8 / 1.92
......... / .........
KN 461
B60 Berco 60.0 / 2.61 54.6 / 2.15
......... / .........

B60 Linser 59.0 / 2.32 53.3 / 2.10

......... / .........

D6C Berco 66.5 / 2.61 61.4 / 2.41

......... / .........

B6 HD Intertrac 66.6 / 2.62 57 / 2.24

......... / .........

D7 Intertrac 66.6 / 2.62 57 / 2.24

......... / .........

D7 Berco 66.6 / 2.62 57 / 2.24

......... / .........

D7G Berco 71.4 / 2.81 66.5 / 2.61

......... / .........

B7-HD Intertrac 71.4 / 2.81 66.5 / 2.61

......... / .........

D8K Berco 76.0 / 2.99 73.8 / 2.90

......... / .........

B9 HD-S 85.7 / 3.37 80.0 / 3.15

......... / .........
Intertrac
D9G Berco 85.7 / 3.37 80.0 / 3.15
......... / .........

12.32.3
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Wear limits for chains Service Manual

Value in
Max value Measured
Track pads Type new
at wear limit value
condition
Measure HTG - Height of pads grousers HTG (n) HTG (w) HTG
mm / inch mm / inch mm / inch
B60L Intertrac 30 / 1.18 12 / 0.47
......... / .........
KN 461
B60 Berco 26 / 1.02 12 / 0.47
......... / .........

B60 Linser 26 / 1.02 12 / 0.47

......... / .........
702076
D55 Berco 28 / 1.10 12 / 0.47
......... / .........

D7 Intertrac 26.5 / 1.04 107 / 4.21

......... / .........
E49446
D7G Berco
SI 873A _ _ ......... / .........
(10813758)

B6 HD Intertrac 42.5/ 1.67 12 / 0.47

......... / .........

D6C Berco 42.5/ 1.67 12 / 0.47

......... / .........

D7G Berco 49.5 / 1.95 22.5/ 0.89

......... / .........

B7-HD Intertrac 49.5 / 1.95 22.5/ 0.89

......... / .........

D8K Berco 46 / 1.81 14 / 0.55

......... / .........

B9 HD-S 49.5 / 1.95 25.5 / 1.0

......... / .........
Intertrac
D9G Berco 52 / 2.05 25.5 / 1.0
......... / .........

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Service Manual Wear limits for chains

Identification of the chain size

In case of a doubt concerning the size of the chains mounted on your machine, You can measure the
distances between the track pads fixing bolts and identify the chain size using the chart below.

Chain Size K (mm) K (inch) C1 (mm) C2 (mm) L1 (mm)

B60 - B60L 190 - 124,4 160,4 62

D6C 202,8 8.0 116,9 155 76,2
B6HD 202,8 8.0 116,9 155 76,2
D7 202,8 8.0 146,05 184,1 76,2
D7G - B7HD 215,9 8.5 146,05 184,1 76,2
D8L 228,6 9.0 149,20 200 76,2
D8K 228,6 9.0 169,86 215,6 75
D9G 260,35 10.25 184,15 235 76,2
BMP 280 280 - 168 241,6 79,5

R 914 C / R 924 C 12.32.5

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Service Manual Wear limits for rollers

12.35: Wear limits for rollers

Value in
Max value Measured
Track rollers Type new
at wear limit value
condition
Measure DTR - Diameter of track roller DTR (n) DTR (w) DTR
mm / inch mm / inch mm / inch
D6 Berco 154 / 6.06 141 / 5.55
......... / .........
KL 18C
B60 Berco 154 / 6.06 141 / 5.55
......... / .........
KL 18D
B60 Berco 156/ 6.15 142 / 5.60
......... / .........
KL 24
B60 Linser 160 / 6.30 144 / 5.65
......... / .........
745021
B6 Intertrac 168 / 6.60 152 / 6.00
......... / .........
A14060E
D7 Intertrac 172 / 6.75 156 / 6.15
......... / .........
A14060H
D7F Berco 185 / 7.30 168 / 6.60
......... / .........
LH 2521
D8K Berco 220 / 8.65 199 / 7.85
......... / .........
LH 2309
B8-HD Intertrac 250 / 9.85 220 / 8.65
......... / .........
A14060H
D8H-B9S Berco 250 / 9.85 220 / 8.65
......... / .........
LH 1593
D9G Berco 260 / 10.25 238 / 9.35
......... / .........
CR 6378
Berco 270 / 10.65 254 / 10.0
......... / .........
LH 1575

12.35.1
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Wear limits for rollers Service Manual

Value in
Max value Measured
Carrier rollers (bearing on one side) Type new
at wear limit value
condition
Measure DCR - Diameter of carrier roller DCR (n) DCR (w) DCR
mm / inch mm / inch mm / inch
B60 Linser 120 / 4.70 108 / 4.25
......... / .........
748006
B60 Berco 120 / 4.70 108 / 4.25
......... / .........
LH 1497
B60 Berco 120 / 4.70 108 / 4.40
......... / .........
LH 1461
D6 Berco _/_ _/_
......... / .........
FT 2772
D7 Intertrac 160 / 6.30 145/
......... / .........
49290
D7 Berco 160 / 6.30 142 / 5.60
......... / .........
FT 2990
D7F Berco 160 / 6.30 142 / 5.60
......... / .........
SI 1137
D7 Intertrac 170 / 157 /
......... / .........
14070B
D7 Intertrac 180 / 164 /
......... / .........
C 14070
D8K Berco 191 / 171,5 /
......... / .........
CR 3512

Value in
Max value Measured
Carrier rollers (bearing on both sides) Type new
at wear limit value
condition
Measure DCR - Diameter of carrier roller DCR (n) DCR (w) DCR
mm / inch mm / inch mm / inch
D8K - Berco 160 / 6.30 142 / 5.60
......... / .........
LH 2471
D8K - Intertrac 165 / 6.50 148 / 5.85
......... / .........
C49540
D7 - Intertrac 200 / 7.90 185 / 7.25
......... / .........
C 14111 A
D9G - Berco 200 / 7.90 180 / 7.10
......... / .........
LH 2154

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Service Manual Wear limits for guide & sprocket wheels

12.38: Wear limits for guide & sprocket wheels

Value in
Max value Measured
Guide wheel Type new
at wear limit value
condition
Measure DIW - Difference of diameter of DIW (n) DIW (w) DIW
idler (or guide) wheel mm / inch mm / inch mm / inch
B60L Berco 20 / 0.79 28 / 1.10
......... / .........
LH 1134A
B60 Berco 20 / 0.79 28 / 1.10
LH 1135A ......... / .........

Berco 20 / 0.79 28 / 1.10

......... / .........
LH 1974
D7G / B7B Berco 22 / 0.87 31 / 1.20
......... / .........
LH 1137A
D7 / B6 Berco 22 / 0.87 31 / 1.20
LH 1136A ......... / .........

B6 Intertrac 25 / 0.98 34 / 1.34

......... / .........
PV 9444A
D8K Berco 24 / 0.94 34 / 1.34
......... / .........
LH 1447A
B9S Intertrac 30 / 1.18 40 / 1.57
......... / .........
PV 9744B
D9G Berco 24 / 0.94 34 / 1.34
......... / .........
LH 2472
D9G Berco 35 / 1.38 46 / 1.81
LH 1140A ......... / .........

Intertrac 35 / 1.38 46 / 1.81

......... / .........
PV 984 A0Y00

Value in
Max value Measured
Sprocket wheels with single teeth Type new
at wear limit value
condition
Measure Z - distance between wear pat- Z (n) Z (w) Z
tern and tip of the tooth mm / inch mm / inch mm / inch

All - 0 ....... / .......

(Wear pattern up to
tip of the tooth)

12.38.1
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Wear limits for guide & sprocket wheels Service Manual

Ordering Value in Max value

Measured
Sprocket wheels with double teeth Type Nb for new at wear
value
template condition limit

Measure GSW - Gap max. between GSW (n) GSW (w) GSW
template and sprocket wheel mm / inch mm / inch mm / inch
D8K
T228 - Z=12 _ 0 10 / 0.4 ...... / ......
43 524 1000 00 1..
D8K
- Z=12 _ 0 10 / 0.4 ...... / ......
Berco LH 999A
D9G
T260 - Z=13 _ 0 10 / 0.4 ...... / ......
43 535 1000 00 0..
D9G
- Z=11 _ 0 10 / 0.4 ...... / ......
Berco LH 2451
B9S
T260 - Z=11 _ 0 10 / 0.4 ...... / ......
43 533 1000 00 0..
9807009
T280 - Z=12 11075844 5 / 0.2 15 / 0.6 ...... / ......
43 545 1000 00 0..

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Service Manual Dismantling and installing track components
Dismantling and installing the carrier roller

12.40: Dismantling and installing track components

Fig. 1 Overview of travel gear parts

2 Idler unit 40 Caterpillar track 54 Hexagon head screw

3 Grease tensioner 41 Chain link 56 Hexagon head screw
4 Cover 42 End pin 59 Grease nipple
5 Cover 43 End ring 60 Seal
5 Locking block 44 End bushing 62 Complete side member
7 Hexagon head screw 45 Track pad 63 Travel gear transmis-
sion
38 Track roller 50 Cylinder head screw 67 Tensioning spring
39 Carrier roller 51 Square nut 68 Spring retainer

1 Dismantling and installing the carrier roller

Relieve tension in the chain 40
chain using a piece of wood clamped between upper edge of side member and chain.
Loosen the screws 56 and remove the carrier roller 39 from the side member.
Place the carrier roller 39 on the threaded holes on the side member and fit the screws 56. Re-
move the wood, align the carrier roller and tighten the screws 56.

R 914 C / R 924 C 12.40.1

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Dismantling and installing track components Service Manual
Removal & installation the guide wheel with grease tensioner

2 Removal & installation the guide wheel with grease tensioner

Note!
Removal and installation of the tensioning spring mounted behind the grease tensioner in the side
frame is not described in this section.
If the tensioning spring has to be removed too, so its tension must be separately released before
releasing the chain tension and opening the chain, see subgroup 12.56.
Likewise, when reinstalling the chain, the spring must first be tensioned and secured inside the side
frame before adjustment of the chain tension, see subgroup 12.56.

Fig. 2 Slide ring seal position

Dismantle the chain 40
Remove the idler 2, complete with grease tensioner 3 from the side member 62.
Disconnect the idler 2 from the grease tensioner 3.
For dismantling and mounting of the idler, see Subgroup 12.76.
For dismantling and mounting of the grease tensioner, see Subgroup 12.81.
Screw the idler 2 and the grease tensioner 3 together. Push the complete idler with grease ten-
sioner into the side member as far as they will go.
Mount the chain 40

3 Dismantling and installing the track roller

Dismantle the chain 40
Lift the corresponding side of the travel gear slightly by shoring up the side of the attachment.

Caution!
Stabilise the raised side between chain and lower edge of side member using wooden timbers.

Loosen the screws 54 and remove the track roller 38. Dismantling and mounting of the track roller,
see Subgroup 12.91.
Place the track roller 38 on the side member 62 and fasten with screws 54.
Lift the side of the machine and carefully remove the wooden timbers.
Mount the chain 40

12.40Wednesday,
.2 R 914 C / R 924 C
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Service Manual Dismantling and installing track components
Dismantling the complete chain

4 Dismantling the complete chain

Fig. 3 Position of chain links and track pads.

a1 Groove end pin a2 Knurled end pin a3 Running direction of

chain

4.1 Relieving tension in the chain

Fig. 4 Relieving tension in the chain - keep your hands away from part 3.

Danger!
Risk of injury as a result of sagging chain and spraying grease.
Due to the risk of grease squirting out (grease under pressure), it is imperative that protective
glasses and industrial gloves are worn when relieving tension in the chain.
When relieving tension in the chain, do not allow the head into too close a proximity of the side
member and under no circumstances touch the grease nipple extension or the grease nipple
through the opening with your hands. Loosen using a suitable tool!

R 914 C / R 924 C 12.40.3

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Dismantling and installing track components Service Manual
Mounting the complete chain

First, loosen and remove all bodies which are stuck in the chain, by manoeuvring backwards and
forwards for example, or as described in the paragraph "Cleaning the travel gear".
Position the machine stably on a level surface.
Unscrew the grease nipple extension 7 with 27mm width across flats around a few turns of thread
until grease is exuded from the longitudinal groove.

Danger!
Loosening of the grease nipple 3 with 22mm width across flats is strictly prohibited.

Tighten the grease nipple extension 7 again, as soon as the desired chain tension is attained.
Upon completion of the adjustment procedure, ensure flawless forwards and reverse travel of the
machine, as well as chain tension.

4.2 Dismantling the chain

The end pins are different from regular pins in that the face side of the end pin features a flare,
as well as a lug or chamfer
1

Note!
Only push in the knurled end pin from the outside of the chain inwards and from the inside of the
chain outwards. Groove end pins can be pushed out from either side.

Roll out the chain in the direction of travel.

Lift the excavator and pull the chain forwards.

5 Mounting the complete chain

Set the excavator down on the outstretched chain and insert chocks.
Pull the chain up over the idler and carrier rollers using tope or attachment, vehicle / lifting gear or
similar.
Observe the running direction of the chain and position of the track pads, (see Fig. 3 on page3).
Insert end rings 43 and end bushing 44, connect chain links and squeeze in the end pin 42 from

5.1 Re-tensioning the chain (see Fig. 5 on page4)

Fig. 5 Re-tensioning the chain - R904, R914, R924, R924 Compact

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Service Manual Dismantling and installing track components
Replacing damaged track pads

Remove the cover 6 on the side member of the undercarriage, where featured.
Screw the high-pressure hose 2 onto the manual grease gun 1.
Connect the high-pressure hose 2 with the grease nipple 3 of the grease tensioner 4 through the
opening 5.
Continue to squeeze in grease until the chain is sufficiently tensioned.
Check chain tension.

5.2 Checking chain tension

Fig. 6 Checking chain tension

Relieve tension in the chain by manoeuvring the machine backwards and forwards.
Place the levelling rule 1 between the carrier rollers
Measure the clearance A between the lower edge of the measuring rule.
In normal operating conditions, the chain should sag 15 to 20 mm between the carrier rollers.
Re-tension the chain as required.

6 Replacing damaged track pads

Caution!
Bent or loose track pads could cause subsequent damage to adjacent track pads and to the crawler
track.
The track pads must therefore be inspected every week, but at least every 50 operating hours, for
secure fastening.
Damaged track pads must be replaced.

Unscrew the fastening screws 50 and remove damaged track pads 45.
Clean the supporting surface on the chain link 41 and fit new track pad 45.
Screw in the fastening screws 50 and tighten crosswise with a torque wrench (see sequence 1, 2,
3, 4) to the prescribed tightening torque (see technical data of travel gear parts)

R 914 C / R 924 C 12.40.5

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Dismantling and installing track components Service Manual
Repairing a damaged chain

Fig. 7 Replacing track pads.

Tighten the screws crosswise

7 Repairing a damaged chain

Separate the chain completely from the broken chain link and set it down on the ground.
Burn through the chain segments, bushings and pins on the damaged chain link at the points in-
dicated.
Remove the fragmented chain parts.
Burn off the bushing 1A on the face side and grind smooth. Fire the pin stub 2B in the middle with
the burning equipment and strike out with the hammer.
Attach two chain segments 6 pressed together with end bushing 3 and one end pin 4 to the chain
link 2.

Mount the chain.

Insert two end rings 5 in the end segments 6 and close with end pins 4.

Fig. 8 Replacing track pads.

1 Complete chain link a1 Grind down X Hexagon head screw

2 Complete chain link a2 Direction of striking
3 End bushing a3 Retain

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Service Manual Dismantling and installing track components
Dismantling the end pin

4 End pin a4 Burn hole

5 End bushing ring b1 Breakage point
6 Chain segment b2 Cuts

8 Dismantling the end pin

inside of the chain out, or drive out using the device shown in the picture below.

either side.
In either case the chain link must be retained

9 Mounting the end pin

Insert rubber rings, chain end rings or snap rings or chain bushing in the chain end link and con-
nect the chain ends.

Caution!
Striking the hardened end pin 42 in or out using the sledgehammer is extremely hazardous for the
mechanic as material could splinter!
This procedure should therefore be carried out using a pin press or a suitable tool (see Fig. 9 on
page8).

Fit the end pin on the outside of the chain and squeeze in using the pin press

R 914 C / R 924 C 12.40.7

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Dismantling and installing track components Service Manual
Mounting the end pin

Fig. 9 Mounting and dismantling the end pin.

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.8 R 914 C / R 924 C
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Service Manual Tension units - Technical data
One free spring tension unit

12.52: Tension units - Technical data

Note!
The correspondence between the tension units and the corresponding excavator models and types
can be found in the subgroup «List of the track components» at the beginning of this group.

1 One free spring tension unit

1.1 Technical data

Spring tension unit - Size B60L D7 D7G D8K

Spring Ident. Nr. 7369109 7371495 7370910

Free length L0 mm 537 638 692

Wire daimeter ØS mm 58 58 64

Pretensioned length L1 mm 481 464 539 583

Preload F1 kN 169 220 250 320

Spring travel (L) mm 75 58 63 65

Pretension force max F2 (Blocking force) kN 396 408 511

Grease tensioner piston diameter ØP mm 100 125 125

1.2 Assembly drawing

R 914 C / R 924 C 12.52.1

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Tension units - Technical data Service Manual
One free spring tension unit

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Service Manual Tension unit with single spring loose
Removal and installation of the complete unit (with tension spring)

12.56: Tension unit with single spring loose

1 Removal and installation of the complete unit (with tension spring)

Note!
The procedure below describes the removal and the installation of the tension unit complete includ-
ing the pretension spring 67.
If only the grease tensioner 3 together with the guide 2 wheel has to be removed, proceed according
to the description «Removal & installation of the idler wheel with grease tensioner» in the the sub-
group «Removal and installation of track components», before in this group.

1.3 Sideframe left 2 Guide wheel unit

3 Grease tensioner 6 Lid to the grease tensioner
13 Grease nipple 15 Spring locking block
16 Mounting screw for spring locking block 67 Tensioning spring (mounted loose)
68 Intermediate sliding piece

1.1 Removal
Remove the access lid 6 from the side frame 1.3.
Connect the manual grease gun with the grease nipple 13 of the grease tensioner 3.
Inject grease (overtension the chain) until the intermediate sliding piece 68 (spring plate) is moved
aside the locking blocks 15.

R 914 C / R 924 C 12.56.1

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Tension unit with single spring loose Service Manual
Removal and installation of the complete unit (with tension spring)

Unscrew the mounting screws 16 and remove the locking blocks 15.

Caution!
Never loosen the screws 16 as long as the locking blocks 15 support the sliding piece 68.

Take the grease gun away from the grease nipple 13.
Remove the chain tension, see «Removal and installation of track components» before in this
group.
Open and roll off the chain.
Pull first the guide wheel 2 complete with the grease tensioner 3 out of the side frame 1.3, then
the sliding piece 68 and the tensioning spring 67.

1.2 Installation
Insert the tensioning spring 67 into the side frame 1.3 and center the spring onto the centering
tube 69 welded inside the side frame 1.3.
Slide the intermediate piece 68 (spring plate) into the side frame so that the spring 67 lays on the
centering shoulder of the piece 68.
Push the guide wheel assembly 2 complete with the grease tensioner 3 into the guiding rails of
the side frame 1.3.
Pull the chain up over the guide wheel and close it (see the heading «Removal and installation of
complete chain» before in this group).
Pump grease into the nipple 13 to tighten the chain, until the spring locking blocks 15 can be
mounted.

Insert the locking blocks 15 and secure them using the screws 16.
Remove the grease gun from the nipple 13.
Carefully unscrew the grease nipple 13 by several turns, and let grease escape, until the correct
chain tension is obtained, see also the headings «Retensioning the chain» and «Checking the
chain tension» before in this group.

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Service Manual Grease tensioner and guide wheel unit
Removal and installation of guide wheel with grease tensioner

12.58: Grease tensioner and guide wheel unit

1 Removal and installation of guide wheel with grease tensioner

See the corresponding heading in subgroup «Removal and installation of track components», before
in this group.

2 Disassembly and assembly of the guide wheel unit

2.1 Disassembly
Remove the tread plug 2.10 and drain the lubrication oil of the unit in an adequate container.
Knock out the roll pins 2.9 and take the guiding rails 2.8 away.
Remove the sealing rings 2.7 from the shaft 2.2.
Pull the shaft 2.2 out of the guide wheel 2.1.
Remove the slipring seals 2.5 from the guide wheel 2.1 and from the guiding rails 2.8.
Press the bushings 2.3 out of the guide wheel.

Fig. 1 Explosion view of the guide wheel

2 Guide wheel complete 2.1 Guide wheel

2.2 Shaft 2.3 Bushing
2.5 Slipring seal 2.7 Sealing ring
2.8 Guiding rail 2.9 Roll pin
2.10 Thread plug 2.11 O-ring

2.2 Assembly
Press the bushings 2.3 into the guide wheel 2.1.
Carefully install the slipring seals 2.5 into the guide wheel 2.1 and into the guiding rails 2.8.

Note !
The slipring seals are parts which are polished in pairs, never interchange the slipring seals, always
install them per pair, as wrapped.

R 914 C / R 924 C 12.58.1

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Grease tensioner and guide wheel unit Service Manual
Disassembly and assembly of the guide wheel unit

Install a new sealing ring 2.7, engage a guiding rail 2.8 onto the shaft 2.2 and install a roll pin 2.9.
Push the shaft 2.2 into the guide wheel 2.1.
Install the second sealing ring 2.7, engage the second guiding rail 2.8 onto the shaft 2.2 and install
the second roll pin 2.9.

2.3 Refilling the guide wheel

Turn the guide wheel so that the thread plug 2.10 is situated on top, and remove the thread plug.
Fill in the prescribed oil quantity into the guide wheel (For oil quality and quantity, refer to the con-
cerned subgroup «List of track components») at the begin of this group).

If the prescribed oil quantity cannot be filled in into the guide wheel:
Pressurize the middle area of the guide wheel with pressure air via the bore of the thread plug
2.10,
the lubrication oil is pressed towards the lateral areas of the shaft.
Complete the oil filling in of the wheel.
Screw in the thread plug 2.10 fitted with a new o-ring 2.11.

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Service Manual Grease tensioner and guide wheel unit
Disassembly and assembly of the grease tensioner

3 Disassembly and assembly of the grease tensioner

3.1 Disassembly
Screw the lubrication nippel 59 out of the body 3.3.
Pull the piston 3.2 out of the body 3.3.
Remove the scraper ring 3.4, the support ring 3.5 and the lip seal ring 3.6 from the piston 3.2.

Fig. 2 Grease tensioner

3 Grease tensioner complete 3.2 Piston

3.3 Tensioner body 3.4 Scraper ring
3.5 Support ring 3.6 Lip seal ring

3.2 Assembly
Install a new lip seal ring 3.6, a new support ring 3.5 and a new scraper ring 3.4 onto the piston 3.2.
Introduce the piston 3.2 into the tensioner body 3.3 and push it in to the stop.
Screw the lubrication nippel 59 fitted with a new sealing ring into the body 3.3.

R 914 C / R 924 C 12.58.3

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Grease tensioner and guide wheel unit Service Manual
Disassembly and assembly of the grease tensioner

12.58Wednesday,
.4 R 914 C / R 924 C
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Service Manual Track roller
Disassembly of the track roller

12.70: Track roller

1 Disassembly of the track roller

Remove the filling plug 8 and drain the lubrication oil of the roller in an adequate container.
Knock out the dowell pins 11 on both sides of the roller shaft 2 and take away both end pieces 3
from the shaft 2.
Take the slipring seals 7 out of the roller body 1 and out of the end pieces 3.
Remove the sealing rings 9 from the roller shaft 2, pull the shaft out of the roller body 1 and press
the collar bushing 5 out of the roller body 1.

Fig. 1 Track roller with toric elastomeric rings

R 914 C / R 924 C 12.70.1

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Track roller Service Manual
Assembly of the track roller

Fig. 2 Track roller with trapezoidal sealing rings

2 Assembly of the track roller

Press the collar bushing 5 into the roller body 1.
Insert the roller shaft 2 into the roller body 1 and install the sealing rings 9 into the grooves in the
roller shaft.
Install the slipring seals 7 into the roller body 1 and into the end pieces 3.

Mount the end pieces 3 onto the both ends of the roller shaft 2, paying attention that the bores for
the dowell pins 11 coïncide in the roller shaft and the end pieces.
Knock the dowell pins 11 into the end pieces 3 from the top (flat) side of the end pieces.
Check the axial play of the roller for easy movement. Apply about 6 bar (85 PSI) air pressure via
the filler hole to check the roller for leaks.

Fig. 3 Track roller - exploded view

1 Roller body 2 Roller shaft

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Service Manual Track roller
Refilling the track roller

3 End piece 5 Collar bushing

7 Slipring seals 8 Oil filling plug
9 Shaft sealing ring 11 Dowell pin
12 Trapezoid ring 13 Slipring
14 O-ring

3 Refilling the track roller

Fill in the prescribed oil quantity into the middle chamber of the roller. For oil quality and quantity,
refer to the concerned subgroup «List of track components») at the begin of this group.

If the prescribed oil quantity cannot be filled in into the roller:

Pressurize the middle area of the roller with pressure air via the bore of the filling plug 8.
the lubrication oil is pressed towards the lateral areas of the roller.
Complete the oil filling in of the roller.
Coat the filling plug 8 with Loctite and screw it in.

Notice!
The rollers having the filling plug 8 in one end piece 3 must preferably be filled before installation,
with the roller in vertical position .
To refill the rollers for which there is no indication of oil quantity, turn the roller, respect the roller
body 1 so that the filler hole is situated at 45° from the top, then fill oil in until it flows out of the filling
bore.

Fig. 4 Position of the roller when refilling oil without quantity indication

R 914 C / R 924 C 12.70.3

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Track roller Service Manual
Refilling the track roller

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Service Manual Carrier roller (supported on one side)
Dismantling

12.75: Carrier roller (supported on one side)

1 Dismantling
Remove the filling plug 8 and drain the oil.
Place the carrier roller with the end piece 3 (cover 19 facing upwards) in the vice.
Remove the screws 4 and then remove the cover 19.
Remove the O-ring 9.
Remove the Allen head screws 18 and remove the stop washer 17.
Pull the carrier roller body 1 with the bushings 5 and 6 and the slipring seals 7 from the shaft 2.
Remove the slipring seal 7 from the carrier roller body 1 and lift off the cap 10.
Press the bushings 5 and 6 from the carrier roller body 1.

Note!
The shaft 2 press-mounted into the end piece 3 and cannot be dismantled.

2 Installation
Press the bushings 5 and 6 into the carrier roller body 1.
Mount the seal 7 in the end cover and the carrier roller body 1.
Place and secure the carrier roller body 1 on the shaft 2.
Secure the retaining washer 17 with the Allen head screws 18 on the shaft 2.
Mount the O-ring 9 to the cover 19.
Press the cover 19 into the carrier roller body 1 and secure it with the screws 4.
Check axial play. Apply compressed air at approx. 6 bar to the carrier roller and check it for leak-
age.
Fill oil into the carrier roller, observing the filling instructions below.

3 Refilling the carrier roller

Fill in the prescribed oil quantity into the middle chamber of the roller. For oil quality and quantity,
refer to the concerned subgroup «List of track components») at the begin of this group.

If the prescribed oil quantity cannot be filled in into the roller:

Notice!
To refill the rollers for which there is no indication of oil quantity, turn the roller, respect the roller
body 1 so that the filler hole is situated at 45° from the top, then fill oil in until it flows out of the filling
bore.

R 914 C / R 924 C 12.75.1

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Carrier roller (supported on one side) Service Manual
Refilling the carrier roller

Fig. 1 Filling position of support roller

1 Track / Carrier roller body 8 Filling plug

2 Track / Carrier roller shaft 9 O-ring
3 End piece 15 Oil level
4 Hex head screws 17 Stop washer
5 Collar bushing 18 Allen head screws
6 Cylindrical bushing 19 Cover
7 Slipring seal

Fig. 2 Exploded view of the carrier roller

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Service Manual Carrier roller (supported on one side)
Refilling the carrier roller

Fig. 3 Sectional drawing of carrier roller

R 914 C / R 924 C 12.75.3

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Carrier roller (supported on one side) Service Manual
Refilling the carrier roller

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Service Manual Slipring seals
Handling and installation instructions for slipring seals

12.80: Slipring seals

1 Handling and installation instructions for slipring seals

2 Installation instructions for slipring seals

Warning!
Slipring seals are precision components made out of chilled cast iron. Therefore sharp knocks and
blows should be avoided!

Do not remove slipring seals from protective packing until they are ready to be used. Protect the
polished seal faces 1 from damage and dirt.

Slipring seals are delivered wrapped per pair since the both halfseals have been lapped together.
New slipring seals must always be installed per pair, as wrapped.

R 914 C / R 924 C 12.80.1

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Slipring seals Service Manual
Installation instructions for slipring seals

the elastomeric ring 3 back from the metallic ring 4.

Employing the tool allows to apply the force necessary for seal installation evenly around the cir-
cumference of the elastomeric ring 3.

Note!
For easier assembly, moisten the bore in the housing and the elastomeric ring 3 with a 1 :1 mixture
of water and spirit.

Fig. 1 Slipring seal with toric elastomeric rings

Fig. 2 Slipring seal with trapezoidal sealing rings

1 Sliding contact face 2 Conicaly designed face of the sliding ring

3 Elastomeric ring (trapezoïdal or toric) 4 Sliding ring
5 Radius of mounting chamber 6 Installation bewel
7 Diameter of the bore 8 Housing face
9 Housing parts 10 Installation tool

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Service Manual Slipring seals
Installation instructions for slipring seals

After installation, the elastomeric rings 3 must not sit wave-like in the housing bore or bulge partially
looped out of the bore (fig. 4).

Fig. 3 Correct positionning of slipring seals

R 914 C / R 924 C 12.80.3

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Slipring seals Service Manual
Installation instructions for slipring seals

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Service Manual

Group 16: Options

Load holding valves for Hoist Cylinders............................................................................16.02

1 Job definition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.02.1
2 Functional description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.02.2
2.1 Actuate cylinder 235 in the raising direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.02.2
2.2 Pressure cut-off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.02.2
2.3 Actuate cylinder 235 in the lowering direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.02.3
3 Sectional drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.02.3
4 Dismantling and assembling valve 238 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.02.4
4.1 Sealing and repair tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.02.4
4.2 Removal and installation of charging piston 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.02.4
4.3 Removal and installation of valve piston 7.7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.02.4
4.4 Removal and installation of pressure relief valve 29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.02.5
5 Setting instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.02.5
5.1 Important notes on setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.02.5
5.2 Setting the secondary pressure, see Fig. 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.02.6
5.3 Setting entrainment for valve 7, see Fig. 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.02.8
6 Hydraulic connections and fastenings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.02.9

Hydraulic installation kit AHS 11 with Tool Control..........................................................16.20

1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.20.1
2 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.20.1
3 System description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.20.2
4 Function and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.20.5
5 Pressure check and adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.20.6
5.1 Important notes for adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.20.6
5.2 Check of secondary pressure relief valves 501 and 502. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.20.7
5.3 Adjustment of pressure cut-off 101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.20.9
5.4 Adjustment of control piston 503 stroke limitation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.20.9
6 Hydraulic circuit diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.20.10
7 Electrical circuit diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.20.10

Hydraulic installation kit AHS 12 with Tool Control..........................................................16.24

1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.24.1
2 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.24.2
3 System description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.24.3
4 Function and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.24.5
5 Pressure check and adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.24.7
5.1 Important notes for adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.24.7
5.2 Check of secondary pressure relief valves 501 / 502 and 521 / 522. . . . . . . . . . . . . . . . . . . . 16.24.7
5.3 Adjustment of pressure cut-off 101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.24.9
5.4 Adjustment of control piston 503 / 523 stroke limitation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.24.9
6 Hydraulic circuit diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.24.10
7 Electrical circuit diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.24.10

Refuelling pump ...................................................................................................................16.30

R 914 C from serial no. 19 527
R 924 C from serial no. 19 846
R 906 Classic from serial no. 23145
R 916 Classic from serial no. 17943

R 914 C / R 924 C 16.00.1

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Service Manual

R 926 Classic from serial no. 17941

1 Technical information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.30.1
2 Electrical diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.30.1
3 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.30.1

List of diagrams ................................................................................................................... 16.91

R 914 C from serial number 19 527

List of diagrams ................................................................................................................... 16.92

R 924 C from serial number 19 846

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.2 R 914 C / R 924 C
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Service Manual Load holding valves for Hoist Cylinders
Job definition

Group 16: Options

16.02: Load holding valves for Hoist Cylinders

1 Job definition
The load holding valve is installed directly on the pressure connection of the hoist cylinder (piston
crown side) installiert.
The load holding valve described here also functions independently of the set pressure. It is imple-
mented for protection of the hoist cylinder.
The load holding valve comprises of brake piston with check valve, as well as check valve and the
charging piston necessary for charging. The pressure relief valve installed in the housing assumes
secondary relief.
The valve prevents an uncontrolled drop of attachment or load in the event of pipe bursting. The load
holding valve blocks the respective cylinder connection when pressure is lost in the control pressure
connection, without leaking oil.

R 914 C / R 924 C 16.02.1

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Load holding valves for Hoist Cylinders Service Manual
Functional description

Fig. 1 Pipe anti-burst device on the hydraulic cylinder

2 Functional description
see Fig. 8

2.1 Actuate cylinder 235 in the raising direction

Hydraulic oil flows from the control valve block 100 connection A5 to valve 238 connection V2.
Sleeves 12 and 42 are shifted and compressed oil pressurises the cylinder on the piston crown side
via connectiol C2. The cylinders 235 are extended. Upon completion of the working movement, the
check valve 8 closes. Return flow is blocked ensuring that the load is retained without oil leakage.

2.2 Pressure cut-off

The secondary side pressure cut-off is resulted via pressurisation of the cone 29.7 via the filter ele-
ment 30. With pressure peaks the cone 29.7 is pushed against the pretensioned pressure spring 29.6
thus relieving pressure on the cylinder crown side. A little oil is discharged via throttle check valve 23,
(see Fig. 8 on page11) simultaneously applying pressure to piston 3, which in turn displaces pistol
7.7. Additional oil now flows out of the cylinder crown side via V2 to the control valve block 100 and
secondary pressure relief valve 221 (extend hoist cylinder 235). Valve 221 opens and allows the oil

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Service Manual Load holding valves for Hoist Cylinders
Sectional drawing

to flow back to the tank.

2.3 Actuate cylinder 235 in the lowering direction

The servo pressure at the control valve block 100 connectiol b5 for actuation of control pistol 220 for
3 via Pil con-
nection and throttle check valve 23.
The charging piston 3 pushes against the valve piston 7.7 and pushes it against the pressure spring
7.5. Following a short stroke, the sleeve 42 firms up against the valve guide 7.1 and the leak oil-free
shut-off is opened. The cylinders 235 are retracted.
The oil now flows out of the cylinder chamber via connections C2 and V2 to the control valve block
and from there back into the hydraulic oil tank. At the same time oil flows from the pump P2 via the
respective connection of the control valve block to the control valve block 235 on the piston rod side.

3 Sectional drawing

Fig. 2 Sectional drawing of pipe anti-burst device

1 O-ring 12 Valve seat (sleeve) 44 Spring guide
2 Slide ring 8.1 Valve guide 29.2 Adjusting screw
3 Pilot piston 8.2 Cone 29.3 Lock nut
4 Housing 9 O-ring 29.4 Spring guide
5 Screw plug 10 Slide ring 29.5 Sealing ring
6 O-ring 13 Pressure spring 29.6 Pressure spring
7 Charging piston com- 14 Spring guide 29.7 Valve cone
plete
7.1 Valve guide 15 O-ring 30 Filter element
7.2 Adjusting screw 16 Supporting ring 31 Screw plug
7.3 Protective cap 17 Screw plug 31.1 Sealing ring

R 914 C / R 924 C 16.02.3

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Load holding valves for Hoist Cylinders Service Manual
Dismantling and assembling valve 238

7.4 Sealing ring 18 O-ring 40 Slide ring

7.5 Pressure spring 19 Screw plug 41 O-ring
7.6 Valve cone 20 O-ring 42 Valve seat (sleeve)
7.7 Valve piston 23 Throttle check valve 43 Pressure spring
7.8 O-ring 27 Protective cap 44 Spring guide
8 Check valve complete 29 Pressure relief valve 46 Seal protection
complete.
11 O-ring 29.1 Valve guide

4 Dismantling and assembling valve 238

see Fig. 2

4.1 Sealing and repair tasks

Note!
The sealing tasks can be carried out with the valve still installed.

Note!
All parts must be cleaned thoroughly prior to assembly and then examined meticulously for reusa-
bility. All sealing rings are to be replaced and a light coating of oil applied.

Set the attachment down on the ground with no load attached.

Relieve pretension in the tank and repeatedly actuate the servo control for lifting /lowering with
diesel engine switched off (ignition and servo control on) to relieve hydraulic pressure of the
RBS valve(s).

4.2 Removal and installation of charging piston 3

Unscrew the screw plug 19 and push the piston 3 out of the housing 4 (if necessary, pressurise
connection T with compressed air).
Pull the O-ring 1 and slide ring 2 onto the charging piston 3 and inspect the radial and axial bore
in the piston for cleanliness.
Insert the complete charging piston 3 into the bore.
Screw in the screw plug 19 with O-ring 20.

4.3 Removal and installation of valve piston 7.7

Unscrew the valve guide 7.1 complete with pressure spring 7.5 and valve cone 7.6 (caution:
spring pretension.
Remove the piston 7.7 from the housing 4 and remove the sleeve 42 with pressure spring 43 and
spring guide, if necessary with solenoid.
Unscrew the respective screw plugs and sealing rings as required.
Fit the sealing rings 40 / 41 onto the sleeve 42. Insert complete spring guide 44, pressure spring
43 and sleeves 42 into the housing bore.
Fit the O-ring 7.8 onto the valve guide 7.1 and push the valve guide 7.1 complete with valve piston
7.7, valve cone 7.6, pressure spring 7.5 into the bore and screw in.

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Service Manual Load holding valves for Hoist Cylinders
Setting instructions

4.4 Removal and installation of pressure relief valve 29

Remove the protective cap 27 on the valve 29.
Remove the complete valve guide 29.1. Remove the filter element 30 , if necessary with solenoid.
Insert the filter element 30 again and screw in valve 29.
Set the prescribed secondary pressure and entrainment at valves 7 and 29 in accordance with the
guideline, see setting instructions.

5 Setting instructions

5.1 Important notes on setting

Note!
The valves 238 have been set to a fixed value by the manufacturer and the correct setting has been
secured with a seal. Missing seals indicate that the original setting has been tampered with.

The actual setting can be ascertained by removing the protective caps 7.3 and 27. Measure dimen-
sion X from the upper edge of the adjusting screw 7.2 / 29.2 to the valve guide 7.1 or lock nut 29.3.

Adjusting screw 7.2 : Set dimension X = 10.2 ± 0.5

mm
Adjusting screw 29.2 : Set dimension X = 9.5 ± 0.5
mm

If a deviation of the original setting is determined, following repair work at the valve for example, the
rough setting can be adjusted by turning the setting screws to the dimension specified above.
Allow the hydraulic oil to heat to operating temperature
Set the speed of the diesel engine to nominal speed
Use a suitable pressure transducer to set the pressure
Note!
We must stress that all work on the valves within the warranty period of the machine may only be
carried out by specialists contracted by the LIEBHERR Company.

Fig. 3 Setting points and additional test points on the pipe anti-burst device

R 914 C / R 924 C 16.02.5

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Load holding valves for Hoist Cylinders Service Manual
Setting instructions

5.2 Setting the secondary pressure, see Fig. 3

Fig. 4 Test points on the pipe anti-burst device and control valve block
Set the attachment down on the ground with no load attached.
Shut down the engine and relieve the valve of pressure.
When unscrewing the plug 5 at connection E or if mounting an overload warning device to the
pressure gauge connectiol 52, place a suitable container below to catch any escaping oil.
Fit the pressure gauge connectiol 50 E of both valves
238, or if mounting an overload warning device, into valve 238 of the left-hand hoist cylinder only.
In place of pressure gauge connection 50, a T-measuring device can be fitted to pressure gauge con-
nection 52 via a measuring hose, see Group 2.01.
Remove the sealing cap from test point 41 (on control valve block 100) and connect a miniature
measuring hose between test point 50 (in connectiol E).
Connect the pressure transducer (600 bar) with pressure gauge connection (1.5 - 2.5 m) to the
other pressure gauge connection 50 of the valve 238 (connection E) or if mounting an overload
protection device to pressure gauge connection 52.
Extend the hoist cylinder 235 to the stop.
Extend secondary pressure relief valve 221 (control piston 220) for the hoist cylinder, unscrew at
least 2 full turns
A reduction in pressure is necessary to ensure that oil can drain via connection V2 of the valve
238, see Fig. 8

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Service Manual Load holding valves for Hoist Cylinders
Setting instructions

Fig. 5 Pressure relief valve 29 and pressure gauge connections of the pipe anti-burst device

Ascertain the clearance X from screw 29.2 to lock nut 29.3

on page 5).
Remove the protective cap 27 from the valve 29.
Loosen the lock nut 29.3 (SW 10) and screw out the adjusting screw 1 full turn 29.2 using an Allen
key (SW 3) 1.
Extend the bucket cylinder all the way to the stop.
Pressure builds up via the measuring hose at connections E of the valve 238 ad at test point
50 with pressure transducer.
Continue to screw in the adjusting screw 29.2
until a pressure of 240 bar has been attained at test point 50, at the same time continue to turn
adjusting screw 29.2 around exactly 1/2 a turn (180° = 170 bar).
Thus, a prescribed set pressure is achieved for valve 29 measuring:

240 bar measured pressure

+ 170 bar pressure increase by turning
±10
= 410 bar

Note!
The setting must be exactly the same for both valves 238.
Setting the valve 29 at the second pipe anti-burst device valve 238

Following successful setting:

Tighten the lock nut 29.3.
Insert the sealing wire into the adjusting screw 29.2 and protective cap 27
Seal the pressure relief valve 29
Set the attachment down onto the ground again
Shut down the engine and relieve the system of pressure.

R 914 C / R 924 C 16.02.7

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Load holding valves for Hoist Cylinders Service Manual
Setting instructions

Disconnect the pressure transducer and remove the measuring hoses and pressure gauge con-
nection 50.
Screw the plug 5 into connectiol E.
Set the secondary pressure relief valve 222, see Fig. 8 to the prescribed pressure (see Group 6).

5.3 Setting entrainment for valve 7, see Fig. 3

Relieve the servo control of pressure
Install the T-device with pressure gauge connection in the control line to connectiol Pil of the valve
238
Connect the pressure transducer (0-60 bar)
-hand servo control and read off the
control pressure at the pressure transducer upon entrainment of the attachment

The control pressure at entrainment should total = 7.5 ± 0.5 bar

If necessary, turn the adjusting screw 7.2 of valve 7 accordingly:

Screwing in the screw 7.2 = Increase pressure

Unscrewing the screw 7.2 = Reduce pressure

Following successful setting, determine clearance X from the screw 7.2 to the valve guide 7.1 and
screw the protective cap 7.3 with sealing ring 7.4 onto the adjusting screw 7.2.
Set dimension X on the second pipe anti-burst device valve 238 and at the same time check the open
begin.
If the actuation pressure is too high, determine clearance X from the left-hand to the right-hand valve
(charging piston) and then unscrew around 1 full turn.
Then set the entrainment on the opposite valve 238 and determine the overlap clearance, set this
clearance on the other valve and at the same time check the open begin.
Secure valve 7 with a seal.
Relieve pressure in the system and remove pressure gauge and T-device.

Fig. 6 Valve 7 with adjusting screw 7.2 and connections PiL / T

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Service Manual Load holding valves for Hoist Cylinders
Hydraulic connections and fastenings

6 Hydraulic connections and fastenings

Fig. 7 Hydraulic connections and fastenings

1 Hydraulic oil tank 100 Control valve block

R 914 C / R 924 C 16.02.9

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Load holding valves for Hoist Cylinders Service Manual
Hydraulic connections and fastenings

220 Control piston / hoist cylinder

6 To the hydraulic oil cooler 221 Secondary pressure relief valve extend
hoist cylinder
14 Rectangular ring 222 Secondary pressure relief valve retract
hoist cylinder
16 Cylinder head screw 224 Pressure balance
20 From the pump 235 Hoist cylinder
23 To pump controller 238 Pipe anti-burst device valve
37 Hexagon head screw 238.7 Charging piston
41 Test point MP 238.8 Check valve
43 Threaded coupling 238.23 Throttle check valve
45 Test point LS 238.29 Pressure relief valve
50 Threaded coupling (install for measuring) 238.30 Filter
52 Pressure gauge connection (only if UL
mounted)
81/1 From right-hand servo control / connec-
tion 1 (lowering)
81/3 From right-hand servo control / connec-
tion 3 (lifting)

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Service Manual Load holding valves for Hoist Cylinders
Hydraulic connections and fastenings

Fig. 8 Hydraulic circuit diagram for pipe anti-burst device

R 914 C / R 924 C 16.02.11

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Load holding valves for Hoist Cylinders Service Manual
Hydraulic connections and fastenings

16.02Wednesday,
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Service Manual Hydraulic installation kit AHS 11 with Tool Control
Introduction

16.20: Hydraulic installation kit AHS 11 with Tool Control

1 Introduction
Installing additional attachments on the machine requires the installation of various components, hy-
draulic lines and hoses to actuate and control the attachments.
These parts can be combined in a hydraulic installation kit. As many different attachments can be
installed, special hydraulic installation kits have been designed for certain attachments.
The AHS 11 hydraulic installation kit is necessary for the installation of the following attachments:

Fig. 1 Machine and hydraulic hammer attachment

2 Technical data

Pressure limitation (values in bar)

R 914 C / R 924 C 16.20.1

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Hydraulic installation kit AHS 11 with Tool Control Service Manual
System description

Pressure limitation (values in bar)

Work tools and respective pressure-relief
valves (P.R.V.) Secondary
Primary pressure
pressure
Secondary pressure relief valve 501
Extend cylinder 511
Position - EV6 at 0% 100 ±10 bar
Position - EV6 at 100% 400 ±10 bar
Secondary pressure relief valve 502
Retract cylinder 511 or operate hammer 510
Stage 1 (hydraulic hammer 510) 200 +10 bar (*)
Stage 2 (cylinder 511) 380 +10 bar

Position - EV6 at 0% 100 ±10 bar (*)

Position - EV6 at 100% 400 ±10 bar
(in auxiliary block 500)
Return flow - dynamic pressure max. 2 bar
Oil requirement for hammer operation via flow
rate limitation set at: (*)
Stroke limitation of control piston 503
Dimension Y of stop screw 500.1 8.5 mm
Dimension Y of stop screw 500.2 8.5 mm

Tab. 1 Technical data

(*) Always observe specifications provided by the hammer manufacturer.

3 System description
Hydraulic installation kit AHS 11 allows control and actuation of an additionally mounted hydraulic cyl-
inder or hammer onto the excavator attachment. It is made of the following elements:
500, installed in main control valve block 100 as standard for actuation
of hammer 510 or cylinder 511;
85, installed on the step plate (double pedal);
B33, installed beneath the step plate on the side of the servo control 85, informs
the electrical control circuit about the presence of the additional attachment;
Y51, installed in the servo oil unit in correlation with both pump control-
lers to execute the flow restriction function for certain working procedures;
Y414, screwed onto the side of the servo oil unit and connected with
the pressure relief valve, implements the flow restriction function for certain working procedures.

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Service Manual Hydraulic installation kit AHS 11 with Tool Control
System description

Fig. 2 Hydraulic system AHS 11 with Tool Control

50 Servo oil unit 85 2-way servo control with foot pedals

88P Distributor 88T Collector pipe
100 Control valve block 500 Directional control valve
501 Pressure relief valve 502 Pressure relief valve
B33 Pressure Switch / flow restriction Y414 Proportional solenoid valve

R 914 C / R 924 C 16.20.3

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Hydraulic installation kit AHS 11 with Tool Control Service Manual
System description

Fig. 3 Complete system AHS 11 with Tool Control

Legend for complete system

Electrical signal to define the power percentage for the flow restriction and pressure relief valves,
according to the values specified in the display

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Service Manual Hydraulic installation kit AHS 11 with Tool Control
Function and operation

Electrical signal to activate the flow restriction and pressure relief

Electrical supply of flow restriction and pressure relief valves, according to the values specified in
the display

Electrical supply of flow restriction valve

Electrical supply of pressure relief valve

Hydraulic system for servo control

Hydraulic system for flow restriction

Hydraulic system for pressure relief

Hydraulic system for supply of the attachment

30 Servo control pump 50 Servo oil unit

85 2-way servo control with foot pedals 100 Main control valve block
500 Directional control valve / cylinder 511 - 510 Hammer
hammer 510
511 Cylinder
A1001Printed circuit board ESP01 A1010Printed circuit board ESP02
B33 Pressure switch / flow and pressure U16 BST
relief
Y51 Flow restriction valve Y414 Proportional solenoid valve

4 Function and operation

The hydraulic installation kit AHS 11 allows the operator to operate two basically different attach-
ments (users) with only one single installation kit:

Note!
For proper use and correct functioning of hydraulic installation kit AHS 11, proper control of the nec-
essary components is imperative.
Incorrect preselection of pressure and flow setting can lead to tool damage (e.g. hydraulic hammer)
or to limited functioning (e.g. miller cutter).

Optional flow rate and pressure relief values must first be stored as percentages in the display
"Set pumps" menu (see Subgroup 8.72).
The operator actuates the servo control 85.
The pump pressure is channelled to one side of the directional control valve 500 of the main
control valve block 100 via the servo control and pushes the valve.
The additional attachment can be charged with high pressure.
At the same time the servo pressure actuates pressure switch B33.
This sensor transmits an electrical signal via printed circuit boards A1010 and A1001 to BST
U16.
The option corresponding to the additional attachment is selected in the menu "set option" on the

R 914 C / R 924 C 16.20.5

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Hydraulic installation kit AHS 11 with Tool Control Service Manual
Pressure check and adjustment

display (see Subgroup 8.72).

These values are transferred via printed circuit board A1001 to BST U16.
The BST then releases the corresponding current for pressure relief valve Y414.
The pressure relief valve Y414 informs the secondary pressure relief valve about the maximum
permissible working pressure.
The BST supplies the corresponding current to flow restriction valve Y51 through printed circuit
board A1010.
The flow restriction valve Y51 transfers pressure to the pump controller.
The maximum permissible working pressure for the attachment being used is set.
The flow rate for operation of the attachment is regulated by the working pump through direc-
tional control valve 500.

Fig. 4 Servo control unit 85 and menu display on the screen

TI symbol 1;
2 is displayed only when the attachment is operated with flow reduction.

Note!
Pessure and flow reduction adjustments must be made at service level 2/3.
For detailed instructions about pressure and flow reduction adjustment, refer to group 8.72.

5 Pressure check and adjustment

5.1 Important notes for adjustment

Always adjust pressure at operating temperature and with engine speed Mode P.

Always use suitable pressure gauges (glycerine damped and with a display accuracy under 1%
of the scale end value).

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Service Manual Hydraulic installation kit AHS 11 with Tool Control
Pressure check and adjustment

Always secure pressure relief valves with sealing wire or protective caps.

Note!
Within the warranty period of the machine, all work on the valves may only be carried out by spe-
cialists contracted by the LIEBHERR company. Pressure-relief valves and throttles must be se-
cured against unauthorised readjustment with sealing wire or protective caps.

5.2 Check of secondary pressure relief valves 501 and 502

Connect the pressure gauge to test point 45.
Screw in pressure cut-off 101.
The pressure must lie above the setting pressure of secondary pressure relief valves 501 -
502.
Disconnect the control line from the cut-in stage of pressure relief valves 501 - 502.

If a hydraulic hammer is installed:

Disconnect pressure line to hammer and seal.
Insert the green coding plug at connection X31.

Fig. 5 Auxiliary control axle AHS 11 within the auxiliary control valve block 500

5.2.1 Check of the pressure for EV6 position at 0%

In menu "Set pumps", select I1 then Opt1 and finally EV6.
Set the value for EV6 to 0%.
Actuate the right-hand foot pedal 85R and check the pressure gauge reads the recommended
pressure for secondary pressure relief valve 501 see Tab. 1.
If the recommended pressure is not reached, adjust pressure relief valve 501 (cylinder 511 extend-
ing) (low pressure).
Actuate the left-hand foot pedal 85L and check the pressure gauge reads the recommended pres-
sure for secondary pressure relief valve 502 see Tab. 1.
If the recommended pressure is not reached, adjust pressure relief valve 502 (cylinder 511 retracting
/ hydraulic hammer 510) (low pressure).

5.2.2 Check of the pressure for EV6 position at 100%

In menu "Set pumps", select I1 then Opt1 and finally EV6.
Set the value for EV6 to 100%.

R 914 C / R 924 C 16.20.7

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Hydraulic installation kit AHS 11 with Tool Control Service Manual
Pressure check and adjustment

Actuate the right-hand foot pedal 85R and check the pressure gauge reads the recommended
pressure for secondary pressure relief valve 501 see Tab. 1.
If the recommended pressure is not reached, adjust pressure relief valve 501 (cylinder 511 extend-
ing) (high pressure).
Actuate the left-hand foot pedal 85L and check the pressure gauge reads the recommended pres-
sure for secondary pressure relief valve 502 see Tab. 1.
If the recommended pressure is not reached, adjust pressure relief valve 502 (cylinder 511 retracting
/ hydraulic hammer 510) (high pressure).

Fig. 6 Servo control 85 and menu indicated in the display

5.2.3 Adjustment of pressure stage 2 (high pressure)

Loosen the lock nut 2.1.
Loosen the lock nut 1.1.
Hold adjustment screw 2 for pressure stage 1 tightly and turn adjustment screw 1 for pressure
stage 2 until the recommended pressure see Tab. 1 is measured at test point 45.
Tighten the lock nut 1.1.
Then adjust pressure stage 1 again.

5.2.4 Adjustment of pressure stage 1 (low pressure)

Fully actuate hydraulic hammer 510 or cylinder 511.
Loosen the lock nut 2.1.
Turn adjustment screw 2 of pressure relief valve 501 until the recommended pressure see Tab. 1
is displayed at the pressure gauge.
Tighten the lock nut 2.1.
Adjust the pressure cut-off 101 to the recommended value see 5.3.

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Service Manual Hydraulic installation kit AHS 11 with Tool Control
Pressure check and adjustment

Fig. 7 Sectional drawing of secondary pressure relief valves 501 - 502

5.3 Adjustment of pressure cut-off 101

Connect the pressure gauge to test point 41.
Actuate the stick cylinder to the stop and adjust the pressure cut-off 101 to the recommended
pressure see Tab. 1 by turning the adjustment screw.
Remove the pressure gauge and seal the test point.

5.4 Adjustment of control piston 503 stroke limitation

Fig. 8 Control piston 503 stroke limitation

The stroke of the control piston 503 for the maximum oil flow rate is adjusted at the factory via stroke
limitation 500.1 / 500.2 and should not be modified.
The dimension Y see Tab. 1 is a reference value for the recommended adjustment.
If the dimension Y does not match the recommended dimension, the stroke limitation can be adjusted
as follows:
Remove the seal and protective cap 1.3, loosen the lock nut 1.2 and turn the stop screw 1.1 ac-
cordingly until dimension Y is reached.
Tighten the lock nut 1.2 and fit and seal the protective cap 1.3.

R 914 C / R 924 C 16.20.9

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Hydraulic installation kit AHS 11 with Tool Control Service Manual
Hydraulic circuit diagram

6 Hydraulic circuit diagram

Refer to 16.51 «Hydraulic schematics for options».

7 Electrical circuit diagram

Refer to 16.52 «Electrical schematics for options».

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Service Manual Hydraulic installation kit AHS 12 with Tool Control
Introduction

16.24: Hydraulic installation kit AHS 12 with Tool Control

1 Introduction
Installing additional attachments on the machine requires the installation of various components, hy-
draulic lines and hoses to actuate and control the attachments.
These parts can be combined in a hydraulic installation kit. As many different attachments can be
installed, special hydraulic installation kits have been designed for certain attachments.
The AHS 12 hydraulic installation kit is necessary for the installation of the following attachments:

ears, concrete crusher, ...

Fig. 1 Machine and attachments

R 914 C / R 924 C 16.24.1

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Hydraulic installation kit AHS 12 with Tool Control Service Manual
Technical data

2 Technical data

Pressure limitation (values in bar)

Work tools and respective pressure-relief
valves (P.R.V.) Secondary
Primary pressure
pressure
Pressure cut-off 101
(this valve restricts the LS pressure and thus the 350 +10 bar
working pressure at test point 41) in the control
valve block 100
Secondary pressure relief valve 501
Extend cylinder 517
Position - EV6 at 0% 100 ±10 bar
Position - EV6 at 100% 400 ±10 bar
Secondary pressure relief valve 502
Retract cylinder 517 or hammer operation 515
Stage 1 (hydraulic hammer 515) 200 +10 bar (*)
Stage 2 (cylinder 517) 380 +10 bar

Position - EV6 at 0% 100 ±10 bar (*)

Position - EV6 at 100% 400 ±10 bar
(in auxiliary block 500)
Secondary pressure relief valves 521 / 522
Retract / extend cylinder 535
Position - EV6 at 0% 100 ±10 bar
Position - EV6 at 100% 400 ±10 bar
Return flow - dynamic pressure max. 2 bar
Oil requirement for hammer operation via flow
rate limitation set at: (*)
Stroke limitation of control pistons 503 - 523 :
Piston 500
Dimension Y of stop screw 500.1 8.5 mm
Dimension Y of stop screw 500.2 8.5 mm
Piston 520
Dimension Y of stop screw 520.1 8.5 mm
Dimension Y of stop screw 520.2 8.5 mm

Tab. 1 Technical data

(*) Always observe specifications provided by the hammer manufacturer.

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Service Manual Hydraulic installation kit AHS 12 with Tool Control
System description

3 System description
Hydraulic installation kit AHS 12 allows control and actuation of an additionally mounted hydraulic cyl-
inder or hammer onto the excavator attachment. It is made of the following elements:
500 and 520 installed within main control valve block 100 as standard
for actuation of hammer 515 or cylinder 517 and cylinder 535;
85 and 86 installed on the step plate (double pedal);
B33, installed beneath the step plate on the side of the servo control 85, informs
the electrival control circuit about the presence of the additional attachment;
Y51, installed in the servo oil unit in correlation with both pump control-
lers to execute the flow restriction function for certain working procedures;
Y414, screwed onto the side of the servo oil unit and connected with
the pressure relief valve, implements the flow restriction function for certain working procedures.

Fig. 2 Hydraulic system AHS 12 with Tool Control

50 Servo oil unit 85/86 Servo control 2-way with foot pedals
88P Distributor 88T Collector pipe
100 Control valve block 500/520Directional control valve
501/502Pressure relief valve 521/522Pressure relief valve
B33 Pressure Switch / flow restriction Y414 Prop.valve

R 914 C / R 924 C 16.24.3

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Hydraulic installation kit AHS 12 with Tool Control Service Manual
System description

Fig. 3 Complete system AHS 12 with Tool Control

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Service Manual Hydraulic installation kit AHS 12 with Tool Control
Function and operation

Legend for complete system

Electrical signal to define the power percentage for the flow restriction and pressure relief valves,
according to the values specified in the display

Electrical signal to activate the flow restriction and pressure relief.

Electrical supply of flow restriction and pressure relief valves, according to the values specified in
the display
Electrical supply of flow restriction valve

Electrical supply of pressure relief valve

Hydraulic system for servo control

Hydraulic system for flow restriction

Hydraulic system for pressure relief

Hydraulic system for supply of the attachment

30 Servo control pump 50 Servo oil unit

85/86 2-way servo control with foot pedals 100 Main control valve block
500 Directional control valve / cylinder 517 - 520 Directional control valve / cylinder 535
hammer 515
515 Hammer 517 Cylinder
535 Cylinder
A1001Printed circuit board ESP01 A1010Printed circuit board ESP02
B33 Pressure switch / flow and pressure U16 BST
relief
Y51 Flow restriction valve Y414 Pressure relief valve

4 Function and operation

The hydraulic installation kit AHS 12 allows the operator to operate three basically different attach-
ments (users) with only one single installation kit:

crete crusher or sorting grapple;

Note!
For proper use and correct functioning of hydraulic installation kit AHS 12, proper control of the nec-
essary components is imperative.
Incorrect preselection of pressure and flow setting can lead to damage of the tool (e.g. hydraulic
hammer) or to limited functioning (e.g. miller cutter).

The optional flow rate and pressure relief values (as percentages) must first be stored in the "Set
pumps" menu of the display (see Subgroup 8.72).

R 914 C / R 924 C 16.24.5

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Hydraulic installation kit AHS 12 with Tool Control Service Manual
Function and operation

The operator actuates the servo control 85.

The pump pressure is channelled to one side of the directional control valve 500 of the main
control valve block 100 via the servo control and pushes the valve.
The additional attachment can be charged with high pressure.
At the same time the servo pressure actuates pressure switch B33.
This sensor transmits an electrical signal via printed circuit boards A1010 and A1001 to BST
U16.
The option corresponding to the additional attachment is selected in the menu "set option" on the
display (see Subgroup 8.72).
These values are transferred via printed circuit board A1001 to BST U16.
The BST then releases the corresponding current for pressure relief valve Y414.
The pressure relief valve Y414 informs the secondary pressure relief valve about the maximum
permissible working pressure.
The BST supplies the corresponding current to flow restriction valve Y51 through printed circuit
board A1010.
The flow restriction valve Y51 transfers pressure to the pump controller
The maximum permissible working pressure for the attachment being used is set.
The flow rate for operation of the attachment is regulated by the working pump through direc-
tional control valve 500.

Fig. 4 Servo controls 85 and 86 and menu indicated in the display

TI symbol 1;
2 is displayed only when the attachment is operated with flow reduction.

Note!
Pessure and flow reduction adjustments must be made at service level 2/3.
For detailed instructions about pressure and flow reduction adjustment, refer to group 8.72.

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Service Manual Hydraulic installation kit AHS 12 with Tool Control
Pressure check and adjustment

The operator actuates the servo control 86.

The pump pressure is channelled to one side of the directional control valve 520 of the main
control valve block 100 via the servo control and pushes the valve.
The additional attachment (hydraulic cylinder 535) can be charged with high pressure, without
pressure relief or flow restriction.

5 Pressure check and adjustment

5.1 Important notes for adjustment

Always adjust pressure at operating temperature and with engine speed Mode P.

Always use suitable pressure gauges (glycerine damped and with a display accuracy under 1%
of the scale end value).

Always secure pressure relief valves with sealing wire or protective caps.

5.2 Check of secondary pressure relief valves 501 / 502 and 521 / 522
Connect the pressure gauge to test point 45.
Screw in pressure cut-off 101.
The pressure must lie above the setting pressure of secondary pressure relief valves 501/502
- 521/522 .
Disconnect the control line from the cut-in stage of the pressure relief valves 501/502 - 521/522.

If a hydraulic hammer is installed:

Disconnect pressure line to hammer and seal.
Insert the green coding plug at connection X31.

Fig. 5 Auxiliary control valve blocks 500 - 520

R 914 C / R 924 C 16.24.7

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Hydraulic installation kit AHS 12 with Tool Control Service Manual
Pressure check and adjustment

5.2.1 Check of pressure for position of EV6 at 0%.

In the menu "Set pumps", select I1 then Opt1 and finally EV6.
Set the value for EV6 to 0%.
Actuate the right-hand foot pedal 85R /86R and check the pressure gauge reads the recommend-
ed pressure for secondary pressure relief valve 501 or 522 see Tab. 1.
If the recommended pressure is not reached, adjust pressure relief valve 501 (cylinder 517 is extend-
ed) or pressure relief valve 522 (cylinder 535 is extended) (low pressure).
Actuate the left-hand foot pedal 85L /86L and check the pressure gauge reads the recommended
pressure for secondary pressure relief valve 502 or 521 see Tab. 1.
If the recommended pressure is not reached, adjust pressure relief valve 502 (cylinder 517 is retract-
ed / hydraulic hammer 515) or pressure relief valve 521 (cylinder 535 is retracted) (low pressure).

5.2.2 Check of the pressure for position of EV6 at 100%.

In the menu "Set pumps", select I1 then Opt1 and finally EV6.
Set the value for EV6 to 100%.
Actuate the right-hand foot pedal 85R /86R and check the pressure gauge reads the recommend-
ed pressure for secondary pressure relief valve 501 or 522 see Tab. 1.
f the recommended pressure is not reached, adjust pressure relief valve 501 (cylinder 517 is extend-
ed) or pressure relief valve 522 (cylinder 535 is extended) (high pressure).
Actuate the left-hand foot pedal 85L /86L and check the pressure gauge reads the recommended
pressure for secondary pressure relief valve 502 or 521 see Tab. 1.
If the recommended pressure is not reached, adjust pressure relief valve 502 (cylinder 517 is retract-
ed / hydraulic hammer 515) or pressure relief valve 521 (cylinder 535 is retracted) (high pressure)
and check current intensity.

Fig. 6 Servo control 85 and menu indicated in the display

5.2.3 Adjustment of pressure stage 2 (high pressure)

5.2.4 Adjustment of pressure stage 1 (low pressure)

Fully actuate hydraulic hammer 515 or cylinder 517 - 535.
Loosen the lock nut 2.1.

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Service Manual Hydraulic installation kit AHS 12 with Tool Control
Pressure check and adjustment

Turn adjustment screw 2 of pressure relief valve 501 until the recommended pressure see Tab. 1
is displayed at the pressure gauge.
Tighten the lock nut 2.1.
Adjust the pressure cut-off 101 to the recommended value see 5.3.

Fig. 7 Sectional drawing of secondary pressure relief valves 501 - 502

5.3 Adjustment of pressure cut-off 101

5.4 Adjustment of control piston 503 / 523 stroke limitation

The stroke of the control piston 503 / 523 for the maximum oil flow rate is adjusted at the factory via
stroke limitation 500.1 / 500.2 or 520.1 / 520.2 and should not be modified.
The dimension Y see Tab. 1 is a reference value for the recommended adjustment.
If the dimension Y does not match the recommended dimension, the stroke limitation can be adjusted
as follows:
Remove the seal and protective cap 1.3, loosen the lock nut 1.2 and turn the stop screw 1.1 ac-
cordingly until dimension Y is reached.
Tighten the lock nut 1.2 and fit and seal the protective cap 1.3.

R 914 C / R 924 C 16.24.9

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Hydraulic installation kit AHS 12 with Tool Control Service Manual
Hydraulic circuit diagram

Fig. 8 Stroke limitation of control pistons 503 - 523

6 Hydraulic circuit diagram

Refer to 16.51 «Hydraulic schematics for options».

7 Electrical circuit diagram

Refer to 16.52 «Electrical schematics for options».

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Service Manual Refuelling pump
Technical information

16.30: Refuelling pump

R 914 C from serial no. 19 527
R 924 C from serial no. 19 846
R 906 Classic from serial no. 23145
R 916 Classic from serial no. 17943
R 926 Classic from serial no. 17941

1 Technical information

Special equipment
Identification Number 10076224
Refuelling pump
Liebherr Identification Number 10354745
Reference HYDAC COOLING 24 V/DC - 12 A
Flow rate 50 L/min
Power 100 W
Maximum operating time 15 minutes
Maximum suction head 5m
Other information Self priming up to 2,5 m
Protection of control unit IP65

2 Electrical diagram
See series diagram, group 110.

3 Overview
The refuelling pump is under the cover on the front right side of the machine (see LIDOS).

1 Glued connection

R 914 C / R 924 C 16.30.1

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Refuelling pump Service Manual
Overview

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Service Manual List of diagrams

16.91: List of diagrams

R 914 C from serial number 19 527

Hydraulic Electrical
Option
schematic diagram

Denomination Ident Ident Ident

Hydraulic installations for additional users

Option AHS 1 10076273 9941720

Option AHS 11 10076218 10080460 9949175

Option AHS 12 with Tool Control 10076220 10081933 9949175

Option rotating device 10076209 10082260 10084116

Option Quick adapter 9949918 10055015

Pressure admission stage lifting 10095647 9935626 9935621

Cab hydraulic adjustable (with parallelo- 10076299 10087132 10073080

gram)

Hydraulic installations for special controls

Option Pressure limiter L.S. 10376228 10376811 10371091

Option mowing bucket 10377682 10377683

Rotary connection 7 ways 10385853 10386222

Swing brake control 10372516 10372911

Hoist limitation basic boom (height) 10366148 10366150 10053393

Hoist limitation basic boom (depth) 10365169 10365903 10053393

Security for hoist cylinders 10367965 9828780 10367970

Industrial mono boom with stick cylinder 10364790 10078989

control stop + hose burst safety valve

LIEBHERR control 10088296 10377434

Bypass filter instal. 10076240 10375573

Positioning swing brake (foot operated) 10076227 10082191

Priority control 10374126 10376019 9824475

Return oil filter for hydraulic hammer 10076230 10081986

Special control 10380342 10380343

Stick cylinder control stop 10372476 10372479 10053393

Commutation pedal hammer / shear 10371726 10371727 10060796

Control commutation 10374937 10083808 9823500

Control commutation AHS 10076242 10048670 9941429

R 914 C / R 924 C 16.91.1

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List of diagrams Service Manual

Hydraulic Electrical
Option
schematic diagram

Denomination Ident Ident Ident

Control commutation PCSA / J.Deere 10366280 10366281 9823500

Control commutation PCSA / J.Deere 10399852 10400122

Control commutation PCSA / Liebherr 10076280 10083808 9823500

Driving of electro generators

Generator 15 kW 10380341 10087055 10071216

10370014

Generator 15 kW LAM execution 10369654 10087055 10071216

10076278
Electric systems

Kit GPS / Data transmission (LISAT) 10079347 10079348

LIDAT 10825621 10825625

9890167

Particle filter Liebherr 10093666 10364425

10372271

B. boom f.high + Lat. adj. m. boom 10083620 10379945

Rebuilding set S6L / S6M 10375220 10071216

Rebuilding set control S5L/R - S6L/R 10398650 10398651

Premounting for radio im roof 10371610 10379433

Additional floodlights

Additional head light (2 rear cab) 9598566 9954351

Additional head light (on boom or slewing 10088237 9936270

arm for boom hydraulic adjusment)

Additional head light Xenon 10403648 10374548

Diesel engine, cooling & additional heaters

Cab aeration v2 10368583 9986209

Refuelling pump 10076223 10056316

Fuel pre-heating 10076261 9699944

Reversible fan drive 10082615 10083952 10078780

Standstill cab heater D5WS 10076244 10070659

Special lubrication systems

Full automatic centralised lubrication 10076214 10078989

16.91Wednesday,
.2 R 914 C / R 924 C
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Service Manual List of diagrams

Hydraulic Electrical
Option
schematic diagram

Denomination Ident Ident Ident

Emergency and safety devices

Travel alarm 10076225 10067753

Delay engine cut-out 10367393 10367403

Hose burst safety valve bucket cylinder 10062535 10370395

10370020
10378476
10379954
10079207

Stick cylinder control valve 10092062 10092063

Tab. 1 Bausätze / Option / Options auf R914C

R 914 C / R 924 C 16.91.3

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List of diagrams Service Manual

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.4 R 914 C / R 924 C
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Service Manual List of diagrams

16.92: List of diagrams

R 924 C from serial number 19 846

Hydraulic Electrical
Option
schematic diagram

Denomination Ident Ident Ident

Hydraulic installations for additional users

Option AHS 1 10076273 9941720

Option AHS 11 10076218 10080460 9949175

Option AHS 11 with proportional control 10829401 10829402 10823212

Option AHS 12 with Tool Control 10076220 10081933 9949175

Option rotating device 10076209 10082260 10084116

Option quick adapter 9949918 10055015

Pressure admission stage lifting 10095647 9935626 9935621

Kabine hydraulic adjustable (with Parallelo- 10076299 10087132 10073080

gram)

Cab tilting device 30° 10367808 10087132 10073080

Connect. for extra hydraulic control AHS 10092954 10092109

Rebuilding set in basic machine AHS 11 10374519 10374520 10376360

Hydraulic installations for special controls

Option mowing bucket 10377682 10377683

Option hydraulic flow limiter 10076232 10083724 10082433

Option pontoon 10378076 10378078

Option special control 10373842 10373844

Hoist limitation basic boom (height) 10366148 10366150 10053393

Hoist limitation basic boom (depth) 10365169 10365903 10053393

Security for hoist cylinders 10367965 9828780 10367970

Security for hoist cylinders (Hammer) 10082432 10067219 10067247

Industrial mono boom with stick cylinder 10364790 10078989
control stop + hose burst safety valve

LIEBHERR control 10088296 10377434

Bypass filter instal. 10076240 10375573

Positioning swing brake (foot operated) 10076227 10082191

Priority control 10374126 10376019 9824475

Return oil filter for hydraulic hamm. 10076230 10081986

R 914 C / R 924 C 16.92.1

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List of diagrams Service Manual

Hydraulic Electrical
Option
schematic diagram

Denomination Ident Ident Ident

Special control 10380342 10380343

Stick cylinder control stop 10372476 10372479 10053393

Hydraulic tubes modification + command 10087127 10089651

basic machine 10082260

Commutation pedal hammer / shear 10371726 10371727 10060796

Control commutation 10374937 10083808 9823500

Control commutation AHS 10076242 10048670 9941429

Control commutation PCSA / J.Deere 10366280 10366281 9823500

Control commutation PCSA / Liebherr 10076280 10083808 9823500

Driving of electro generators

Generator 15 kW 10380341 10087055 10071216

10370014

Generator 15 kW LAM execution 10369654 10087055 10071216

10076278

Electric systems

Kit GPS / Data transmission (LISAT) 10079347 10079348

LIDAT 10825621 10825625

9890167
Particle filter Liebherr 10093666 10364425
10372271

B. boom f.high + Lat. adj. m. boom 10083620 10379945

Special cab 10096171 9914711

10379433

Rebuilding set S6L / S6M 10375220 10071216

Premounting for radio im roof 10371610 10379433

Additional floodlights

Additional head light (2x rear cab) 9598566 9954351

Additional head light (4x front high cab) 10367776 9947563

Additional head light (on boom or slewing 10088237 9936270

arm for boom hydraulic adjusment)

Diesel engine, cooling & additional heaters

Cab aeration v2 10379534 9986209

Refuelling pump 10076223 10056316

Refuelling pump install 80 l/min 10373463 10375126

16.92Wednesday,
.2 R 914 C / R 924 C
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Service Manual List of diagrams

Hydraulic Electrical
Option
schematic diagram

Denomination Ident Ident Ident

Kit motorstop and spark catcher 10368534 10094192

Hydraulic oil pre-heating 240 V AC 10382697 10383397

Fuel pre-heating 10076261 9699944

Cool water pre-heating 10370886 9942147

Cool water pre-heating 240 V AC 10382367 10383397

Reversible fan drive 10082615 10083952 10078780

Air compressor 10376580 10062784

Standstill cab heater D5WS 10076244 10070659

Special lubrication systems

Full automatic centralised lubrication 10076214 10078989

Emergency and safety devices

Travel alarm 10076225 10067753

Stick cylinder valve control 10092062 10092063

Tab. 1 Bausätze / Option / Options auf R924C

R 914 C / R 924 C 16.92.3

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.4 R 914 C / R 924 C
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Service Manual

Group 17: Cab / Heater / Air-Conditioning System

Auxiliary heating...................................................................................................................17.30
1 Job definition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.30.1
2 Tasks in general . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.30.2
3 System description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.30.2
3.1 Individual components of the heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.30.4
4 Operation and functioning of the auxiliary heating. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.30.5
4.1 Initial start-up of heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.30.5
4.2 Notes on safety for heating operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.30.6
4.3 Activation, see Fig. 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.30.6
4.4 Control functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.30.7
4.5 Functioning in heater operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.30.7
4.6 Switching off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.30.8
4.7 Settings of the mini-clock. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.30.8
5 Subsequent installation of the auxiliary heating. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.30.10
5.1 Installing the auxiliary heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.30.11
5.2 Installing the batching pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.30.12
6 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.30.13
7 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.30.13
7.1 Troubleshooting with the diagnostic equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.30.13
7.2 Fault codes, error descriptions and remedial measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.30.15
7.3 Checking the flame scanner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.30.21
7.4 Checking the overheating gauge and temperature gauge . . . . . . . . . . . . . . . . . . . . . . . . . . 17.30.22
8 Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.30.22

Heating and air-conditioning system .................................................................................17.50

1 Job definition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.50.1
1.1 Notes in general regarding the air-conditioning system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.50.1
2 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.50.1
3 System description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.50.2
4 Exploded view of heating and air-conditioning system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.50.3
5 Functional description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.50.3
5.1 Functioning of the air-conditioning system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.50.4
6 Operation of the heating and air-conditioning system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.50.7
6.1 Activating the control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.50.8
6.2 Setting the desired cab temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.50.9
6.3 Switching the temperature display over to Fahrenheit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.50.9
6.4 Air-conditioning mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.50.10
7 Recirculated air and fresh air. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.50.10
7.1 Air ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.50.11
7.2 Operation with auxiliary heating (special equipment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.50.11
8 Operation and description of the test menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.50.12
9 Maintenance tasks for the heating and air-conditioning system . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.50.19
9.1 Filter elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.50.19
9.2 Heating system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.50.20
9.3 Air-conditioning system" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.50.21
10 Tasks on the cooling circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.50.23
10.1 Drying and evacuation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.50.23
10.2 Checking for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.50.24
10.3 Filling and draining, see Fig. 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.50.24

R 914 C / R 924 C 17.00.1

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11 Display of faults and instructions regarding the remedying of faults. . . . . . . . . . . . . . . . . . 17.50.28

11.1 Error code “FO“ faulty room temperature gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.50.28
11.2 Error code “F1“ faulty blow-out temperature gauge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.50.29
11.3 Error code “F3“ faulty ventilation flap for footing area - front windshield . . . . . . . . . . . . . . . . 17.50.29
11.4 Error code “F4“ pressure distortion and faulty magnetic clutch . . . . . . . . . . . . . . . . . . . . . . . 17.50.29
11.5 Error code “F5“ faulty data transfer operating unit / control unit . . . . . . . . . . . . . . . . . . . . . . 17.50.30
12 Electrical diagram for the air-conditioning system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.50.31
13 Inspection plan for air-conditioning system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.50.32
13.1 Maintenance tasks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.50.32

17.00Wednesday,
.2 R 914 C / R 924 C
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Service Manual Auxiliary heating
Job definition

Group 17: Cab / Heater / Air-Conditioning

System

17.30: Auxiliary heating

1 Job definition
The auxiliary heating functions independently of the diesel engine as a cooling circuit or heating cir-
cuit of the warm water heating connected to the diesel engine.
The auxiliary heating heats the interior of the operator's cab through its own ventilation channels. It
also heats the cooling water of the engine.
This will ensure that the engine, particularly in colder temperatures:
– will start up easily
– will be more energy-efficient
– will be better preserved

Fig. 1 Heater

R 914 C / R 924 C 17.30.1

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Auxiliary heating Service Manual
Tasks in general

2 Tasks in general

Machine 1062 / 1063 / 1064 / 1065

Onwards of serial number 21034
Type D5WS
Heating medium Water / refrigerant
Fuel Commercially-approved diesel (DIN EN 590)
PME (DIN V 51606)
Nominal voltage 24 volt
Operating range
above the voltage limit 32 volt
below the voltage limit 20.4 volt
Regulation of heat flow High Low
Heat flow 5000 watts 2400 watts
Fuel consumption 0.62 l/h 0.27 l/h
during operation 37 watts 10 watts
for start-up 110 watts
in after-run 8 watts
Minimum water flow rate of heater 250 l/h
Minimum water flow rate of water pump against
0.1 bar 950 l/h
Permissible ambient temperature
Heater operation -40°C to +80°C
Batching pump operation -40°C to +80°C
in storage -40°C to +105°C
Permissible operating pressure up to 2.5 bar overpressure
Preheating time approx. 20 - 50 seconds.
After-run time approx. 130 seconds.
Weight
without refrigerant and accessories approx. 2.3 kg
with water pump and batching pump approx. 2.9 kg

Tab. 1 Technical data (all data ± 10%)

3 System description
The auxiliary heating is comprised of several main parts:
– Mini dial 6
– Water pump 8
– Batching pump 14
– Exhaust gas muffler 15 with exhaust hose
– Combustion air hose 18
– Heater 20 with retainer 21
– Console 22
– Auxiliary water pump 23
The heating process is initiated by the mini-clock 6 installed in the left-hand console in the operator's
station. The water pump 8 mounted below the cooler on the console 22, the auxiliary water pump 23
and the heater 20 are thus activated. Air is drawn in by the combustion air hose 18. Supply of fuel is

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.2 R 914 C / R 924 C
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Service Manual Auxiliary heating
System description

resulted directly from the batching pump 14 mounted on the fuel tank, also activated upon start-up.
The exhaust gasses are channelled out into the open air via the exhaust gas muffler 15 with exhaust
hose.

Fig. 2 Main parts of the heater

R 914 C / R 924 C 17.30.3

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Auxiliary heating Service Manual
System description

3.1 Individual components of the heater

Fig. 3 Individual components of the heater

2 Control unit 50 Cladding

3 8-pin plug connection 51 Pressure spring
7 Combustion air blower 52 Cover for cladding
9 Temperature gauge 53 Cover for combustion air housing
10 Combustion chamber 54 Muzzle
11 Overheating gauge 55 Retainer
12 Heat exchanger 56 Sealing kit
16 Glow plug 57 O-ring
17 Flame scanner 58 Cover

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Service Manual Auxiliary heating
Operation and functioning of the auxiliary heating

4 Operation and functioning of the auxiliary heating

Fig. 4 Sectional drawing of the heater

1 Electric motor 9 Temperature gauge 17 Flame scanner

2 Control unit 10 Combustion chamber 18 Combustion air hose
3 Plug connection (8-pin) 11 Overheating gauge
4 Relay for vehicle fan 12 Heat exchanger A Exhaust gas
5 Main fuses 13 Pot sieve B Fuel
6 Mini-clock 14 Batching pump V Combustion air
7 Combustion air blower 15 Exhaust gas muffler WA Water discharge point
8 Water pump 16 Glow plug WE Water intake

4.1 Initial start-up of heater

The following points are to be noted for initial start-up, and following installation or repair:
Aerate the coolant circuit and the fuel supply thoroughly.
Open the coolant circuit (set temperature gauge to „warm“) prior to carrying out the test-run.

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Operation and functioning of the auxiliary heating

During the test-run of the heater check all water and fuel connections for leaks and ensure secure
fastening.
Check the coolant level in the expansion tank

4.2 Notes on safety for heating operation

The following should be noted during operation of the auxiliary heating:
Switch off the heater before refuelling.
It is not permissible to use the heater in areas where flammable vapours or dust can accumulate.
The installation room of the heater must remain free.
Under no circumstances may
– fuel canisters
– oil nozzles and spray nozzles
– gas cartridges
– fire extinguishers
– cleaning rags
– items of clothing
– paper
be transported or stored on or next to the heater.

4.3 Activation, see Fig. 4

Switch on the auxiliary heating.
If the air-conditioning system is switched on: the text SH (auxiliary heating) is displayed for a
few seconds, (see Fig. 5 on page6).
The air-conditioning system switches off and can not be switched on again during operation of
the auxiliary heating.
When the auxiliary heating is switched off and the after-run time has expired, the air-condition-
ing system is once again ready for operation.

Upon activation the indicator lamp in the mini-clock 6 lights up. The water pumps 8 and 23 start up
and following a specific program involving pre-rinsing and preheating, the combustion air blower 7,
glow plug 16 and combustion batching pump 14 initiate combustion. When a stable flame has formed,
the glow plug 16 switches off upon expiry of a predetermined time period.

Fig. 5 Display on the operating unit for heating and air-conditioning system

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Service Manual Auxiliary heating
Operation and functioning of the auxiliary heating

4.4 Control functions

If the heater does not ignite within 90 seconds of the beginning of fuel delivery, the start procedure is
repeated. If the heater does not ignite following a further 90 seconds of fuel delivery, a fault shut-down
occurs.*
If the flame goes out of its own accord during operation, a new start is initiated. If the heater does not
ignite within 90 seconds of a renewed fuel delivery or if it does ignite but then goes out again within
15 minutes, a fault shut-down occurs. This can be remedied by switching off briefly and restarting.
If overheating (e.g. water deficiency, poorly aerated coolant circuit) occurs, the overheating gauge is
actuated. Delivery of fuel is interrupted and a fault shut-down occurs. After remedying the cause and
allowing the coolant temperature to drop below 70°C, the heater can be activated again by switching
off briefly and then restarting.
If the upper or lower voltage limit is reached (see Tab. 1 on page 2), a fault shut-down occurs.
With faulty glow plug or interruption of an electrical line to the batching pump, the heater will not start.
The speed of the blower motor is monitored constantly. If the blower motor will not start, if it is blocked
or if the speed drops below 40% of the set speed, a fault shut-down occurs after 60 seconds.
*= Following an impermissible number of unsuccessful start attempts, the control unit becomes
blocked.
Releasing this lock or a readout of the faults is only possible with the help of diagnostic equipment
(with mini-clock installed), (see “Troubleshooting” on page 13). If a modular dial is installed (optional)
readout and releasing of the lock is possible without diagnostic equipment.

4.5 Functioning in heater operation

With the heater switched on 20 the heat of the vehicle's own heat exchanger 42 and the diesel engine
40 is supplied.
When the coolant temperature has reached approx. 30°C, the vehicle's fan is activated and the heat
is also supplied to the cab interior.
Depending on the heating requirement, the heater is regulated in stages: High - Low - Off (control
interval).
Fixed temperature thresholds are also programmed into the electronic control unit.
With a control temperature of < 70°C the heater operates constantly in the „High“ stage.
With a coolant temperature of approx. 80°C the heater switches to the „Low“ stage.
If the heating requirement is so insufficient in the „Low “stage that the coolant temperature reaches
85°C, the machine switches to control interval.
An after-run of approx. 130 seconds then follows and then the heater switches off (control interval).
In the control interval, the indicator lamp lights up and the water pump continues running.

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Operation and functioning of the auxiliary heating

Fig. 6 Connection to the coolant circuit

8 Water pump 42 Heat exchanger in the operator's cab

20 Heater 44 Connector
40 Diesel engine

4.6 Switching off

Note!
When switching off, fuel supply is discontinued. The combustion air blower and the water pump con-
tinue to run for approx. 180 seconds longer and are then switched off automatically.

Switching off can be resulted in two ways:

– During continuous operation by pressing button 33, (see Fig. 7 on page8).
– When the pre-set heating time has expired.

4.7 Settings of the mini-clock

Fig. 7 Mini-clock

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Service Manual Auxiliary heating
Operation and functioning of the auxiliary heating

30 Button for activating the setting options 34 Display for time, preselection and heating
time
31 Button for setting the time forwards 35 Symbol for activated preselection time
32 Button for setting the time backwards 36 Symbol for heating operation
33 ON / OFF button for activating / deactivating 37 Symbol for preselection time (1, 2 or 3)
preselection time

Note!
– If no button is pressed within 15 seconds, the display switches back to its initial mode (= normal
time display).
– When setting the time with buttons 31 and 32, time adjustment will become quicker if the button
is held pressed.

Initial start-up of the mini-clock

After shutting down the power supply, all symbols in the display 34 begin flashing. The heater can
not be started in this condition. The actual time must first be set.

Setting the time

Push button 30 for longer than 3 seconds
The time display starts flashing.
Press buttons 31 and 32 until the actual time is displayed.
Press button 30 shorter than 5 seconds.
The time is displayed and the double point flashes.

Note!
If button 30 is not pressed within 5 seconds of setting the time, the clock switches to „Setting heating
time“.

Setting the heating time

Push button 30 for longer than 3 seconds
The time is flashing.
The mini-clock switches to „Setting heating time“.
The heating symbol and the heating time start flashing in the display.
Set the heating time with buttons 31 and 32 (from 10 to 120 minutes).
Press button 30
The time is displayed and the double point flashes.

Setting preselection time

Press button 30 once, twice or three times.
Preselection time 1, 2 or 3 is called up and indicated in the display (35 and 37).
Set the preselection time with buttons 31 and 32.

Switching on the heater

Press button 33.
The remaining heating time and the symbol 36 are indicated on the display.

Switching off the heater

Press button 33.
The heater continues to run for approx. 3 minutes, the actual time is indicated in the display.

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Subsequent installation of the auxiliary heating

Continuous operation
Press button 32 and hold it pressed.
Press button 33.
The heater switches on.
Press button 33 again.
The heater switches off.

Activating / deactivating the preselection time

Note!
Up to three preselection times can be set and activated for this mini-clock. Each preselection time
is deactivated upon conclusion of the heating procedure and must be reactivated for the next heat-
ing procedure.

Press button 30 once, twice or three times until the desired preselection time appears in the dis-
play.
Activate the preselection time with button 33.
Upon activation, the symbol „ON“ 35 appears on the display.
If the preselection time is activated, the symbol (37) 1, 2 or 3 appears on the display.
Deactivate the preselection time with button 33.

5 Subsequent installation of the auxiliary heating

Caution!
Risk of burns and short-circuits!
Before commencing any tasks, switch off the battery main switch or disconnect the vehicle bat-
tery.
Before working on the heater, switch off the heater and allow components to cool.

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Service Manual Auxiliary heating
Subsequent installation of the auxiliary heating

Fig. 8 Installing the auxiliary heating

8 Water pump 28 Fuel line

15 Exhaust gas muffler 42 Heat exchanger in the operator's cab
18 Combustion air hose 70 Shut-off valve water flow to engine
20 Heater 71 Shut-off valve water return-flow to engine
22 Console A Water flow from engine
23 Auxiliary water pump B Water flow to heat exchanger in the opera-
tor's station
24 Water flow hose C Water return-flow from heat exchanger
25 Separation point heater - water flow D Water return-flow to engine
26 Separation point heater - heat exchanger E Air suction
27 Water return-flow hose F Exhaust point

5.1 Installing the auxiliary heating

Mount the heating 20 on the console 22, (see Fig. 8 on page11).
Mount the complete console 22 beneath the cooler.
Close the water taps 70 and 71 on the diesel engine, (see Fig. 8 on page11).
Disconnect the water hose 24 (feed at bottom of engine) so that the hose reaches from the diesel
engine to the separation point 25.
At the same time ensure that the water hose does not become kinked and does not scrape against
any rotating parts (e.g. fan wheel).
Secure the water hose 24 to the separation point 25 using a hose clamp.
Disconnect the water hose 24 from the heat exchanger in the operator's station 42 and secure it
to the separation point 26 using a hose clamp.
Mount and connect the batching pump 14 to the tank, (see Fig. 9 on page12).
Lay out and connect the fuel line 28 from the tank to the heater, (see Fig. 10 on page12).
Fasten the combustion air hose 18 to the slewing platform.
Fasten the exhaust gas muffler 15 and the exhaust hose to the slewing platform with a clamp.
Open the water taps 70 and 71 on the diesel engine.

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Subsequent installation of the auxiliary heating

5.2 Installing the batching pump

Fig. 9 Installation position of batching pump

14 Batching pump 62 Fuel sieve

61 Plug connection X98 63 Connection to fuel tank

Fig. 10 Laying of line to the batching pump

A correct laying of line B incorrect laying of line

The following must be noted when installing the batching pump and laying the fuel lines:
– Trim the fuel lines and tubes with a sharp knife only. Do not pinch the tube when cutting and cut
cleanly ensuring that no burring occurs.
– Never lay or secure fuel lines in immediate proximity to the exhaust gas channels of the heater or
the diesel engine.
– Always fix the fuel lines flush to prevent blisters occurring, (see Fig. 10 on page12).
– Always mount the batching pump with the pressure side pointing upwards. Ensure also that the
installation angle is between 15° and 35°, (see Fig. 10 on page12).

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Service Manual Auxiliary heating
Maintenance

6 Maintenance
– Check the fuel sieve 62 of the batching pump 14 for contamination, (see Fig. 9 on page12).

7 Troubleshooting
Prerequisites:
Ensure that
– there is sufficient fuel in the tank.
– there is no summer diesel remaining in the fuel line in winter.
– the exhaust air and combustion air channels are OK.
– the fuses are OK.
Check the supply voltage U Batt (Kl. 30).
– Disconnect the 8-pin plug X101 (S1 / B1) and measure the voltage present in plug B1 / pin 1 (wire
2.52 red) and pin 2 (2.52 brown). If a deviation of battery voltage is ascertained, check the fuses,
the supply lines, the earth connection and the positive terminal on the battery for a drop in voltage
(corrosion / interruption).
Check the actuation signal (S+).
– Disconnect the 8-pin plug X101 S1 / B1 and then press button 33 on the mini-clock. Measure the
voltage present in the plug B1 between pin 7 (wire 0.52 yellow) and pin 2 (2.52 brown). If no voltage
is present, check the supply line (wire 0.52 yellow), the 5A fuse at the main fuses 5 and the mini-
clock 6 .
Check the mini-clock.
– Remove plug X95 at the mini-clock, establish a bridge between wire 0.52 red and wire 0.52 yellow.
If voltage is present in plug X101 (B1) between pin 7 (wire 0.52 yellow) and pin 2 (wire 0.52 brown),
the mini-clock must be replaced.

7.1 Troubleshooting with the diagnostic equipment

The diagnostic equipment with adapter cable is required for further troubleshooting regarding query-
ing of the error memory and deleting the locking for the control unit, (ID no. see Group 2.01).
The electronic control unit can store up to 5 fault codes which can then be read out and displayed by
the diagnostic equipment.

Fig. 11 Diagnostic equipment

65 Deleting the stored error 68 Reverse action of errors F5 - F1

66 Deleting the stored error 69 Forward action of errors F1 - F5
67 Diagnosis - call up fault code 70 Display

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Troubleshooting

Fig. 12 Connection of diagnostic equipment with adapter cable

6 Mini-clock 68 Diagnostic equipment

20 Heater 69 Adapter cable set

The actual error is displayed as „AF“ and is always written in memory F1.
Foregone errors are transferred to memory F2 - F5, the content of memory F5 is overwritten as re-
quired.
A faulty current circuit, as well as a faulty component will be displayed in the diagnostic equipment.

Querying the fault code

Press the button 67.
„AF“ (=actual error) and a 3-digit number (=fault code) appears on the display.

Releasing the locking and deleting the fault code

After remedying the cause of the error:
Press buttons 65 + 66 simultaneously for at least 2 seconds.
The control unit is unlocked and the stored errors F1 - F5 are deleted.
Switch off the auxiliary heating and switch back on again.

Note!
An additional adapter cable is required for connection of the diagnostic equipment due to poor ac-
cessibility of the plug connections, see tools in Group 2.01.
Open the cover of the right-hand console.
Disconnect the plug of the mini-clock from the cable set.
Connect the adapter cable of the diagnostic equipment in between.

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Troubleshooting

7.2 Fault codes, error descriptions and remedial measures

Fault
Error description Remedial measures
code
010 Overvoltage: Overvoltage is present for at least 20 seconds without inter-
Deactivation ruption at the control unit heater without function
Disconnect the plug connection X101 (B1/S1).
Start up the vehicle engine.
Measure the voltage in the plug X101 (B1 between pin 1
and pin 2).
Voltage > 28 volts:
Check the alternator regulator or battery.
011 Undervoltage: Undervoltage is present for at least 20 seconds without in-
Deactivation terruption at the control unit heater without function
Disconnect the plug connection X101 (B1/S1).
Start up the vehicle engine.
Measure the voltage in the plug X101 (B1 between pin 1
and pin 2).
Voltage > 20 volts:
Check the fuses, the supply lines, the earth connections
and positive terminal on the battery for a drop in voltage
(corrosion).
012 Overheating Temperature on the overheating gauge > 125°C.
(software - threshold Check the water circuit:
value)
Check all hose connections for leaks.
Check the direction of throughflow from thermostat and
check valves.
Aerate the water circuit.
Ensure correct functioning of the water pump.
Check the temperature gauge and overheating gauge
014 Possible overheating Difference of temperature values from overheating gauge
detected (difference and temperature gauge > 25K.
evaluation). Prerequisite for this fault code - display is that the heating is
The heating with the active and that the water temperature at the overheating
date of manufacture gauge has reached at least 80°C.
12.97 features the fol-
Check all hose connections for leaks.
lowing values:
Difference of temper- Check the direction of throughflow from thermostat and
ature values from check valves.
overheating gauge >
Aerate the water circuit.
15K.
Water temperature at Ensure correct functioning of the water pump.
overheating gauge at
Check the temperature gauge and overheating gauge
least 70°C.

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Troubleshooting

Fault
Error description Remedial measures
code
015 Operational shut- The control unit is blocked.
down:
Unblocking of the control unit with the diagnostic equip-
Permissible number
ment.
of 10 possible over-
heatings exceeded. Check the water circuit:
Check all hose connections for leaks.
Check the direction of throughflow from thermostat and
check valves.
Aerate the water circuit.
Ensure correct functioning of the water pump.
Check the temperature gauge and overheating gauge
017 Overheating detected Temperature on the overheating gauge > 130°C.
EMERGENCY-OFF:
Check the water circuit:
(hardware - threshold
value) Check all hose connections for leaks.
Check the direction of throughflow from thermostat and
check valves.
Aerate the water circuit.
Ensure correct functioning of the water pump.
Check the temperature gauge and overheating gauge
020 Glow plug - interrup- Functional check of the glow plug when installed:
tion:
Unplug the 14-pin plug pin 9 (1.52 white) and pin 12 (1.52
brown).
021 Glow plug outlet -
short circuit, overload Establish a voltage of 18 volts ± 0.1 volts at the glow plug.
or earth fault Measure the current strength after approx. 25 seconds.
(carry out a check Current strength = 4.5 amperes ± 1.5 amperes.
with a maximum of 18 Glow plug = OK.
volts.
If the glow plug is not OK:
The glow plug will be-
come ruined if the val- Inspect the drive train of the glow plug for damage.
ue is exceeded.
For fault code 021:
Ensure short-circuit
protection of mains Check assembly of the connector and the waved washer.
power supply)!
Check the drive train for short circuit.

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Troubleshooting

Fault
Error description Remedial measures
code
030 Speed of combustion Blower wheel or combustion air blower motor blocked
air blower motor out- (frozen solid, contaminated, stiff, drive train scraping against
side the permissible end of shaft...).
range:
Remedy the blockage.
Carry out a check
with approx. 15 volt + Measure the speed of the combustion air blower motor:
0.2 volts.
Unplug the 14-pin plug pin 14 (0.752 brown) and pin 13
Ensure correct con-
(0.752 black).
nection of lines!
Brown = + Mount the reflective strips on the shaft.
Black = -
Charge the combustion air blower motor with 15 volts.
(ensure short-circuit
protection of mains Measure the speed with non-contact speedometer.
power supply)!
Speed < 1000 rpm:
Replace the combustion air blower.
Speed > 1000 rpm:
Replace the control unit.
031 Combustion air blow- Ensure correct layout of drive train for the combustion air
er motor: blower motor and inspect for damage.
Interruption.
Measure the speed of the combustion air blower motor:
Carry out a check
with approx. 15 volt + Unplug the 14-pin plug pin 14 (0.752 brown) and pin 13
0.2 volts. (0.752 black).
Ensure correct con-
Mount the reflective strips on the shaft.
nection of lines!
Brown = + Charge the combustion air blower motor with 15 volts.
Black = -
Measure the speed with non-contact speedometer.
(ensure short-circuit
protection of mains Speed < 1000 rpm:
power supply)!
Replace the combustion air blower.
Speed > 1000 rpm:
Replace the control unit.

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Troubleshooting

Fault
Error description Remedial measures
code
032 Combustion air blow- Blower wheel or combustion air blower motor blocked (con-
er motor: taminated, stiff, drive train scraping against the end of the
Short circuit. shaft...):
Carry out a check
Remedy the blockage.
with approx. 15 volt +
0.2 volts. Measure the resistance.
Ensure correct con-
Resistance < 2 k = earth fault:
nection of lines!
Brown = + Replace the combustion air blower.
Black = -
Resistance > 2 k = no earth fault:
(ensure short-circuit
protection of mains Measure the speed of the combustion air blower motor.
power supply)!
Measure the speed of the combustion air blower motor:
Unplug the 14-pin plug pin 14 (0.752 brown) and pin 13
(0.752 black).
Mount the reflective strips on the shaft.
Charge the combustion air blower motor with 15 volts.
Measure the speed with non-contact speedometer.
Speed < 1000 rpm:
Replace the combustion air blower.
Speed > 1000 rpm:
Replace the control unit.
038 Relay control of vehi- Check the electrical line to the relay.
cle blower:
Remedy the interruption.
Interruption
Replace the relay.
039 Relay control of vehi- Remove the relay.
cle blower: Fault code 038 appears in the display.
Short circuit, overload
Remedy the interruption.
of earth fault
Replace the relay.
041 Water pump: Inspect the supply line to the water pump for clear passage:
Interruption
Unplug the 14-pin plug pin 10 (0.52 brown) and pin 11
(0.52 purple).
Remedy the interruption.
If necessary, replace the water pump.
042 Water pump: Disconnect the plug connection in the cable harness „wa-
Short circuit, over- ter pump“:
load, earth fault
If fault code 041 is displayed:
Water pump faulty.
Replace the water pump.
047 Batching pump: Disconnect plug connection in the cable harness „batch-
Short circuit, over- ing pump“:
load,
If fault code 048 is displayed:
earth fault
Replace the batching pump.

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Troubleshooting

Fault
Error description Remedial measures
code
048 Batching pump: Inspect the cable harness of the batching pump for clear
Interruption passage.
Remedy the interruption.
If necessary, replace the batching pump.
050 Operational shut- The control unit is blocked.
down:
Delete the error memory of the control unit with the diag-
Too many start at-
nostic equipment.
tempts
(10 start attempts, ad- Unlock the control unit.
ditionally a start re-
Check amount of fuel and fuel supply.
peat for every start
attempt)
051 Time exceeded: Upon start-up, the flame scanner registers a temperature >
Blowing cold 70°C for longer than 240 sec.
Check exhaust gas and combustion air channelling
Check the flame scanner.
052 Safety time: Check exhaust gas and combustion air channelling
Exceeded
Check amount of fuel and fuel supply.
053 Terminating the flame Warning!
from regulating stage The heating initiates a restart upon termination of the flame
„High“ from regulation stage „High“ or „Low“ as well as permissible
start attempts with subsequent start repeats as required!
056 Terminating the flame Restart or start repeat = successful fault code - display
from regulating stage is deleted.
„Low“
Fault as no more new start attempts are permissible:
Check exhaust gas and combustion air channelling
Check amount of fuel and fuel supply.
Check the flame scanner, see fault codes 064 and 065.
060 Temperature scan- Dismantle the control unit and check the connecting ca-
ner: ble of the temperature gauge for damage.
Interruption
Drive train OK, short circuit temperature gauge:
Plug the 14-pin plug pin 3 into pin 4.
Switch on the heating.
If fault code 061 is displayed:
Dismantle and check the temperature gauge.
If fault code 060 is displayed:
Check the control unit, replace as necessary.

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Troubleshooting

Fault
Error description Remedial measures
code
061 Temperature scan- Dismantle the control unit and check the connecting ca-
ner: ble of the temperature gauge for damage.
Short circuit, overload
Drive train OK:
or earth fault
Remove the 14-pin plug at the control unit.
The inspection can
Unplug pin 3 (0.52 blue) and pin 4 (0.52 blue).
only be carried out if
the heater is still in- Plug in 14-pin plug at the control unit.
stalled in the machine
Switch on the heating.
if no test rig is availa-
ble. If fault code 060 is displayed:
Dismantle and check the temperature gauge.
If fault code 061 is displayed:
Check the control unit, replace as necessary.
064 Flame scanner: Dismantle the control unit and check the connecting ca-
Interruption ble of the flame scanner for damage.
Drive train OK:
The inspection with a
bridge in the 14-pin Change the 14-pin plug pin 1 over to pin 2.
plug can only be car-
Switch on the heating.
ried out if the heater is
still installed in the If fault code 065 is displayed:
machine or if a test rig
Dismantle and check the flame scanner.
is available.
If fault code 064 is displayed:
Check the control unit, replace as necessary.
065 Flame scanner: Dismantle the control unit and check the connecting ca-
Short circuit, over- ble of the flame scanner for damage.
load, earth fault
Drive train OK:
The inspection can Remove the 14-pin plug at the control unit.
only be carried out if
Unplug pin 1 (0.52 blue) and pin 2 (0.52 brown).
the heater is still in-
stalled in the machine Plug in 14-pin plug at the control unit.
if no test rig is availa-
Switch on the heating.
ble.
If fault code 064 is displayed:
Dismantle and check the flame scanner.
If fault code 065 is displayed:
Check the control unit, replace as necessary.

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Troubleshooting

Fault
Error description Remedial measures
code
071 Overheating gauge: Dismantle the control unit and check the connecting ca-
Interruption ble of the overheating gauge for damage.
Drive train OK:
The inspection with a
bridge in the 14-pin Change the 14-pin plug pin 5 over to pin 6.
plug can only be car-
Switch on the heating.
ried out if the heater is
still installed in the If fault code 072 is displayed:
machine or if a test rig
Dismantle and check the overheating gauge.
is available.
If fault code 071 is displayed:
Check the control unit, replace as necessary.
072 Overheating gauge: Dismantle the control unit and check the connecting ca-
Short circuit, over- ble of the overheating gauge for damage.
load, earth fault
Drive train OK:
Remove the 14-pin plug at the control unit.
The inspection can
Unplug pin 5 (0.52 red) and pin 6 (0.52 red).
only be carried out if
the heater is still in- Plug in 14-pin plug at the control unit.
stalled in the machine
Switch on the heating.
if no test rig is availa-
ble. If fault code 071 is displayed:
Dismantle and check the overheating gauge.
If fault code 072 is displayed:
Check the control unit, replace as necessary.
090 Control unit faulty Replace control unit.
092 - 103
091 External interference Disruption of control unit due to interference voltages from
voltage the onboard power supply from poor batteries, charging
equipment, other fault sources.
Remedy the fault sources.
Faults which are not displayed by the diagnostic equipment
Fault description Remedial measures
Heater will not start Upon activation of the heater, the water pump and the vehi-
cle blower start immediately.
Dismantle and check the temperature gauge.

7.3 Checking the flame scanner

A check of the flame scanner is to be carried out with a digital multimeter. If the resistance value of
the flame scanner is outside of the value chart, the flame scanner is to be replaced.

7.3.1 Value charts of the flame scanner

Temp (°C) -50 0 10 20 30 50 80 90

R( 803 1000 1022 1062 1097 1194 1309 1347
U (V) 1,407 1,639 1,661 1,719 1,738 1,840 1,948 1,983

R 914 C / R 924 C 17.30.21

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Temp (°C) 100 130 150 200 250 300 350 400
R( 1385 1498 1573 1758 1941 2120 2297 2470
U (V) 2,016 2,111 2,171 2,308 2,432 2,542 2,642 2,732

7.4 Checking the overheating gauge and temperature gauge

A check of the overheating gauge and temperature gauge is to be carried out with a digital multimeter.
If the resistance value is outside the value chart, the overheating gauge or the temperature gauge is
to be replaced.

7.4.1 Value chart of the overheating gauge and temperature gauge

Temp (°C) 0 10 20 30 40 50 60 70
R (K 32,54 19,87 12,48 8,06 5,33 3,60 2,48 1,75
U (V) 4,275 3,960 3,561 3,100 2,611 2,135 1,705 1,339

Temp (°C) 80 90 100 110 120

R (K 1,25 0,91 0,67 0,50 0,38
U (V) 1,041 0,805 0,622 0,483 0,376

8 Electrical system

Note!
The electrical components and connections can be obtained in the circuit diagram of Group 8.

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Service Manual Heating and air-conditioning system
Job definition

17.50: Heating and air-conditioning system

1 Job definition
The operator's cab is fitted with a heating and air-conditioning system as standard. This can be used
for heating and air-conditioning, as well as for ventilation of the cab.
It allows the operator:
– to generate the desired room temperature in the cab
– quick dehumidification (reheating) of the cab during “humid seasons“
– regulatory discharge of air via flaps and blower control

1.1 Notes in general regarding the air-conditioning system

– The air-conditioning system is only operational if the vehicle engine is running
– During cooling operation, the air humidity is lowered in the vehicle interior. This prevents the win-
dows from steaming up
– The air-conditioning system works most efficiently if the windows and doors are closed. If, howev-
er, the interior becomes extremely hot as a result of direct sunlight with the machine switched off,
briefly opening the windows / doors will speed up the cooling process
– With high ambient temperatures and high air humidity, condensation will drop from the vaporiser
and forms a puddle of water beneath the machine. This is normal and should not be taken as an
indication of leakages
– Contamination is kept to a minimum by the filter in the recirculation grill. Switch over to recircula-
tion mode if the outside air is polluted. The elements of the recirculation grill must be cleaned or
replaced at regular intervals in order that output of the air-conditioning system does not become
impaired

Caution!
For safety reasons we recommend that any interventions or repairs to the air-conditioning system
are carried out by mechanics trained in refrigeration engineering. For all tasks on the cooling
circuit, the safety and accident-prevention guidelines, and in particular the environmental protection
guidelines regarding handling of the refrigerant being used, must be observed.

2 Technical data

Machine Unit R 914 C / R 924 C

Heater and air-conditioning unit Type KL 2/4
Operating voltage Volts DC 24
Refrigerant Type R134a
Amount of refrigerant kg approx. 1.6 (without cab elevation)
Amount of cooling oil in the circuit cm3 200
Quality of cooling oil PAG SP 10
Vaporiser - cooling output KW max. 7.5
Radiator - heating output KW max. 9.5
Heat exchanger - air flow m3/h 1165
Heat exchanger - power consump- A 13,4
tion
Compressor Type SD 7 H 15
Compressor weight kg 5,3

R 914 C / R 924 C 17.50.1

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Heating and air-conditioning system Service Manual
System description

Machine Unit R 914 C / R 924 C

Diameter of magnetic clutch mm 119
Voltage Volts DC 24
Pushbutton
Low pressuredeactivation bar 1.5 ± 0.5
activation bar 3.4 max.
High pressuredeactivation bar 25.5 ± 0.5
activation bar 18.0 ± 0.5
Defrost thermostatdeactivation °C m1.0 ± 1.0
activation °C k5.5 ± 1.0
Pressure control valve 9 bar 32.0 ± 4

Tab. 1 Technical data

3 System description
The air-conditioning system is comprised of 4 main parts connected by hoses:
– Cooling compressor 1 with electromagnet - clutch Y20 is powered by the diesel engine via V-
belt and is thus situated next to the diesel engine on the fan side
– The capacitor 2 is mounted at the front on the combined radiator (for engine coolant, hydraulic
oil, etc.)
– The heater and air-conditioning unit 20 is situated in the operator's cab - arranged behind the
operator's seat - and forms the low-pressure section of the system. It comprises essentially the
heater and vaporiser battery (heat exchanger) 8 and the expansion valve 6. The vaporiser of the
air-conditioning cooling circuit and the heat exchanger of the warm water heating are combined
in the heat exchanger 8 to form a battery unit. The defrost thermostat B43 is mounted on the
vaporiser battery 8 and protects the vaporiser battery 8 against icing and shuts down the
compressor
– Dry collection unit 3 is situated in the high-pressure section of the system behind the operator's
cab and comprises of the interior filter dryer 4 and inspection glass 5. The collecting sump 3, filter
dryer 4 and inspection glass 5 are combined in a single unit and may not be replaced individually
– The cooling water of the diesel engine is channelled to the heat exchanger via hoses and repre-
sents a separate circuit separate from the air-conditioning circuit

1 Air-conditioning circuit B255 Temperature sensor / drawn air

2 Capacitor unit B257 Temperature unit / exhaust air
3 Collecting sump M13 Engine / vaporiser blower
4 Filter dryer (internal) M75 Engine / outside air flap
5 Inspection glass M76 Engine / air flap rear wall
6 Expansion valve M77 Engine / air flap control console
8 Heat exchanger M78 Engine / air flap for foot area and wind-
shield
9 Bypass valve U37 Control unit / heating and air-condition-
ing system
10 Dry collector unit U38 Operating unit
20 Heater and air-conditioning unit housing Y20 Magnetic clutch / air-conditioning
B43 Defrost thermostat / air-conditioning Y46 Solenoid valve / heating system
system
B44 Pushbutton / air-conditioning system

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Service Manual Heating and air-conditioning system
Exploded view of heating and air-conditioning system

4 Exploded view of heating and air-conditioning system

Fig. 1 Heating and air-conditioning system

5 Functional description
see Fig. 1 / see Fig. 3

R 914 C / R 924 C 17.50.3

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Functional description

5.1 Functioning of the air-conditioning system

The compressor 1 compresses the gaseous refrigerant R134a and forces it through the heat ex-
changer 2 (capacitor) which is blow through with outside air from the fan wheel of the combined ra-
diator. The pressurised refrigerant, heated via compression in the compressor, is cooled and thus
also condenses in the capacitor in the heat exchanger 2.
The liquid coolant flows into the collecting sump 3 and continues through the dryer 4 and inspection
glass 5 to the expansion valve 6 at the vaporiser inlet where the pressurised refrigerant is relieved of
pressure and vaporised.
The heat required for vaporisation is acquired from the air flow of the blower via the vaporiser. This
means that the interior air is cooled and blown back into the cab. The cab temperature is thus low-
ered.
The gaseous refrigerant at the vaporiser outlet flows on to the compressor 1 where it is compressed
and a new cycle then begins.

5.1.1 Coolant compressor 1

The compressor 1 transports and channels the refrigerant R134a in the circuit where it is com-
pressed.

5.1.2 Capacitor 2
The air-charged finned capacitor 2 channels the quantity of heat from the system out into the ambient
air and liquefies the gaseous refrigerant R134a.

5.1.3 Dry collector unit 10

The dry collector unit 10 is installed downstream from the capacitor 2 and collects the liquid refriger-
ant. This should guarantee that liquid refrigerant, free of bubbles is channelled to the expansion valve
6 in operating mode.
The refrigerant R134a can only eliminate a small quantity of humidity. Water which has not been re-
leased is usually segregated at the valve in ice form at vaporisation temperatures below 0°C and will
cause the system to malfunction. Corrosion damage may also be caused in the system from high lev-
els of humidity.
To ensure that no water ends up in the circuit, a sieve or filter is installed at the end of the dryer 10.
Foreign substances such as acids and dirt particles are also collected here.
The main drying is resulted via a hollow body made of sintered silicate balls. This prevents complete
residual drying and the binding of acids. Correct filling of refrigerant and humidity content of the sys-
tem can be checked at the inspection glass 5.
During air-conditioning operation the liquid refrigerant flows bubble-free through the inspection glass
5. Furthermore, the white float ball 5a must be situated at the top of the inspection glass. This would
otherwise indicate a deficiency in the refrigerant. The system must be topped up with refrigerant
R134a.

The colour of the indicator pearl 5b in the inspection glass is dependent on the humidity con-
tent in the cooling circuit, see Fig. 2.
– If the pearl is coloured blue, the humidity content is OK
– If the pearl is coloured pink, the dry collector unit is saturated with humidity and must be replaced
immediately

5.1.4 Expansion valve 6

The expansion valve 6 supplies refrigerant R134a into the vaporiser and also serves as a regulation
element. It is controlled by a temperature gauge mounted on the outlet of the vaporiser 8.

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If the outlet temperature of the vaporiser drops below a certain limit, the liquid refrigerant could flow
back to the compressor and the compressor may sustain damage.
To avoid this, the temperature gauge works upon the expansion valve 6, whereby it restricts supply
to the vaporiser 8.

5.1.5 Heat exchanger 8

The heat exchanger 8 serves as a vaporiser for the air-conditioning system.
The ventilator blows air through the fins and pipe walls of the vaporiser.
The refrigerant flows as a liquid into the heat exchanger. It accumulates the heat required for vapor-
isation of the through-flowing refrigerant, thus channelling cold air back.

5.1.6 Safety organs

Upon reaching a maximum pressure on the high-pressure side, the pushbutton B44 on the dryer 10
shuts down the coolant compressor 1. This should prevent ruination of the system.
The pressure control valve 9 (with membrane) installed in the dry collector unit opens when a pres-
sure of 32 bar is reached. The pressure control valve 9 is an extra safeguard should pushbutton B44
sustain damage.

Fig. 2 Dryer 3

5.1.7 Defrost thermostat B43

Protects the vaporiser battery 8 against icing:

In temperatures below +1 degrees on the temperature gauge B43, the magnetic clutch shuts down
the compressor to prevent the vaporiser batteries from icing. The blower (fan blower and radial blow-
er) are not affected.

R 914 C / R 924 C 17.50.5

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Fig. 3 Functional diagram for heating and air-conditioning system

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Service Manual Heating and air-conditioning system
Operation of the heating and air-conditioning system

Air circuit
A Cab - interior air 1 blown out at the control console
B Outside air 2 blown out into the footing area and on the
front windshield
C Air heated or cooled air in the heater and 3 blown out at the rear wall
vaporiser battery
D Outside air heated in the capacitor battery

Refrigerant circuit
E High pressure (liquid form) G Low pressure (liquid form)
F High pressure (gaseous) H Low pressure (gaseous)

Components:
1 Air-conditioning circuit B255 Temperature sensor / cab
2 Capacitor unit B257 Temperature unit / exhaust air
3 Collecting sump M13 Engine / vaporiser blower
4 Filter dryer M75 Engine / outside air flap
5 Inspection glass M76 Engine / air flap rear wall
6 Expansion valve M77 Engine / air flap control console
8 Heat exchanger M78 Engine / air flap for foot area and wind-
shield
9 Bypass valve U37 Control unit / heating and air-conditioning
system
10 Dry collector unit U38 Operating unit
20 Heater and air-conditioning unit Y20 Magnetic clutch / air-conditioning
B43 Defrost thermostat Y46 Solenoid valve / heating system
B44 Pushbutton / air-conditioning system

6 Operation of the heating and air-conditioning system

Fig. 4 Operating element

R 914 C / R 924 C 17.50.7

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Operation of the heating and air-conditioning system

Control keys
1 Air-conditioning operation ON / OFF (cooling 7 Heating mode manual / automatic
mode)
2 Increase cab temperature 8 Fresh air mode / recirculated air mode
3 Lower cab temperature 9 Air flap rear wall OPEN / CLOSED
4 Control ON / OFF 10 Air-flap right-hand console OPEN / CLOSED
5 Vaporiser fan speed 11 Ventilation flap front windshield footing area
MIDDLE / CLOSED
6 REHEAT-mode 12 Ventilation flap front windshield footing area
MIDDLE / OPEN

Main display screen displays

13 Recirculated air mode 20 Automatic operation
14 REHEAT-mode 21 Bar indicator for fan speed in manual opera-
tion
15 Air-conditioning operation (cooling mode) 22 Symbol for fan speed in manual operation
16 Air flap rear wall OPEN 23 Symbol for heating mode in manual opera-
tion
17 Air flap 24 Bar indicator for heating mode in manual
operation
18 Air flap 25 Set value / error code
19 Air flap 26 Temperature unit (°)

Note!
To attain an optimum air-conditioning setting, select automatic operation 20, the manual bar indica-
tor 21 and 24 are no longer shown on the display. The temperature Manu - Auto can no longer be
affected. Only the heating can be altered manually. The automatic air-conditioning operation is not
affected.
Should problems arise with drawn air etc., the fan speed can be adjusted manually in automatic op-
eration.

6.1 Activating the control unit

Fig. 5 Activating the control unit

Switch on the system using button 4
While the control unit is undergoing a self-test, the software version is indicated for approxi-
mately 12 seconds
Heating and ventilation of the cab are operational. The heating output or the sped of the fan are con-
trolled automatically if the symbol AUTO (20) is activated.

17.50Wednesday,
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Operation of the heating and air-conditioning system

6.2 Setting the desired cab temperature

Fig. 6 Setting the cab temperature

The 4-digit segment display 25 indicates the desired cab temperature.
Increase the temperature with the button 2
Lower the temperature with the button 3
The set temperature remains stored until the next modification.
Air-conditioning operation must be switched on if cooling is required (see 6.3).
To set the heating output manually, press the button 7
The heating symbol flashes for 5 seconds
As long as the heating symbol continues flashing, the heating output can be increased or lowered
with button 2 or 3
Press button 7 to activate automatic operation again

6.3 Switching the temperature display over to Fahrenheit

Fig. 7 Switching the temperature display over to Fahrenheit

Press fresh air mode button 8 and hold pressed.
Symbol 13 appears
Press button 3.
The temperature is displayed in Fahrenheit
Pressing both buttons 8 and 3 again switches the temperature display back to °Celsius.

R 914 C / R 924 C 17.50.9

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Recirculated air and fresh air

6.4 Air-conditioning mode

Fig. 8 Air-conditioning and REHEAT function

Switch on the air-conditioning via button 1
Symbol 15 is activated
The compressor is only switched on via the control unit if required
To attain the desired dehumidification of the cab, switch on the air-conditioning system during
heating mode
Press the REHEAT-button 6
Symbol 14 is activated
REHEAT means that the heating and the air-conditioning are activated simultaneously. This will
achieve a quicker dehumidification of the cab. Emission of the air at the front windshield can not be
switched off during REHEAT mode and the fan continues to run at high speed. After 10 minutes the
REHEAT-mode is switched off automatically again and the system continues running with the old pa-
rameters.

7 Recirculated air and fresh air

Fig. 9 Recirculated air and fresh air

The heating and air-conditioning system can be switched over to recirculated air and fresh air modes.
To open / close the fresh air flap, press button 8
Symbol 13 indicates that the fresh air flap is closed
To set the fan speed manually, press the button 5
The fan symbol flashes for 5 seconds
As long as the fan symbol continues to flash, the fan output can be increased or reduced manually
by pressing button 2 or 3, see Fig. 6
Press button 5 to activate automatic operation again

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Recirculated air and fresh air

7.1 Air ventilation

Fig. 10 Position of air vent

The air vent is situated on the seating console 8a, on the right-hand control console 8b, on the front
windshield 8c and on the cab rear wall 8d. The open position of the respective air flap is indicated by
an arrow in the display.
To achieve optimum comfort:
During heating mode, open the air vent for the footing area 8a, right-hand control console 8b and
if necessary, front windshield 8c
During air-conditioning mode, open the air vent for cab rear wall 8d and right-hand control console
8b
Optimum heating and cooling effect is attained during recirculated air mode
Hi

Note!
If the machine is used over a lengthy period of time without the air-conditioning system being
activated, start up the compressor every 2 weeks via the REHEAT-button 6.

7.2 Operation with auxiliary heating (special equipment)

Fig. 11 Operation with auxiliary heating

Note!
The auxiliary heating may only be activated if the ignition is switched off. No manual adjustments
may be carried out during auxiliary heating mode.

Switch on the auxiliary heating, the auxiliary heating is then switched off automatically when the
diesel engine is switched on

R 914 C / R 924 C 17.50.11

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Operation and description of the test menu

8 Operation and description of the test menu

8.0.1 Start vehicle engine

Fig. 12 Ignition switch S1

Start up the engine using ignition switch S1

8.0.2 Activate the system

Fig. 13 Activate control operation

Press the ON / OFF button 4
While the control unit is undergoing a self-test, the software version is indicated for approxi-
mately 12 seconds

8.0.3 Access to the test menu

Fig. 14 Access to the test menu

Press the button 1 and then release
Press buttons 7, 6 and 5 simultaneously and then release
The control unit is now running in test mode, the sum of the set value in the regulator menu
(520 corresponds with the basic setting) is displayed. If this setting deviates from the factory
setting, the sum is indicated flashing. Symbol 13 shows that D+ (vehicle engine is running) is
acquired. All air flaps are closed

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8.0.4 1st test stage - cab temperature is displayed

Fig. 15 Display of cab temperature

Press the button 8 and then release
The actual cab temperature is displayed

8.0.5 2nd test stage - blow-out temperature is displayed

Fig. 16 Display of blow-out temperature

Press the button 8 and then release
The actual blow-out temperature is displayed

8.0.6 3rd test stage - currently without function

Fig. 17 Display without function

Press the button 8 and then release
The display is currently without function

R 914 C / R 924 C 17.50.13

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8.0.7 4th test stage - solenoid valve heating flow is activated

Fig. 18 Solenoid valve heating flow is activated

Press the button 8 and then release
The solenoid valve in the heating flow for the air-conditioning system is activated
A functional check (throughflow, power consumption) can be undertaken
Test stage 4 will only be carried out if D+ (vehicle engine running) is recorded.

8.0.8 5th test stage - magnetic clutch compressor is activated

Fig. 19 Magnetic clutch compressor is activated

Press the button 8 and then release
The magnetic clutch for the air-conditioning system is activated
A functional check (power consumption, visual inspection) can be undertaken
Test stage 5 should be carried out for a max. 5 min., otherwise the vaporiser will become excessively
iced.

8.0.9 6th test stage - slow fan speed is activated

Fig. 20 Slow fan speed

Press the button 8 and then release
Minimum fan speed of the vaporiser fan is activated
A functional check (power consumption ) can be carried out
All air flaps are closed
Test stage 6 is only undertaken if there is no pressure distortion or if an electrical short circuit occurs
in the magnetic clutch circuit.

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8.0.10 7th test stage - middle fan speed is activated

Fig. 21 Middle fan speed

Press the button 8 and then release
Middle fan speed of the vaporiser fan is activated
A functional check (power consumption ) can be carried out
All air flaps are closed

8.0.11 8th test stage - quick fan speed is activated

Fig. 22 Quick fan speed

Press the button 8 and then release
Quick fan speed of the vaporiser fan is activated
A functional check (power consumption ) can be carried out
All air flaps are closed

8.0.12 9th test stage - close recirculated air / fresh air flap

Fig. 23 Close recirculated air / fresh air flap

Press the button 8 and then release
The recirculated air / fresh air flap is closed
After approx. 10 seconds the flap is manoeuvred into the final position and the functional check
can then be carried out (power consumption, visual inspection)

R 914 C / R 924 C 17.50.15

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8.0.13 10th test stage - open recirculated air / fresh air flap

Fig. 24 Open recirculated air / fresh air flap

Press the button 8 and then release
The recirculated air / fresh air flap is opened and the quick fan speed is activated
After approx. 10 seconds the flap is manoeuvred into the final position and the functional check
can then be carried out (power consumption, flow speed, visual inspection)

8.0.14 11th test stage - open rear wall flap

Fig. 25 Open rear wall flap

Press the button 8 and then release
The rear wall flap opens and the quick fan speed is activated
After approx. 10 seconds the flap is manoeuvred into the final position and the functional check
can then be carried out (power consumption, flow speed, visual inspection)

8.0.15 12th test stage - close rear wall flap

Fig. 26 Close rear wall flap

Press the button 8 and then release
The rear wall flap closes and the fan is switched off
After approx. 10 seconds the flap is manoeuvred into the final position and the functional check
can then be carried out (power consumption, visual inspection)

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8.0.16 13th test stage - open armrest flap

Fig. 27 Open armrest flap

Press the button 8 and then release
The armrest flap opens and the quick fan speed is activated
After approx. 10 seconds the flap is manoeuvred into the final position and the functional check
can then be carried out (power consumption, flow speed, visual inspection)

8.0.17 14th test stage - close armrest flap

Fig. 28 Close armrest flap

Press the button 8 and then release
The armrest flap closes and the fan is switched off
After approx. 10 seconds the flap is manoeuvred into the final position and the functional check
can then be carried out (power consumption, visual inspection)

8.0.18 15th test stage - open flap front windshield / footing area

Fig. 29 Open flap front windshield / footing area

Press the button 8 and then release
The flap front windshield / footing room opens and the quick fan speed is switched off
After approx. 10 seconds the flap is manoeuvred into the final position and the functional check
can then be carried out (power consumption, flow speed, visual inspection)

R 914 C / R 924 C 17.50.17

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Operation and description of the test menu

8.0.19 16th test stage - close flap front windshield / footing area

Fig. 30 Close flap front windshield / footing area

Press the button 8 and then release
The flap front windshield / footing area closes and the fan is switched off
After approx. 10 seconds the flap is manoeuvred into the final position and the functional check
can then be carried out (power consumption, visual inspection)

8.0.20 17th test stage - inspection of LCD-display

Fig. 31 Inspection of LCD-display

Press the button 8 and then release
All segments and symbols of the LCD-display are activated
Functional check (visual inspection)

8.0.21 18th test stage - exiting the test menu and initiating a RESET

Fig. 32 Exiting the test menu

Press the button 4 and then release
The control unit initiates a RESET and the software version is displayed for approx. 10 seconds

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8.0.22 One test stage back in the test menu

Fig. 33 Test stage back

Press the button 6 and then release
With the button 6 REHEAT, it is possible in the test menu to execute the previous test stage

9 Maintenance tasks for the heating and air-conditioning system

Fig. 34 Filter elements in the operator's cab

9.1 Filter elements

If the filters become contaminated, the air flow rate in the heater and air-conditioning unit 20 is re-
duced, causing more frequent icing and shutting down of the air-conditioning system.
– The recirculated air and outside air filters 1 and 3 of the system are to be removed and cleaned
thoroughly every 500 operating hours, and even more frequently when working in extremely dusty
conditions
– Under no circumstances may the machine be operated without this filter, even for short periods of
time, as this will lead very rapidly to the heat exchanger 8 (see Fig. 35) becoming contaminated

R 914 C / R 924 C 17.50.19

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Maintenance tasks for the heating and air-conditioning system

Note!
Blow out the filter elements with compressed air or clean with cold or lukewarm water.
Never use hot water or steam jet to clean the elements. Replace the filter elements if they be-
come damaged or if they are in poor condition.

Cleaning or changing the recirculated air filter:

To remove the recirculated air filter 1, fold the backrest of the operator's seat forwards
Open the quick-release fastener 2 by turning one quarter of a turn
Remove the recirculated air filter 1

To clean the fresh air filter

Remove the deflector 4 on the rear side of the cab
Remove the outside air filter 3
Blow out the filter elements 1 / 3 with compressed air or clean in cold or lukewarm water

9.2 Heating system

The following maintenance tasks are to be carried out on the hating system once a year prior to onset
of the hot season.
– Check the entire coolant circuit for leaks
– Retighten the connection points of the cooling circuit, the hose connections on the cooling circuit,
the seals of the shut-off valves and the hose clamps
– The system must be operated with anticorrosive and antifreeze in the coolant

Fig. 35 Heater unit and solenoid valve

Aerating the heater unit:

For aeration, remove the red cap from the air vent valve above opening A (see arrow)
Press in the valve to allow air to escape

Cleaning solenoid valve Y46:

Remove and clean solenoid valve Y46 for hot water supply once a year prior to the onset of the
hot season
The solenoid valve must also be cleaned if heating output is insufficient
Rinse the membrane of the solenoid valve with water
At the same time, ensure that the compensation bore on the membrane is not clogged with dirt

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Service Manual Heating and air-conditioning system
Maintenance tasks for the heating and air-conditioning system

Inspecting the heat exchanger:

Inspect the fins of the heat exchanger 8 once a year for damage
Blow out with compressed air if contaminated
Realign the fins as required

9.3 Air-conditioning system"

Note!
To prevent the compressor from sustaining damage, switch on the air-conditioning system every 2
to 3 weeks for approx.10 minutes, regardless of the respective season, by switching to Reheat-
mode (refrigerant is distributed throughout the cooling circuit).
The following tasks are to be carried out every 500 operating hours :

Checking the capacitor:

Check the capacitor 8 for contamination
If necessary, fold down the capacitor 8 and blow out from the inside out (blower side) with com-
pressed air
At the same time, ensure that the fins of the capacitor are clean
With excessive contamination, overpressure occurs in the cooling circuit and the air-conditioning sys-
tem is switched off automatically.

Checking the air-conditioning compressor:

Tighten the fastening screws 7 of the air-conditioning compressor and the retainer on the engine
Check condition of the compressor V-belt

Fig. 36 Air-conditioning compressor 1 and capacitor 2

Checking the dry collector unit 10:

With the diesel engine running and the air-conditioning system switched off, check the refrigerant
level at the inspection glass 5 of the dry collector unit 3

R 914 C / R 924 C 17.50.21

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Maintenance tasks for the heating and air-conditioning system

Fig. 37 Dry collector unit

Note!
The white float ball 5a drops to the bottom of the inspection glass if the refrigerant indicates any
deficiencies.
If the cooling effect of the system deteriorates, have a refrigeration engineer refill the system.

Ascertain the degree of humidity of the drying substance in the dry collector unit 3
To do this, observe the colour of the indicator pearl 5b in the inspection glass
If the pearl is blue, the degree of humidity in the cooling circuit is OK. If the pearl is coloured pink,
however, the dry collector unit is saturated with humidity.
Replace the dry collector unit 3 immediately
Carry out a visual inspection of the dry collector unit 3
Should it be determined that the dry collector unit 3 is rusted or damaged (e.g. at the fastening of
the console, at the hose connection), replace the dry collector unit 3 (pressure tank)
In both of the previously stated instances, as well as in all other cases, always ensure that the dry
collector unit 3 is replaced by a mechanic trained in refrigeration engineering.
The cooling circuit must be drained, checked for leaks and then refilled. Check the hose lines for
points of wear, replace and if necessary, retighten the hose connections.

Fig. 38 Blower motor on the heater - air-conditioning unit

Additional maintenance tasks:

The following additional maintenance tasks are to be carried out at least once a year by a mechanic
trained in refrigeration technology:
Check functioning of the blower motor 13 (M13)

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Service Manual Heating and air-conditioning system
Tasks on the cooling circuit

Check functioning of the air flaps in the heating and air-conditioning system
Ensure secure seating of the electrical connections (sound contact)
Inspect the electrical lines for points of wear
Check the defrost thermostat 7 (B43) in the vaporiser (functioning, secure seating and for dam-
ages)
Check functioning of the pushbutton B44 on the dry collector unit 3, see Fig. 37

10 Tasks on the cooling circuit

– Avoid all direct contact with the refrigerant and wear industrial gloves. The eyes in particular
should be protected against liquid refrigerant by wearing protective glasses. Should refrigerant
nevertheless come into direct contact with the eyes, avoid rubbing and rinse with plenty of cold
water. Seek immediate medical assistance.
– When draining the system, the refrigerant should never be allowed to evaporate into the atmos-
phere, but rather the cooling circuit must be siphoned for the purpose of reutilisation or dismantled
in an environmentally-friendly manner
– Never subject any parts of the cooling system to high temperatures, such as steam jets, welding
or by placing in a drying kiln following painting. If necessary, drain the refrigerant
– Repairs may only be carried out if the cooling system has been completely drained. It is possible
for residual pressure to remain in the system following drainage. This residual pressure should
therefore be dissipated before loosening the connections
– Following intervention into the cooling circuit, seal all openings immediately with sealing plugs to
prevent air humidity from penetrating the system
– During assembly, always use sound connections and sealing elements. We recommend that new
seals be used
– Wet all sealing surfaces and seals with a special refrigerant before installing
– The connection points must be sealed with Loctite AVX 786 (drying time 1-2 hours)
– Store all spare-parts dry and well packed. Before installing spare-parts, ensure that the parts are
stored for a sufficient period of time at the installation site to ensure that the parts adapt to the
respective ambient temperature (formation of condensation)
– Blow out refrigerant hoses, pipelines, capacitor and vaporiser with nitrogen prior to installation
– Only remove the sealing plugs directly prior to installation of the parts. This must be observed in
particular for the collecting sump
– Only fill in refrigerant R134a into the system
– Under no circumstances may the system be switched on of parts are (even partially) damaged
– If it is assumed that the cooling circuit has been left open for a considerable length of time, for
example if the refrigerant has evaporated completely, it is imperative that the collecting sump is
replaced. This is also recommended following intervention into the system, with subsequent refill-
ing
– With any subsequent tasks on the air-conditioning system, it is imperative that the specific equip-
ment and special tools are used. Should faults occur which require extensive repair, we recom-
mend contacting an after-sales service point adept in refrigeration engineering

10.1 Drying and evacuation

Evacuation of the cooling systems entails complete dissipation of the system before refilling refriger-
ant, thus to establish sealing of the system by allowing to stand for a lengthy period of time in the
vacuum generated, and not least, by allowing the system to dry following this process.
If even traces of water remain in the refrigerant circuit, these will mix with the refrigerant and cause
various resulting damages. The compressor may not be employed for evacuation, but rather a vac-
uum pump which can attain an end vacuum below 1 Torr must be used.

R 914 C / R 924 C 17.50.23

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Tasks on the cooling circuit

10.2 Checking for leaks

Before commencing evacuation, fill in nitrogen via the pressure relief valve (approx. 22 bar) and
check all connection points of the cooling system using a suitable leak-search spray. If a leak is de-
termined, it will become evident in the form of foam bubbles.
If a drop in pressure is determined, the leak must be located. After filling the refrigeration system with
refrigerant, the system must be checked again for leaks.

10.3 Filling and draining, see Fig. 39

Filling
Only vapourous refrigerant may be sucked in when filling a running machine. Under no circumstanc-
es may the intake volume specified for the system be exceeded. Monitor the weight when filling from
a large cylinder.
If the correct working procedure is applied, the collector should be filled with approximately 1/3 of liq-
uid refrigerant and the vaporiser up to the maximum for the precalculated vaporisation temperature,
thus the suction line should be only a few degrees warmer than the vaporiser temperature indicated
at the thermometer.

Filling procedure:
Connect the pressure hose with pressure gauge to the compressor pressure side 10 (high-pres-
sure red)
Connect the suction hose with pressure gauge to the compressor suction side 11 (low-pressure
blue)
Connect the vacuum pump 18 in accordance with the diagram
Turn the pressure valve 10 and suction valve 11 on the compressor 1 around to the left as far as
it will go (not applicable if Schrader valve featured)
Then turn around 2 - 3 turns using a valve ratchet
Open the valve from the suction side and pressure side
Switch on vacuum pump 18 and evacuate for approx. 30 minutes, or until the suction pressure
gauge 11 attains complete vacuum
If any leaks are present, no vacuum or only partial vacuum will be attained. In this case, an
inspection for leaks is to be undertaken
Remedy any leaks, dissipate pressure from the system and evacuate again
Close the valve from the suction side 11 and pressure side 10
Switch off the vacuum pump 18, check the suction motor to see if the vacuum remains
Disconnect the pressure gauge hose from the vacuum pump 18 and connect a refrigerant cylinder
14
Open the refrigerant cylinder 14 and loosen the middle connector from the pressure gauge
Air can escape
Tighten the connection again
Open the valve 12 from the pressure side 10 and fill in refrigerant (gaseous) from the refrigerant
cylinder 14
Until pressure in the system and the cylinder is the same
Then close the valve 12 from the pressure side 10
Check the system for leaks
Start up the engine and switch off the cooling system

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Tasks on the cooling circuit

Disconnect the valve 12 from the suction side 11 and fill in refrigerant
Inspection glass free of bubbles
Allow the cooling system to run for approx. 15 min. until the pressure in the system rises (not ap-
plicable if Schrader valve featured)
Check for leaks again
Close all windows and doors of the operator's cab and set the blower to max.
Insert the thermometer into an air vent nozzle and start the engine
Apply full revs briefly and then allow the engine to run in lower idle for approx. 3 min., then run the
engine up into upper idle
If the temperature in the air vent drops to approx. + 6°C at an ambient temperature of approx.
20°C, the system is OK (this specification only applies, however, if the temperature of the op-
erator's cab has not been influenced by direct sunlight)
Turn both connections (suction side and pressure side of the compressor) all the way around to
the left as far as they will go
Loosen suction connection and pressure connection and fit and tighten the dust caps

R 914 C / R 924 C 17.50.25

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Heating and air-conditioning system Service Manual
Tasks on the cooling circuit

Fig. 39 Diagram for filling and draining the air-conditioning system

1 Air-conditioning circuit 11 Suction side

2 Capacitor unit 12 Shut-off valve
3 Collecting sump 13 Shut-off valve
4 Filter dryer 14 Refrigerant cylinder
5 Inspection glass 15 Weigher
6 Expansion valve 16 Nitrogen cylinder
7 Pressure side 17 Pressure control valve
8 Heat exchanger 18 Vacuum pump
9 Bypass valve 19 Shut-off valve
10 Dry collector unit 20 Dry collector unit

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Service Manual Heating and air-conditioning system
Tasks on the cooling circuit

Note!
Compressor with Schrader valve (without screw valve). It should be noted with these test connec-
tions on the compressor that valve openers (depressors) are featured in the filling hoses of the pres-
sure gauge strip.

Draining:
For repair tasks, the air-conditioning system must in most cases be drained of refrigerant. The refrig-
erant must be processed for reutilisation.
As a rule, the refrigerant is drained as vapour. It is then allowed to condense in a cooled container,
whereby the machine parts are warmed slightly for this purpose.
The containers in which the refrigerant is delivered may never be used for drainage, but rather only
suitable pressure cylinders which correspond with the labelling and comply with the guidelines of the
pressure gas directives.
When siphoning the refrigerant, it must be ensured that the cylinders are not filled with more than the
permissible amount of refrigerant per litre, in order that the space necessary for expansion of the gas
is maintained.
If only mechanical working procedures, such as the replacement of a part with threaded union, are
required, it is sufficient to remove the refrigerant with a pressure of up to 0.2 - 0.5 bar above atmos-
pheric pressure before opening the connecting points. During the carrying out of these tasks, a small
amount of refrigerant flows out of the separation point, thus preventing the infiltration of air and air
humidity.
In many cases, this allows the part being inserted, e.g. a vaporiser or capacitor, to be rinsed with the
escaping refrigerant so that an evacuation is no longer necessary prior to refilling.
If soldering or welding tasks are to be carried out, this may only be undertaken while circulating nitro-
gen through the system. The nitrogen should exit the cooling circuit by the shortest route possible to
ensure that products of decomposition are quickly discharged.

Air-conditioning service equipment

Fig. 40 Air-conditioning service equipment

Note!
For evacuation, recycling (cleaning, drying) and filling of refrigerant. Observe the manufacturer's in-
structions for the equipment before using.

R 914 C / R 924 C 17.50.27

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Display of faults and instructions regarding the remedying of faults

11 Display of faults and instructions regarding the remedying of

faults

Fault Cause Remedy

System will not start Air-conditioning system off, Check electrical connections
electrical connections loose
Fuse faulty Replace fuse
Overpressure Clean the capacitor fins
System starts but shuts down Overpressure due to high Allow the system to run until
again outside temperatures pressure stabilises
Hoses kinked, pushbutton
B44 faulty
System will not start Underpressure, dryer Replace dryer, by cooling sys-
clogged, saturated tem specialists only
Underpressure, expansion Clean expansion valve, replace
valve clogged as necessary, by cooling sys-
tem specialists only
Leaks in the system Check system for leaks. Refill re-
Refrigerant deficiency frigerant, by cooling system
specialists only
Replace collecting sump, filter
dryer and inspection glass unit
System is running but has no Solenoid valve faulty Replace solenoid valve
cooling effect Heating on Switch off heating
System not running in automatic
operation
Intense noises from com- Ball bearing on compressor Replace compressor, by cool-
pressor faulty ing system specialists only
Magnetic clutch faulty Replace magnetic clutch
Whistling noise from the V- V-belt worn Replace V-belt
belt V-belt too loose Apply tension to V-belt

11.1 Error code “FO“ faulty room temperature gauge

Fig. 41 Faulty room temperature gauge is indicated by flashing

The control unit has registered an error with the room temperature gauge, the control is no longer
operational. Cause of gauge fault, short circuit or interruption of gauge line, plug connection on gauge
or control unit, temperature gauge faulty.
The control will only become operational again after remedying the gauge fault, display of the gauge
fault will then be discontinued. If a gauge fault occurs, the control continues running to the setting
which applied before the fault was detected.

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Service Manual Heating and air-conditioning system
Display of faults and instructions regarding the remedying of faults

11.2 Error code “F1“ faulty blow-out temperature gauge

Fig. 42 Faulty blow-out temperature gauge is indicated by flashing

The control unit has registered an error with the blow-out temperature gauge, the control is no longer
operational. Cause of gauge fault, short circuit or interruption of gauge line, plug connection on gauge
or control unit, temperature gauge faulty.
The control will only become operational again after remedying the gauge fault, display of the gauge
fault will then be discontinued. If a gauge fault occurs, the control continues running to the setting
which applied before the fault was detected.

11.3 Error code “F3“ faulty ventilation flap for footing area - front windshield

Fig. 43 Faulty ventilation flap for footing area - front windshield is displayed flashing
The control unit has registered an error of the ventilation flap for footing area - front windshield, the
control is still operational. Cause of gauge fault, short circuit or interruption of gauge line, plug con-
nection on vent flap motor or control unit, vent flap faulty.
The fault will no longer be displayed following remedying of the error. If a fault flap occurs, the control
continues to function normally.

11.4 Error code “F4“ pressure distortion and faulty magnetic clutch

Fig. 44 Error pressure distortion and magnetic clutch is displayed flashing

The control unit has registered an error for the pushbutton or the magnetic clutch. Cause of the gauge
fault, short circuit or interruption of the supply line to the magnetic clutch, plug connection to coupling
or control unit.

R 914 C / R 924 C 17.50.29

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Display of faults and instructions regarding the remedying of faults

Underpressure or overpressure (insufficient refrigerant) in the cooling system of the air-conditioning

system. The fault will no longer be displayed following remedying of the error. If a distortion in pres-
sure / fault in the magnetic clutch occurs, the control continues to function normally, only the magnetic
clutch outlet is interrupted.

11.5 Error code “F5“ faulty data transfer operating unit / control unit

Fig. 45 Faulty data transfer is indicated by flashing

Data transfer from operating unit to control unit is faulty. Cause of fault, short circuit or interruption of
data line to control unit, plug connection at operating unit or control unit.
The operating unit continues trying to generate a data connection to the control unit, if the connection
is OK again, fault “F5“ will no longer be displayed.
If data transfer from the operating unit can not be established again, the ignition must be switched off
and a RESET is initiated when the ignition is switched on again.

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Electrical diagram for the air-conditioning system

12 Electrical diagram for the air-conditioning system

Fig. 46 Electrical diagram for the air-conditioning system

R 914 C / R 924 C 17.50.31

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Heating and air-conditioning system Service Manual
Inspection plan for air-conditioning system

B43 Thermostat / air-conditioning system X7 4-pin plug connection air-conditioning

electronics
B44 Pushbutton / air-conditioning system X8 6-pin plug connection blower motor
B255 Temperature sensor / cab X9 Plug connection rear servo motor
2-pin
B257 Temperature sensor / exhaust air X11 Plug connection servo motor fresh air 4-
pin
M13 Engine / vaporiser blower X12 Plug connection rear servo motor
6-pin
M75 Engine / outside air flap X13 Plug connection Servo motor armrest 6-
pin
M76 Engine / air flap rear wall X14 Plug connection servo motor windshield
6-pin
M77 Engine / air flap control console X79 Plug connection air-conditioning 2-pin
M78 Engine / air flap for foot area and wind- X84-2 Plug connection air conditioning 2-pin
shield
U38 Operating unit X84-3 Plug connection air conditioning 2-pin
V1 Blocking diode air-conditioning control X87 Plug connection 3-pin
X1 Plug connection 24-pin X88 Plug connection 2-pin
X2 Plug connection 37-pin X435 Plug connection air-conditioning cou-
pling 1-pin
X3 Plug connection 10-pin X1027 Plug connection Lighting air-condition-
ing operating unit
X4 Plug connection 4-pin Y20 Magnetic clutch / air-conditioning
X5 Plug connection air-conditioning elec- Y46 Solenoid valve / air-conditioning
tronics KL. 30
X6 Plug connection air-conditioning elec-
tronics 6-pin

13 Inspection plan for air-conditioning system

Machine : _____________ State of repair : _____________
Type : _____________ Customer : _____________
Machine no. : _____________ Dealer : _____________
Delivery date : _____________ Mechanic : _____________
Operating hours : _____________

13.1 Maintenance tasks

Maintenance tasks performed yes no

1. Check filling level of air-conditioning system
2. Check vaporiser 8 for contamination, clean as necessary
3. Check capacitor 2 for contamination, blow out as necessary
4. Check filter / dryer 4, replace as necessary (corrosion)
5. Ensure proper functioning of overpressure switch B44
6. Check bypass valve 9
7. Ensure secure fastening of defrost gauge on expansion valve 6
8. Clean or replace fresh air filter

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Inspection plan for air-conditioning system

Maintenance tasks performed yes no

9. Clean or replace recirculated air filter
10. Check compressor fastening and drive belts
11. Evacuate refrigerant, recycle and refill system, check cooling output (meas-
ure difference of suction and blow-out)
12. Ensure proper functioning of defrost thermostat B43 (off + 1° C, on + 5.5° C)
13. Ensure sound automatic functions, where featured (heating, cooling, fan
speed), see 8
14. Check electrical lines for points of wear and ensure secure seating of plug
15. Align vaporiser fins with fin comb
16. Check humidity of refrigerant (inspection glass)

Caution!
For safety reasons, we recommend that all interventions and repairs on the air-conditioning system
are undertaken by mechanics trained in refrigeration engineering (see Group 17.50 “Working on
the cooling circuit“).

R 914 C / R 924 C 17.50.33

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Service Manual

Group 18 : Centralized lubrication

Lube hoses repair instructions ...........................................................................................18.50

Centralized lubrication system ...........................................................................................18.51

1 Function and description of the centralized lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.51.1
2 Positions of lubrication points and distributors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.51.2
3 Centralized lubrication of the uppercarriage and of the attachment . . . . . . . . . . . . . . . . . . . . . . . . . 18.51.5
4 Grease filter cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.51.6
5 Research of breakdowns and propositions of solutions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.51.7
6 Positions of lubrication points and distributors - special equipment’s . . . . . . . . . . . . . . . . . . . . . . . . 18.51.8
6.1 With adjustable boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.51.9
6.2 With industrial equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.51.10
6.3 With demolition equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.51.11
6.4 With tunnel equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.51.12
6.5 With mechanical adjustable boom. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.51.13

Pump of the centralized lubrication system ......................................................................18.56

1 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.56.1
2 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.56.2
3 Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.56.2
4 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.56.5
5 Installation / Removal of the pump elements in the electric pump. . . . . . . . . . . . . . . . . . . . . . . . . . . 18.56.6
5.1 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.56.6
5.2 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.56.6
6 Integrated time controller (EP-tronic). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.56.7
6.1 Lubrication control by proximity switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.56.7
7 Control and command functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.56.8
8 Setting of the controller unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.56.9
8.1 Setting of the cycle duration CD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.56.9
8.2 Setting of the number of strokes NS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.56.9
9 Rescue lubrication and lubricant quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.56.10
10 Diagnostic software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.56.11
10.1 Communication with controller unit through a PC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.56.11

Progressive distributor SX-E...............................................................................................18.58

1 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.58.1
2 Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.58.1
2.1 Progressive distributor SXE-2 - Basic elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.58.1
2.2 Progressive distributor SXE-2 - Metering element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.58.3
2.3 Progressive distributor SXE-2 - Blind unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.58.3
2.4 Progressive distributor SXE-2 - Combination of outlets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.58.3
2.5 Progressive distributor SXE-2 - Element with stroke monitor . . . . . . . . . . . . . . . . . . . . . . . . . 18.58.7
2.6 Progressive distributor SXE-2 - Element with proximity sensor . . . . . . . . . . . . . . . . . . . . . . . 18.58.8
3 Functional description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.58.9
4 Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.58.12

Progressive distributor MX-F ..............................................................................................18.59

1 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.59.1

R 914 C / R 924 C 18.00.1

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2 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.59.1
2.1 Progressive distributor MX-F- Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.59.1
2.2 Progressive distributor MX-F - Combination of outlets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.59.3
3 MX-F Distributors - Functional description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.59.6
4 Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.59.7

18.00Wednesday,
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Service Manual Lube hoses repair instructions

Group 18 : Centralized lubrication

18.50: Lube hoses repair instructions

In the event of damage to lubrication hoses (breakage, tearing, kinking, etc...) Liebherr provides a
special repair kit that allows you to repair the hoses, so that they do not have to be replaced (espe-
cially efficient for very long hoses that are part of an attachment).
The repair kit enables you to repair efficiently and safely damaged and torn hoses. Short lines show-
ing damage are best replaced, which is also possible with the repair kit (spare connecting elements).
The procedure for installation is the same as for repair (no need for straight screw connection 5).

Product ID no.: Hose size (ND)

Hose repair kit 10114979 4 / 6,3

Repair kit for connecting pieces, complete 10014611 4 / 6,3

Mounting of collet
Hold the lubrication hose 1 using gripper tongues 2.
Grease or oil the hose end.
Turn the collet 3 (WS17) anticlockwise to open it.
Open it until dimension X is reached, see Fig. 1.
Remove the gripper tongues 2.

Fig. 1 Mounting of collet

Mounting of pipe nozzle

Oil the thread and the conical end of the pipe nozzle 4.
Turn the pipe nozzle 4 (WS12) into the mounted collet 3 (WS17) to the stop.

R 914 C / R 924 C 18.50.1

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Fig. 2 Mounting of pipe nozzle

Note!
The diameters of hoses might vary slightly, due to manufacturing processes. If the hose diameter is
smaller, it might be possible to mount the collet 3 onto the hose without the need of force or tools,
so that the hose is not properly held in place in the collet.
Corrective :
Slightly press the tip (1 or 2 mm) of the collet 3 at the hose insertion side to an oval shape.
This prevents that the hose is pushed off the collet when the pipe nozzle 4 is screwed in.

Connecting lubrication hoses

Use straight screw connectors 5 to connect high-pressure hoses 1.
Tighten the screw connection 5 with the prescribed torque.
The hose repair is now completed.

Fig. 3 Completed hose repair

1 High-pressure hose 4 Pipe nozzle

3 Collet 5 Straight screw connection

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Service Manual Centralized lubrication system
Function and description of the centralized lubrication system

18.51: Centralized lubrication system

1 Function and description of the centralized lubrication system

This system of lubrication is called "progressive", what means that all connected lubrication points
are supplied successively and in an pre-established order by a quantity of grease.
For the description and the functions of the main progressive distributor (Type SX-E), see the sub-
group 18.58. For the description and the functions of the secondary progressive distributors (Type
MX-F), see the subgroup 18.59.
The centralized lubrication system permits, to grease all lubrications points of the excavator that re-
quire at least a daily lubrication, via an unique lubrication fitting.
This lubrication fitting 1 is mounted on top of the face of the hydraulics tank.
The grease injected by the lubrication fitting 1 is brought separately to the points of lubrication in lim-
ited quantity, first via the main distributor 2 then via the secondary distributors 3, 4, 5, 6,.... on the face
of the structure of the uppercarriage and on the equipment.
To the centralized lubrication system are connected:
– the roller races of the swing ring,
– the orientation crown's teeth,
– all equipment's bearings.
Points of lubrication in the undercarriage, can not be reached by the centralized lubrication system.

Note !
Automated centralized lubrication (implanted in option)
In option, the unit of centralized lubrication can be equipped with an electric pump. Thanks to this
electric pump, all bearings connected to the lubrication system are greased according to one regular
time interval, making the manual lubrications useless.
For the description and the functions of the electric pump, see the subgroup 18.56.

R 914 C / R 924 C 18.51.1

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Positions of lubrication points and distributors

Fig. 1 Centralized lubrication system

1 Centralized grease nipple 32 Relief valve

2 Main distributor (Type SXE-2) B51-1 Proximity sensor (Option)
3-7 Secondary distributor (Typ MX-F) U4 Lubrication pump (Option)
13 Grease filter

2 Positions of lubrication points and distributors

The diagram below represents the disposition of the lubrication points and lubrication distributors for
a standard excavator R 934 B (with gooseneck boom and backhoe bucket), as well as the number
and the nominal dimension of the distributors and the grease quantity distributed by lubrication cycle
corresponding to the standard adjustment (constructor setting).
On shovels provided with other facilities (adjustable boom, Industry equipment, demolition equip-
ment, tunnel equipment,...), the elements of the progressive circuit can differ, see also the diagrams
at the end of this subgroup.

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Service Manual Centralized lubrication system
Positions of lubrication points and distributors

See following page.

1 Grease nipple 7 Secondary distributor / Cylinder
stick protection
2 Main distributor 9 Secondary distributor / Quick
change adapter
3 Secondary distributor / Swing ring & hoist 13 Grease filter
cylinder
4 Secondary distributor / Boom 32 Relief valve
5 Secondary distributor / Stick B51-1 Proximity sensor
6 Secondary distributor / Connecting link U4 Lubrication pump
6* Secondary distributor / Connecting link with cylinder stick protection and / or quick
change adapter

Connecting link with cylinder stick protection : Element 220* replaced by element 400*
With quick change adapter : Element 220* replaced by element 500*
With cylinder stick protection and quick change adapter : Element 220* replaced by element 760*

R 914 C / R 924 C 18.51.3

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Positions of lubrication points and distributors

18.51Wednesday,
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Service Manual Centralized lubrication system
Centralized lubrication of the uppercarriage and of the attachment

3 Centralized lubrication of the uppercarriage and of the attachment

The machine is equiped with a centralized lubrication system, which represents a significant saving
of time, during the daily lubrication. All the lubrication points of the uppercarriage (swing ring, swing
gear pinion), all the bearing positions of the attachment and even the tilting cylinders on the cylinder
side are linked with the lubrication system. It is possible, in option, to connect the undercarriage steer-
ing axle to a centralized grease nipple.

Manual lubrication of the excavator

The central lubrication requires approx. 3.5 cm3 grease per working hour. For an average 8-hour
day, the system distributes approx. 28 to 30 cm3 grease.
A conventional hand grease gnu applies at least 1.5 cm3 of grease per stroke. Lubrication with 30
cm3 requires about 30 hand gun strokes.
The requiered grease should ideally added to the system every half day, or at least once per shift (i.e.
every 8 to 10 hours) :
per shift, add about 20 hand gun strokes of grease through the central lubrication nipple 1.
or
per half day, add about 10 hand gun strokes of grease through the central lubrication nipple 1.
For the grease specifications, please refer to the lubricant table in subgroup 1.50.

During lubrication, check whether the ckeck pin 27 at the main distributor 2 is moving back and forth,
indicating that the grease is being distributed through the system. The main distributor 2 is located at
the front of the revolving deck.
if the check pin does not move, inspect the system for the following possible defects :
– Plugging or crushing of the supply line
– High grease viscosity due to cold temperature
– Grease filter at the central lubrication nipple 1 blocked
Identify and eliminate the cause.

R 914 C / R 924 C 18.51.5

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Grease filter cleaning

Fig. 2 Manual lubrication

4 Grease filter cleaning

Fig. 3 Grease filter

1 Lubrication nipple 4 Sealing ring

2 Filter element 5 Sealing ring
3 Fitting 6 Filter housing

Note!
The filter element 2 located behind the lubrication nipple 1 must be inspected every 1000 operating
hours for the contamination and cleaned, if necessary.

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Research of breakdowns and propositions of solutions

Disconnect the lubrication line from the filter outlet.

Remove the filter housing 6 and take out the filter element 2.
When reinstalling the filter, ensure that sealing ring 4 is properly aligned. Close and tighten the
filter housing 6 with 80 Nm.
Reconnect the lubrication line

5 Research of breakdowns and propositions of solutions

Symptoms Origins Solutions
Leak of grease on the Excessive pressure of the Check the circuit (bruising or obstruction)
relief valve system
Blocked progressive dis- Check the outlays of the distributors and, if
tributor necessaryn replace the distributor
Blocked lubrication circuit Clean the bearnig either plugged or satu-
rated. Then to adjust the number of
impulses and the time of cycle.
Blocked lubrication circuit Check the concordance of the grease used
and, if necessary, drain and replace it.
Spring of the relief valve Replace the relief valve
deficient
Too much grease on Wrong dosage to the dis- Adjust dosage (number of impulses and
one or several tributors time of cycle) and clean the lubricatin
lubrication points points summarily
Too much grease on all Number of impulses of the Reduce the number of impulses of the
lubrication points pump too elevated or pump or increase the lenght of the cycle
too short cycle time
The pump is out of The piston head came out Disassemble the concerned element, and
order (the mixer’s of the groove reassemble it correctly
blades doesn’t
turn / the indica-
tor blinks)
Deficient motor Replace the pump
Electric supply toward the Check the electric connections, repair if
motor is deficient necessary
No grease rolls on all Deficient proximity sensor Check the connections of the sensor and
lubrication points replace it if necessary. Complete the
lubricant tank. Check the incator of
warning in the cabin.
Too short lubrication cycle Adjust the number of impulses of the pump
Too long or too short lubri- Adjust the time of cycle
cation cycle
Pipes toward main distribu- Replace the pipe. If necessary complete
tor either destroyed or the lubricant tank.
damaged
Deficient pump See «pump is out of order»
No grease roll on one Pipe or hose toward the Replace the hose or the pipe - do not plug.
lubrication point secondary distributor If necessary, complete the lubricant
damaged or destroyed tank
Fitting leaks Tight the fitting or replace it. If necessary
complete the lubricant tank

R 914 C / R 924 C 18.51.7

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Positions of lubrication points and distributors - special equipment’s

Pipe or hose damaged or Replace the pipe - do not plug. If neces-

destroyed sary, complete the lubricant tank
Pipe or hose disconnected Check the pipe and replace if non leakproof
or bent - do not plug. If necessary, complete
the lubricant tank.
Non leakproof main or sec- Check the distributor, in particular the seal-
ondary distributor ing. Replace if necessary
Indicator of the inte- Grease’s viscosity too ele- Check the type of grease, if necessary,
grated controller vated, incompatible drain and replace
or on the control with the external tem-
panel of the cabin perature
blinks
Deficient motor Replace the pump
Rotation rate of the motor Replace the pump
pump too low
Drive overload. Mechani- Replace the pump
cal blockage of the
motor
Deficient proximity sensor Check the connections of the sensor.
Replace it if necessary. Complete the
lubricant tank
Empty lubricant tank Complete the lubricant tank
Deficient controller unit Check the connections, if necessary
replace the pump

6 Positions of lubrication points and distributors - special equip-

ment’s
The diagrams below represents the disposition of the lubrication points and lubrication distributors for
a excavator R 934 B with special equipment (adjustable boom, Industry equipment, demolition equip-
ment, tunnel equipment, and mechanical adjustable boom) as well as the numbers and the codifica-
tion of the elements of distribution, and the quantities of grease repartees by lubrication cycle
corresponding to the standard adjustment (constructor setting). Under reserves of all modifications.
For all complementary information, inform yourselves by your Service Client Liebherr.

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Service Manual Centralized lubrication system
Positions of lubrication points and distributors - special equipment’s

6.1 With adjustable boom

1 Grease nipple 7 Secondary distributor / Cylinder stick

protection
2 Main distributor 8 Secondary distributor / Adjustable
boom
3 Secondary distributor / Swing ring & hoist cylinder 9 Secondary distributor / Quick change
adapter
4 Secondary distributor / Boom 13 Grease filter
5 Secondary distributor / Stick 32 Relief valve
6 Secondary distributor / Connecting link B51-1Proximity sensor
6* Secondary distributor / Connecting link on cylinder U4 lubrication pump
stick protection and / or quick change adapter

R 914 C / R 924 C 18.51.9

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Positions of lubrication points and distributors - special equipment’s

6.2 With industrial equipment

1 Grease nipple 13 Grease filter

2 Main distributor 32 Relief valve
3 Secondary distributor / Swing ring and hoist B51-1Proximity sensor
cylinder
4 Secondary distributor / Boom U4 Lubrication pump
5 Secondary distributor / Stick

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Positions of lubrication points and distributors - special equipment’s

6.3 With demolition equipment

1 Grease nipple 8 Secondary distributor / Intermediate boom

2 Main distributor 13 Grease filter
3 Secondary distributor / Swing ring 32 Relief valve
4 Secondary distributor / Boom B51-1Proximity sensor
5 Secondary distributor / Stick U4 Lubrication pump

R 914 C / R 924 C 18.51.11

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Positions of lubrication points and distributors - special equipment’s

6.4 With tunnel equipment

1 Grease nipple 8 Secondary distributor / Intermediate boom

2 Main distributor 13 Grease filter
3 Sec. distributor / swing ring & hoist cylinder 32 Relief valve
4 Secondary distributor / Boom B51-1Proximity sensor
5 Secondary distributor / Stick U4 Lubrication pump

18.51Wednesday,
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Positions of lubrication points and distributors - special equipment’s

6.5 With mechanical adjustable boom

1 Grease nipple 6* Secondary distributor / Connecting link

2 Main distributor 7 Secondary distributor / Cylinder stick protec-
tion
3 Secondary distributor / Swing ring and hoist 13 Grease filter
cylinder
4 Secondary distributor / Boom 32 Relief valve
5 Secondary distributor / Stick B51-1Proximity sensor
6 Secondary distributor / Connecting link U4 Lubrication pump

R 914 C / R 924 C 18.51.13

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18.51Wednesday,
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Service Manual Pump of the centralized lubrication system
Function

18.56: Pump of the centralized lubrication system

1 Function
The centralized lubrication system can be equiped, in option, with an electrical pump. This pump re-
places the manual lubrication of the uppercarriage and the attachment. While excavator work, all the
bearing positions connected with the centralized lubrication system, are lubricated according to a
constant time interval. The bearing positions of the undercarriage can not be connected to the auto-
matic lubrication system.

Fig. 1 Pump of the centralized lubrication system

R 914 C / R 924 C 18.56.1

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Technical data

2 Technical data

Excavator Unit R 900 C to R 926

Motor
Operating voltage Volt 24 V DC
RPM U/min. 15
Current : A
Idle at + 20 °C 0,4
Full load at + 20 °C 1,1
Security A 3
Pump
Max. operating pressure bar 280
(adjustment of the pressure relief valve 9)
Admissible operating temperature °C -35 to + 80
Reservoir capacity:
transparent reservoir kg 4
Rotation direction of the blades Clockwise
Flow rate of the pump element: mm 3
PE-120 120
PE-120 V (adjustable) 40 - 120

Tab. 1 Technical data

3 Description
The set of the lubrication unit U4 is constituted of a transparent lubricant tank 13 with a stirrer 12, of
an electric motor 10 that operates a lubrication pump 15 as well as an integrated controller unit 16,
situated underneath, that triggers the operation of lubrication.
The proximity sensor B51-1 integrated at the distributor controls the programmed number of strokes.
The unit of lubrication can be equiped with maximum three separated elements of pumps, independ-
ent one of the other.
A supplempentary lubrication cycle can be activated via the switch S84 on the right control panel or
via the switch 19 on the pump.

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Service Manual Pump of the centralized lubrication system
Description

Fig. 2 Pump of the centralized lubrication system

Fig. 3 Controller unit connection

R 914 C / R 924 C 18.56.3

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Description

Fig. 4 Exploded view of the centralized lubrication pump

3 Pump housing 13 Supply container

4 Screen 15 Pump element
5 Eccentric cam with pressure ring 16 Controller unit
6 Pressure ring with blades 21 Grease feed plug
7 Delivery piston 22 Lubrication nipple
9 Relief valve 23 Tank cover
10 DC motor 25 Emergency grease nipple
12 Stirrer

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Service Manual Pump of the centralized lubrication system
Operation

4 Operation
A DC motor 10 continually operates the eccentric cam 5 and pressure ring 6. This eccentricity effects
the suction and pressure strokes of the delivery piston 7, whereby the integrated non-return valve 8
prevents the delivery media from being sucked back out of the main line.
The stirrer 12 pushes the lubricant out of the supply container 13 through a screen 4, which reduces
any air bubbles, to the suction area in the pump housing 3. A scraper on the stirrer 12 enables a visual
check of the lubricant volume still present in the transparent supply container 13.
The pressure relief valve 9 secures the pump with a pre-set value, (see Tab. 1 on page2).
Each rotation of the eccentric cam 5, triggers a movement of the piston 7 and provides a certain flow
rate, depending on the piston diameter, (see Tab. 1 on page2)

Fig. 5 Cross-section view of the centralized lubrication pump

3 Pump housing 10 DC motor

4 Screen 12 Stirrer
5 Eccentric cam 13 Supply container
6 Pressure ring 15 Lubrication pump
7 Delivery piston 16 Controller unit
8 Non-return valve 19 On / Off switch
9 Pressure relief valve

Note!
Cross-section a - Pump unit intake, cross-section b - Pump unit delivery.

R 914 C / R 924 C 18.56.5

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Installation / Removal of the pump elements in the electric pump

5 Installation / Removal of the pump elements in the electric pump

Caution!
Rotating stirrer!
Risk of hand and finger injury!
Switch the pump off before installation or removal of the pump elements.

Fig. 6 Installation / Removal of the pump elements 15

5.1 Disassembly
Disassemble the pump element 15 with the piston 7 slightly showing above. Keep it at an angle
and extract it throught the housing drilling.
During the dismantling, pay attention that the piston 7 does not remain in the pump housing.
Remove the sealing ring 14 from the pump housing 3.

5.2 Assembly
Install the sealing ring 14 on the pump housing 3.
Install pump unit with piston partially extended 7, insert at angle in top of housing bore (see
figure A).
When piston head rests on pressure ring, move unit into vertical position (see figure B)
Piston head must run in guide ring 6 groove.
Screw and tighten pump unit 15.

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Service Manual Pump of the centralized lubrication system
Integrated time controller (EP-tronic)

6 Integrated time controller (EP-tronic)

Fig. 7 Lubrication execution

2 Main distributor B51-1 Proximity sensor

2.3 Dosing unit CD Cycle duration
a 1.Schmiervorgang NS Number of strokes
b 2.Schmiervorgang

6.1 Lubrication control by proximity switch

During an operation of lubrication, the different lubrication points are supplied successively in a de-
fined order (progressive Circuit). For each piston stroke in the dosing unit 2.3 of the main distributor
2, the integrated proximity sensor B51-1 generates an impulse.
The integrated time controller 16 stops the pump as soon as a complete lubrication cycle is started,
that means, as soon as the impulses number reaches a preset value (Number of impulses).

R 914 C / R 924 C 18.56.7

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Control and command functions

7 Control and command functions

After excavator start, the light in the button S84 and the green indicator 17 lights up about 1,5 sec.
This indicate the operational readiness of the controller (start up monitoring).
On first connection of the timer starts immediately a lubrication cycle.
During a lubrication operation by the centralized lubrication unit, the control indicators integrated into
the push button S84 and the green indicator 17 lights up permanently.
The lubrication process is stopped automatically after having reached the preset number of strokes
NS at the proximity switch B51-1 see Fig. 7.
Next lubrication process starts automatically after elapsing of the preset duration cycle CD.
In case of functionally default during the lubrication process (trough impulse signal of proximity switch
B51-1, about 20 minutes after start of lubrication process), both LED's 17 and 18, and the control light
of button S84, lights up together.
Possible causes are :
– plugged or crushed lubrication line ( in that case, lubricant flows out trough relief valve 9),
– defective proximity switch B51-1 or a default of its wire.
– by very low temperature, use of too viscous lubricant,
– lack of lubricant into the container,
– defaults in the 24 V electrical circuit for the motor 10.
Find immediately the possible causes of failure and resolve them.
The electronic integrated controller device has parameters memory at its disposal. This also serves
to keep a record of parameters elapsed (like duration, number of strokes,…).
Should the ignition be switched off during lubrication or operational pauses occur, then the time is
stopped and recorded. Once the ignition is switched on again the remaining lubrication or pause time
is read from the memory and the sequence will be resumed where it was interrupted.
If the internal battery of the controller unit is defected, the red LED 18 starts to blink, at intervals of
0,5 seconds.
Anytime, with a fully functional lubrication unit, an additional lubricating procedure can be started by
the pump, after pressing the push button S84, at the rear of the desk, or using button 19 on the motor
housing, next to controller unit 16. This supplementary lubrication cycle is also used for function's
test. The pump starts immediately with a lubrication cycle, the cycle duration elapsed or recorded is
initialised and starts again.

Fig. 8 Operation of the lubricating system

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Setting of the controller unit

8 Setting of the controller unit

8.1 Setting of the cycle duration CD

The cycle duration can be set on graduating switch CD (Cycle Duration) after having removed the
transparent cover, between 0,5 and 8 hours.
The original cycle duration (factory settings) is :

Excavator type R 900 C to R 926

Cycle duration CD in hours 1

8.2 Setting of the number of strokes NS

Remove the transparent cover. The number of strokes necessary to the realization of a complete lu-
brication cycle, can be adjust via the potentiometer NS.
The original number of strokes (factory settings) is :

Excavator type R 900 C to R 926

Number of strokes NS 5

1 Starting-up NS=
1,5 s at startup

2 Lubrication operation NS=

while lubrication

3 Measuring error of the prox-

imity sensor

4 Accumulator error

Fig. 9 Setting of CD / NS

R 914 C / R 924 C 18.56.9

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Pump of the centralized lubrication system Service Manual
Rescue lubrication and lubricant quantity

9 Rescue lubrication and lubricant quantity

Rescue lubrication
If the lubrication pump is deficient, the lubrication points connected can be provided by centralized
way using a filling gun connected to the grease nipple 25.
Daily or per shift, inject about 200 cm3 lubricant into the grease nipple 25, or, as alternative, inject as
much a necessary lubricant until it flows out from the hoist cylinder bearing / uppercarriage.

Lubricant quantity
The lubricant consumption depends on the cycle duration and the value of strokes preset in factory.
For example, a cycle duration of 1 hour and a number of strokes = 5 (Factory setting for excavator
R 914 C) induces an average consumption of about 25 cm3 lubricant per working hour, about 2,3 kg
of lubricant every 100 working hours.
For a specific excavator, provided with special equipment, the exact grease consumption on each
stroke can be found into the corresponding diagrams into sub group 18.51 "Centralized lubrication
system".

Refill the lubricant container

Check the lubricant container 13 level weekly, and if necessary, refill it.
Regarding the lubricant quality, refer to the Lubricant's chart, in the subgroup 1.50.
Refilling the lubricant container should only be done via special fitting 21. Insert a grease cartridge in
the special filling pump 31 delivered, connect the pump to the fitting 21 and push the content of the
cartridge into the container 13.
Avoid refilling the container via cover 23, this could create an air pocket and cause the pump 15 to
run dry. Without the special filling pump 31 or grease cartridges, the container 13 can be refilled
trough grease fitting 22 using a grease pump.
After refilling, position and screw carefully the plugs.

Fig. 10 Refilling the lubricant container

9 Pressure relief valve Überdruckventil 22 Grease fitting

13 lubricant container 23 Container cover

18.56Wednesday,
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Service Manual Pump of the centralized lubrication system
Diagnostic software

19 Switch 25 Emergency grease nipple

21 Special fiting 31 Filling pump

10 Diagnostic software

10.1 Communication with controller unit through a PC

The diagnostic program "BEKA-DiSys" can be used to set a new installed unit, as for to check and
set a centralized lubrication unit while service and maintenance works.
PC minimal configuration requisite is :
– IBM PC with 486 MHz processor
– 8 MB RAM
– Windows 95, 98, ME, NT or 2000
– Double speed CD-ROM drive
The communication and diagnostic software "BEKA-DiSys" is available under reference nr. 1000 84
27 at your spare parts service.
True the user friendly interface of this program, it is possible, easily and quickly, to :
– choose the interface's language,
– extract data's
– execute the settings,
– execute hardware tests,
– follow a lubrication cycle progress
– read a list of defaults with date and time
– read a parameter's service and executed modifications or settings statistic.
The complete software kit includes :
– Diagnose Software CD-ROM,
– Connection cable to transfer data's between controller unit switch and PC serial switch,
– Software description,
– Subscribe form

R 914 C / R 924 C 18.56.11

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Diagnostic software

Every connection cable is coded and identified at every data's transfer from the controller unit.
Thanks to that identification, the controller unit can also edit a historic of interventions, by specifying
the software user and the date of intervention.

Fig. 11 Window of the diagnostic software

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Service Manual Progressive distributor SX-E
Function

18.58: Progressive distributor SX-E

1 Function
The progressive piston distributors SXE-2 are distribution units with hydraulic sequence control,
whose pistons are controlled by the lubricant supply so that the lubricant is forced in sequence
through the individual outlets. If faults occur in the lubricant flow, e.g. blockage of lubricant lines or
lubricant points, this will block the distributor.
This blocking is used to monitor the distributor. A strong counter-pressure that is difficult to overcome
occurs in manually operated pumps if there is a blockage. In automatic pumps, the lubricant escapes
via the pressure-relief valve. The progressive distributors SXE-2 are produced in variable modular
formats. This has the advantage that the distributor, i.e. the number of lubricant points and their vol-
umes can be changed as required without too much outlay.
The progressive distributor SXE-2 consists mainly of distributor panels. These consist of a basic unit
and a dosing unit or a blind unit. Basic units are divided into start units, middle units and end units.
This modular design means that both the delivery rate of individual outlets and the number of outlets
themselves can be modified.
The various delivery rates per piston stroke are achieved by the different piston diameters of the dos-
ing units, which can be exchanged as required. A blind unit can be used to reduce the number of lu-
bricant points in an existing distributor or a basic unit with dosing unit can be removed. The distributor
can be expanded at any time by adding another basic unit with dosing unit.

Fig. 1 Progressive distributor SXE-2 with 4 elements and 6 outlets

AE Basic unit - Start unit GE Basic unit - End unit

BE Blind unit ME Basic unit - Middle unit
DE Dosing unit x Inlet threaded fitting
EE Basic unit - End unit y Outlet threaded fitting

2 Description

2.1 Progressive distributor SXE-2 - Basic elements

Each progressive distributor SXE-2 assembly must consists of :
:

– 1 A starting element AE (without piston)

– 1 Three or more metering (distribution) elements DE
– 1 An end element EE

R 914 C / R 924 C 18.58.1

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Progressive distributor SX-E Service Manual
Description

Note!
Three delivery elements are always required for correct functionality of a progressive distributor
SXE-2, i.e. each distributor must have at least three metering elements.
Blind elements which do not contain distribution pistons as well starting element are not counted.

Fig. 2 Starting element , a = distributor outlet, b = distributor inlet

Basic units are divided into start units, middle units and end units (see figures 2 - 4 - 5). Each dosing
or blind unit fits every basic unit.
Each distributor must consist of a start unit, one to eight middle units and an end unit. The units are
sealed with O-rings, which have to be installed in the middle and end units.
Any of the inlet threaded fittings can be screwed into the distributor inlet of the start unit. The outlet
threaded fittings can be screwed into the distributor outlets.

Fig. 3 Threaded fittings

1 Straight fitting 2 Angled fitting 3 Angled swivel fitting

Fig. 4 Middle element with O-ring set 998 and distributor outlet a (on both sides)

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Service Manual Progressive distributor SX-E
Description

Fig. 5 End element with O-ring set 998 and distributor outlet a (on both sides)

2.2 Progressive distributor SXE-2 - Metering element

The progressive distributor SXE-2 dosing units are responsible for the precise distribution of the lu-
bricant supply. They contain pistons with various diameters that are used to achieve the required de-
livery rates.
The dosing units are screwed onto the distributor units. The dosing and basic units are sealed with
O-rings.
Dosing units are screwed onto the basic units with two Allen screws M5x35, tightening torque of
5 Nm.

Fig. 6 Dosing element - Blind element, O-ring-set 998

2.3 Progressive distributor SXE-2 - Blind unit

A blind unit can be used if a lubricant point in the system is no longer required or distribution outlets
are added for future additional lubricant points. This unit does not have a piston, therefore the distrib-
utor must consist of at least 4 distributor panels, i.e. a start unit, at least two middle units, an end unit
and three dosing units.
Fittings are sealed with O-rings like the dosing units. The O-ring set used for dosing units can also
be used in this case.
The blind units, like dosing units, are screwed onto the basic units with two Allen screws M5x35 and
a tightening torque of 5 Nm.

2.4 Progressive distributor SXE-2 - Combination of outlets

2.4.1 Progressive distributor SXE-2 - 2 outlets combined

It may be necessary to combine two or more outlets on the progressive distributor for larger lubricant
points. Each basic unit in the progressive distributor has two outlets.

R 914 C / R 924 C 18.58.3

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Progressive distributor SX-E Service Manual
Description

It is possible to combine the delivery rate of two outlets from the same basic unit or the delivery rates
of outlets from two different, but neighbouring, basic units.
To combine the delivery rates from two outlets on the same basic unit, the two outlets are combined
by removing the sealing screw between the outlet sides and plugging one outlet with a plug screw.
The delivery rate from the sealed side is now forced through the open side, i.e. the delivery rate of
the open side doubles.
To separate combined outlets on the progressive distributor, reinsert the sealing screw and sealing
ring.

Fig. 7 2 outlets per distributor unit (standard design) sealing screw 1

Fig. 8 2 distributor unit’s oulet combined

one sealing screw 1 removed; with plug screw 2

2.4.2 Distributor SXE-2 - Combination of 3 - 4 oulets with a distributor link

If the overall delivery rate of a distribution panel in the progressive distributor is still insufficient with
combined outlets, e.g. with very large lubricant points or main distributors, it is possible to combine
the outlets of several distribution panels.
Two, three or four outlets of different, but neighbouring, distributor panels can be combined together
with help of distributor links.
The delivery rates of two outlets on different distributor panels can be combined with help of a distrib-
utor link with outlet. Remove the outlet threaded fittings of the two outlets being combined and insert
a distributor link 3 with outlet instead. The sealing screws 1 located between the outlets of each indi-
vidual distributor unit must remain in place. The delivery rates from the outlets of the two distributor

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Service Manual Progressive distributor SX-E
Description

panels are now forced through the distributor link outlet, i.e. the delivery rate of the two distributor
panels are added.

Fig. 9 Link outlet 3 with hollow screw 4 (with outlet) and hollow screw 5 (without outlet)

Fig. 10 3 outlets combined with a distributor link with outlet, one sealing screw removed
1

1 Sealing screw 3 Distributor link with outlet

2 Plug screw

If three outlets are combined, one of the sealing screws on one of the two basic units concerned must
be removed.
A distributor link with outlet replaces, on one side, the outlet threaded fittings of the neighbouring dis-
tributor panels whose outlets are being combined. When the sealing screw 1 is removed from the out-
let on the basic unit opposite the distributor link 3, it must be replaced by a plug screw 2. The delivery
rates of all three outlets are then forced through the distributor link outlet.
If four outlets are combined, the sealing screws 1 in both basic units must be removed and a plug
screw 2 inserted in both outlets opposing the distributor link 3. The delivery rates of all four outlets
are then forced through the distributor link 3 outlet.

R 914 C / R 924 C 18.58.5

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Progressive distributor SX-E Service Manual
Description

Fig. 11 4 outlets combined with a distributor link with outlet, two sealing screw removed

1 Sealing screw 3 Distributor link with outlet

2 Plug screw

2.4.3 Distributor SXE-2 - Combination of 3 or 4 outlets using a link without outlet

Three or four outlets of different, but neighbouring, distributor panels can be combined together with
help of distributor links without outlets.
If three outlets are combined sorties (see Figure 13), one of the sealing screws 1 on one of the two
basic units concerned must be removed. A distributor link 3 replaces, on one side, the outlet threaded
fittings of the neighbouring distributor panels whose outlets are being combined.
The outlet opposite the distributor link 3 on the basic unit where the sealing screw 1 has been re-
moved is now the outlet for all delivery rates of all combined outlets.

Fig. 12 Distributor link 3 with hollow bolt 5 (without outlet)

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.6 R 914 C / R 924 C
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Service Manual Progressive distributor SX-E
Description

Fig. 13 3 outlets combined with a distributor link 3 (without outlet 5), one sealing screw released
If four outlets are combined, the sealing screws 1 of both basic units concerned must be removed.
The outlet threaded joints on the distributor panels being combined are replaced on one side with a
distributor link 3 without outlet. One of the outlets opposite the distributor link 3 must be sealed with
a plug screw 2. The other outlet then serves as the outlet for all combined delivery rates from the out-
lets of the distributor panels concerned.
The distributor links can be combined together to combine five or more outlets. The procedure is as
described above.

Fig. 14 4 outlets combined with a distributor link 3 (without outlet 5) and ohne sealing; sealing
screw 1 released

2.5 Progressive distributor SXE-2 - Element with stroke monitor

An optical stroke monitor can be installed on the progressive distributor SXE-2 instead of a proximity
sensor. This can only be installed on dosing units 400 SXE-2 to 769 SXE-2. Retrofitting is not possi-
ble, therefore optical stroke monitoring must be requested when ordering.

R 914 C / R 924 C 18.58.7

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Progressive distributor SX-E Service Manual
Description

Fig. 15 Progressive distributor SXE-2 with stroke monitor

2.5.1 Function of the stroke monitor

A pin 8 is attached to the piston of the dosing unit 7. This appears during every piston stroke in the
transparent cap 9.

Fig. 16 Cross-section view of the stroke monitor

2.6 Progressive distributor SXE-2 - Element with proximity sensor

A proximity sensor can be installed in any position on a dosing unit 400 SXE-2 to 760 SXE-2 in the
progressive distributor SXE-2. Dosing units with proximity sensors must be ordered separately. Ret-
rofitting a proximity sensor onto an existing dosing unit is not possible.
Proximity sensors can be retrofitted in a progressive distributor only by replacing the dosing unit con-
cerned.
Remove the transparent cap and screw the proximity sensor 6
Distributors with proximity sensors are used to monitor the system or, with sequencers, to count the
piston strokes of the distributor.

Fig. 17 Progressive distributor SXE-2 with integrated proximity sensor 6

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Service Manual Progressive distributor SX-E
Functional description

2.6.1 Function of the proximity sensor

A pin 8 is attached to the piston of the dosing unit 7. This approaches the proximity sensor 6 during
each piston stroke and triggers a signal. This signal can be processed in various ways depending on
the controller type or application.

Fig. 18 Proximity sensor 6 on a dosing unit 7

3 Functional description
The progressive distributor is based on distributor panels that are connected together by tie rods with
washers and nuts to form distributors. The dosing units are screwed onto the basic units with Allen
screws. Individual units are sealed with O rings.
These four following figures shows what happens inside of the distributor.

Phase A
The lubricant flows through the distributor inlet to the second dosing unit and piston (II)

Fig. 19 Cross-section view A : progressive distributor with pressure room d

a Pressure ducts
b Already conveyed
c Subsequent delivery stroke

R 914 C / R 924 C 18.58.9

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Progressive distributor SX-E Service Manual
Functional description

Phase B
The piston (II) is pushed to the left and the lubricant is pushed to outlet 2 from the left pressure cham-
ber of the delivery piston.
Subsequently, the dosing piston (III) is progressively pushed and the lubricant delivered to outlet 3.

Fig. 20 Cross-section view B of the progressive distributor

Phase C
After the piston is pushed (II), the lubricant is moved to the left side of the delivery piston (I) and
moved from the right pressure chamber of the delivery piston (I) to outlet 4.
Subsequently, the delivery pistons (II) and (III) are pushed and the lubricant delivered to outlets 5 and
6.

Fig. 21 Cross-section view C of the progressive distributor

Phase D
After the delivery piston is pushed (III), the lubricant is moved to the right side of the delivery piston
(I) pushing the lubricant out of the left pressure chamber of the delivery piston (I) to outlet 1.
A new progressive piston distributor cycle then begins. The described function repeats itself as long
as lubricant is supplied to the progressive distributor.

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Service Manual Progressive distributor SX-E
Functional description

Fig. 22 Cross-section view D of the progressive distributor

R 914 C / R 924 C 18.58.11

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Progressive distributor SX-E Service Manual
Exploded view

4 Exploded view
Progressive distributor's SXE-2 components are available at your Liebherr Client Service, as spare
parts for service and maintenance works. (see Fig. 23 on page12) - Only for information / example.

Note!
Modifications on lubrication circuit, without consultation and previous authorization of the Liebherr
Service are not allowed. In contrary case, the guarantee expires.

Fig. 23 Exploded view of the spare parts - Example

1 Starting element 15 Plug screw

2 Central element 16 Gasket ring
3 End element 17 Distributor link
6 Tir rods 19 Cover
7 Washer 20 Proximity sensor
8 Hexagonal nut 101 Dosing element 150
9 Angle coupling 102 Dosing element 300
10 Elongation 103 Dosing element 220
11 Gasket ring 104 Dosing element 400
12 Straight fitting 105 Dosing element 500
13 Socket screw 998 O-ring set
14 Outlet 999 O-ring set

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Service Manual Progressive distributor MX-F
Function

18.59: Progressive distributor MX-F

1 Function
The progressive piston distributors are distributor devices with a hydraulic sequence control, the pis-
tons of which are regulated by the supplied lubricant in a way that the lubricant inevitably and suc-
cessively escapes at the individual outlets. In the case of malfunctions during the flow of lubricant,
e.g. clogging of lubricating line or lubricating points, the distributors will block up. This blockage is
used for the monitoring of the distributors. In the case of manually operated pumps a virtually insur-
mountable counter pressure occurs during the blockage. In the case of automatic pumps such as e.g.
the electropump EP-1 the lubricant escapes at the relief valve. The progressive distributors are man-
ufactured in a variable disk construction, permitting a variable configuration according to the amount
of lubricating points, their positions on the vehicle and their necessary lubricant dose. Which also of-
fers the advantage that the distributor can be extended or shortened according to the hydraulic
scheme to realise. Due to this disk construction there is also the possibility of constructing an overall
progressive distributor from individual distributor disks with different outputs per piston stroke. The
difference in output per piston stroke is achieved by different piston diameters. To ensure the proper
functioning of a progressive distributor a minimum of three pistons, i.e. a minimum of three output
elements is required.

Fig. 1 Progressive distributor MX-F with 4 output elements and 8 outlets

AE Initial element x Inlet fitting

ME Middle element y Outlet fitting
EE End element

2 Description

2.1 Progressive distributor MX-F- Elements

Each progressive distributor MX-F consists of :
I

– 1 initial element AE (without piston)

– 2-11 middle elements ME
– 1 end element EE

R 914 C / R 924 C 18.59.1

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Progressive distributor MX-F Service Manual
Description

The progressive distributors consists of the individual components initial element AE (without piston),
middle elements ME and end element EE, all of which are assembled in distributor blocks by using
tie rods (hexagon socket screws) with lock washers. The individual elements are sealed with 0-rings.
All union pieces with a threaded connection of M10x1 can be screwed into an initial element AE with-
out inlet union piece. The outlet fittings are screwed into the middle and end elements ME / EE.

Fig. 2 Progressive distributors AE, ME and EE

2.1.1 Outlet fitting of progressive distributor MX-F

A polyamide or steel tube is usually screwed onto the distributor with a union screw B and a double
conical ring C. The socket piece used as a union piece for the high-pressure hose can also be at-
tached directly at the distributor with the union screw B.

Fig. 3 Union screw B and double conical C

2.1.2 Relief valve for progressive distributor MX-F

The check valves are used in connection with high-pressure hoses, e.g. in the case of lubrication ar-
eas with elevated counter pressure or in main distributors. The polyamide tube and high-pressure
hose are screwed onto the check valve of the progressive distributor MX-F with a union screw and a
double conical ring. Check valves with union screw and cutting ring require no additional union piece.

Fig. 4 Check valve for MX-F distributor D and check valve with cutting ring E

18.59Wednesday,
.2 R 914 C / R 924 C
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Service Manual Progressive distributor MX-F
Description

2.2 Progressive distributor MX-F - Combination of outlets

2.2.1 Distributor MX-F - Combining 2 outlets

For larger lubrication areas the assembly of two or more outlets at the progressive distributor may be
required. The individual disks of the progressive distributor have two outlets. When assembling two
outlets at the progressive distributor the two outlets of one disk are connected. To achieve this, the
grub screw F separating the two sides is removed and a lock screw G screwed in to the side, which
is to be closed. The output of the closed side is now escaping on the other side, i.e. the output of the
open side is doubled.

Fig. 5 Distributor with one outlet

Fig. 6 Distributor with two outlets

2.2.2 Distributor MX-F - Combining several outlets

If the total output of the outlets assembled in one disk of the progressive distributor is not sufficient,
e.g. in the case of large bearing spots or main distributors, there is the possibility of assembling the
outlets of several distributor disks. To achieve this, two distributor disks are connected with a pipe or
distributor bridge as described here. Depending on which element the grub screw separating the two
sides of a distributor disk is removed from, in this way three outlets are connected. Subsequently, the
output of the closed outlets escaped at one outlet. The dosage is calculated on the basis of the output
value of all assembled piston sides.

R 914 C / R 924 C 18.59.3

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Progressive distributor MX-F Service Manual
Description

Fig. 7 Distributor with three outlets

Fig. 8 Distributor with four outlets

2.2.3 Distributor MX-F - Combining several outlets using bridges

Lock screws G are generally required for the assembly of outlets.

Fig. 9 Lock screw G

To separate assembled outlets on progressive distributors the grub screw F must be screwed back in.

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.4 R 914 C / R 924 C
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Service Manual Progressive distributor MX-F
Description

Fig. 10 Grub screw F

Distributor elements can be assembled with pipe or distributor bridges. The assembly of outlets with
a pipe bridge H, always concerns at least three outlets, as the output must be directed through one
of the disks of the progressive distributor. Furthermore, the grub screw F must always be removed
from one of the two distributor disks assembled with a pipe bridge. One pipe bridge H can also be
used for the assembly of four outlets. To achieve this, the grub screws must be removed from both
distributor disks and one of the two outlets must be closed off from the pipe bridge with a lock
screw G. Also individual parts of pipe bridges H can be ordered.

Fig. 11 Pipe bridge H with 2 reductions 7, lock nut B and double cone ring C

Two types of distributor bridges are available

Shipment 1 - Distributor bridges without outlet I
They have the same function as pipe bridges H.

Fig. 12 Distributor bridge without outlet I

Shipment 2 - Distributor bridges with outlet J
Two, three or four outlets can be connected at different adjacent distributor disks by using distributor
bridges with outlet J. For the connection of four outlets the grub screw F must be removed from both
distributor disks and a lock screw G must be screwed into the outlets situated opposite the distributor
bridge. As a result, the output of all four outlets escapes at the outlet of the distributor bridge. For the
connection of three outlets the grub screw must be removed from one of the two concerned distributor

R 914 C / R 924 C 18.59.5

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Progressive distributor MX-F Service Manual
MX-F Distributors - Functional description

disks. As a result, the output of all three outlets escapes at the outlet of the distributor bridge. For the
connection of only two outlets (on different adjacent distributor disks) the grub screw F may not be
removed from either of the two concerned distributor disks. As a result, the output of both the outlets
escapes at the outlet of the distributor bridge.

Fig. 13 Distributor bridge with outlet J

3 MX-F Distributors - Functional description

Phase A
The lubricant flows via the inlet of the distributor through all distributor disks to the piston (I).

Fig. 14 Cross-section view A of the distributor

a Pressure ducts d Pressure room

b Already conveyed
c Subsequent delivery stroke

Phase B
The piston (I) is shifted to the left and the lubricant is pressed from the left pressure range of the de-
livery piston to the outlet 1. After that, the proportioning pistons (II) and (III) are progressively shifted
and the lubricant is primed to the outlets 2 and 3.

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.6 R 914 C / R 924 C
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Exploded view

Fig. 15 Cross-section B of the distributor

Phase C
After the piston (III) has been shifted, the lubricant is directed to the left side of the delivery piston (I)
(figure C) and primed from the right pressure range of the delivery piston to the outlet 4. Subsequent-
ly, the delivery pistons (II) and (III) are shifted and the lubricant is pressed to the outlets 5 and 6. After
the delivery piston (III) has been shifted, the lubricant is once more directed to the right side of the
delivery piston (figure A) and a new cycle of the progressive piston distributor is initiated. The de-
scribed function is repeated as long as lubricant is fed to the progressive distributor.

Fig. 16 Cross-section C of the distributor

I Piston 3 Outlet
II Piston 4 Outlet
III Piston 5 Outlet
1 Outlet 6 Outlet
2 Outlet d Pressure room

4 Exploded view
Progressive distributor's MX-F components are available at your Liebherr Client Service, as spare
parts for service and maintenance works. (see Fig. 17 on page8) - Only for information / example

R 914 C / R 924 C 18.59.7

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Progressive distributor MX-F Service Manual
Exploded view

Note!
Modifications on lubrication circuit, without consultation and previous authorization of the Liebherr
Service are not allowed. In contrary case, the guarantee expires.

Fig. 17 Exploded view of the spare parts - example

1 Initial element 20 Pipe union

2 Middle element 45 MX - F 30 Lock screw
3 Middle element 75 MX - F 31 Socket screw
4 Middle element 105 MX - F 32 Pipe bridge
5 Middle element 105 MX - F 997 Gasket set
8 End element 998 Gasket set
9 Ratchet wheel 999 O-Ring set
10 Socket screw

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