OM Rus Atlas 1505

Workshop Manual
ATLAS 1305 / 1505 / 1605 /1705
Training Center
The present Workshop Manual was compiled
specifically for service technicians belonging to
the ATLAS TEREX organization.
Generally, service technicians work under their

own responsibility for industrial safety during
maintenance and repair work on ATLAS TEREX
products.
In order to prevent personal and material dama-

ge, it is necessary to observe all effective safety
instructions and legal regulations.
Only qualified and trained specialists are autho-

rized to service and repair ATLAS TEREX pro-
ducts properly.
The service technicians are obliged to perform
training courses.
For machine care and maintenance work, refer

to the Operating Manuals.
The contents of this Manual is in the property of

ATLAS TEREX GmbH, Delmenhorst, Germany,
and protected by copyright. No part of this docu-
ment may be reproduced.
ATLAS-TEREX GmbH
Delmenhorst / Germany
Tel.: 04221 / 491 - 0
e-Mail: u.bardeck@atlas-terex.de
Revised: 08.2004
Order Nr.: xxxxxxx
Training Center
Training Center Workshop manual
Revised: 08.2004 1305 / 1505 / 1605 /1705 Mobile
Contents
1 Technical data
2 Display and controls
3 Engine
4 Vehicle engine
5 Pumps
6 Pilot Control Equipment
7 Control block
8 Main rotation connection
9 Slewing gear gears and motor
10 Pressure setting tables / setting regulations
11 Cylinders
12 Hydraulic accessories
13 Air conditioner system
14 Power shift transmission
15 Electricity
16 Axles
17 Hydraulic circuit diagrams
18 Maintenance
19 Miscellaneous
Page 1 of 1
Training Center Workshop Manual
Revised: 08.2004 1305 / 1505 / 1605 / 1705 Mobile
Chapter 1
Technical data
Contents
1 Technical data............................................................................................................... 2
Page 1 of 6
Workshop Manual Training Center
1305 / 1505 / 1605 / 1705 Mobile Revised: 08.2004
1 Technical data
Size Unit 1305 M 1505 M 1605/1705 M
Service weight t 13 - 14 14 - 16 15,5 - 17,5
Max. shovel capacity l 900 1120 1120
Motor manufacturer Deutz Deutz Deutz
Type BF4M2012 BF4M2012C BF6M2012C
Power kW 67 80 105
(PS) 91 109 142
Speed min-1 2000 2000 2000
Hydraulic system AWE5 AWE5 AWE5
Max. volume l/min 188 260 260
Max. pressure bar 360 360 360
Slewing speed min-1 9 9 9
Slewing radius mm 1980 2190 2190
Dimensions PL PL PL
Axle width (A) mm 2490 2490 2490
Wheel base (B) mm 2500 2500 2500
Height (C) mm 3075 3075 3075
Tyres 8x 10.00-20 8x 10.00-20 8x 10.00-20
Max. driving speed km/h 20/Option 30 20/Option 30 20/Option 30
Creeping speed km/h 1 1 1
Page 2 of 6 Chapter 1
Technical data
Revised: 08.2004 1305 / 1505 / 1605 / 1705 Mobile
Size Unit 1305 M 1505 M 1605/1705 M

A3.2, C3.41, A5.2, C6.41, A6.2, C6.41,
Hydraulic adjusting system C346, D33, C53.46, C53.46,
F415 D53.3, F415 D53.3, F416
Dredging depth m 4,0 / 5,4 4,2 / 5,6 4,2 / 5,6
Dredging width m 7,5 / 8,9 7,8 / 9,2 7,8 / 9,2
A3.2, C3.0, A5.2, C6.0, A6.2, C6.0,

Mechanical adjusting
C33, D33, C53.3, D53.3, C53.3, D53.3,
system
F415 F415 F415
Dredging depth m 3,7 / 5,2 4,1 / 5,5 4,1 / 5,5
Dredging width m 7,2 / 8,6 7,5 / 8,9 7,5 / 8,9
A3.2, C3.3M, A5.2, C6.3M, A6.2, C6.3M,

Monoblock system
D33, F415 D53.3, F415 D53.3, F416
Dredging depth m 3,8 / 5,2 4,3 / 5,7 4,3 / 5,7
Dredging width m 7,1 / 8,5 7,3 / 8,7 7,3 / 8,7
Max. tear-out force kN 64 82 112
Max. break-away force kN 106 130 141
Sound level in acc. with EG
2000/14
LWA outside level dB(A) 100 103 101
LPA cab level dB(A) 75 75 75
Chapter 1 Page 3 of 6
Technical data
1305 / 1505 / 1605 / 1705 Mobile Revised: 08.2004
Size Unit 1305 M 1505 M 1605/1705 M

Hydraulic pump,
open circuit
Nominal volume ccm 95 130 130
Slewing direction right
Maximum speed (load) min-1 2000 2000 2000
Driving power kW 67 88 105
Max. operating pressure bar 345 345 345
Max. rate of flow l/min 190 252 252
Min. rate of flow l/min 35 35 35
Power regulator
Nominal voltage V 24 24 24
Mode 1 driving power kW 67 88 105
for control power 1 mA 100 100 100
Load Sensing (S)

set at differential pressure bar 22+1 22+1 22+1
Technical data
Revised: 08.2004 1305 / 1505 / 1605 / 1705 Mobile
Size Unit 1305 M 1505 M 1605/1705 M

A6VM107 with A6VM107 with A6VM107 with
Vehicle engine braking valve braking valve braking valve
NG25 NG25 NG25
Nominal volume ccm 107 107 107
Alternating slewing direction
Max. speed min-1 3700 3700 3700
Max. displacement volume ccm 107 107 107
Min. displacement volume ccm 53 53 53
Hydr. VG circuit retarder

(side A)
for displacement volume 1 ccm 63 63 63
Pilot valve adjusting point for
bar 390+30 390+30 390+30
high pressure 1
Adjustment:
depending on high pressure
(HA)
Assembly model A
Commencement of adjustment
bar 260 260 260
Vgmin
at operating pressure
bar 10 10 10
Max. adjustment range
Hydraulic saturation drive

Brake valve (F)
Max. volume flow l/min 196 196 196
Commencement of opening bar 7 7 7
End of opening bar 30 30 30
Make time msec 4085 4085 4085
Secondary valves
Commencement of opening for
bar 450 450 450
absolute pressure
Technical data
1305 / 1505 / 1605 / 1705 Mobile Revised: 08.2004
Technical data
Revised: 08.2004 1305 / 1505 / 1605 / 1705 Mobile
Chapter 2
Display and controls
Contents
1 General view of cab ...................................................................................................... 2

2 Seat with consoles ........................................................................................................ 3
3 Left switch panel ........................................................................................................... 4
4 Right switch panel......................................................................................................... 5
5 "DELUXE" Control and display ..................................................................................... 6
6 "STANDARD" Controls and display ............................................................................ 11
7 Control panel heating and air conditioning.................................................................. 16
1305 / 1505 / 1605 / 1705 Mobile Revised: 08.2004
1 General view of cab
10
9
5
4 4
6 7
3 8
2
1
17 15 13
16 14 12
18 11
M+P-05C-0035
1 Slider, side window 10 Windshield

2 Lever for cab door 11 Right console with switch panels
3 Lever for pilot control 12 Superstructure slewing lock
4 Windshield locking rods left/right 13 Accelerator pedal
5 Side window 14 Brake pedal with lock
6 Multifunction lever 15 Foot lever for adjusting angle of steering column
7 Windshield vent outlet 16 Foot lever for adjusting angle of steering column
8 Side window vent outlet 17 Boom adjusting peda
9 Sun visor 18 Left console with switch panel
Revised: 08.2004 1305 / 1505 / 1605 / 1705 Mobile
2 Seat with consoles
4
3
6 12
5
11
8
1 13
10 7
2
9
M+P-05C-0005 M+P-05B-6629 M+P-05B-6630
1 Air outlets for legroom

2 Cab-door unlatching lever
3 Right console
4 Seat
5 Handwheel for adjusting seat angle
6 Lever for adjusting seat back angle
7 Left console
8 Release lever for horizontal seat springing
9 Bar for adjusting seat with consoles forwards/back
10 Lever for ajusting seat springing and seat height
11 Lever for forwards/back seat movement
12 Handwheel for outward curvature of lumbar support
13 Handwheel for armrest angle adjustment
1305 / 1505 / 1605 / 1705 Mobile Revised: 08.2004
3 Left switch panel
1 Control lever for:

Folding jib
Slewing
2 Left pushbutton for special functions
3 Right pushbutton for special functions
4 Pushbutton for horn
5 Lever for dozer blade/pads
6 Spare, for optional extra (✦)
Revised: 08.2004 1305 / 1505 / 1605 / 1705 Mobile
4 Right switch panel
3
4
2 5
6
7
1
8
10
11
12
M+P-05C-0002
1 Control lever for:

Lifting
Lowering
Bucket/grab
2 Control and display panel
3 Pushbutton to rotate grab to right
4 Pushbutton to rotate grab to left
5 Pushbutton to cancel precision control
6 Pushbutton to preselect direction of travel
8 Cigarette lighter/electric power socket
9 Ignition key
10 Pushbutton to hazard warning flashers
11 Control panel for heater/air conditioner
1305 / 1505 / 1605 / 1705 Mobile Revised: 08.2004
5 "DELUXE" Control and display
M+P-05C-0004
1 Parking brake pushbutton 12 Work-area lights pushbutton

2 Central lubrication pushbutton 13 Automatic idling system pushbutton
3 Pushbutton pilot control deactivated 14 Inching speed pushbutton
4 Rotating beacon light pushbutton 15 Automotive driving pushbutton
5 Overload warning device pushbutton 16 Swing axle lock pushbutton
6 Cruise control pushbutton 17 Pressure cut-in stage pushbutton
7 Windshield wiper pushbutton 18 Operating mode pushbuttons F1 to F3
8 Intermittent wipe / windshield washer operation 19 Pushbutton to decrease pressure differential
pushbutton 20 Pushbutton to increase pressure differential
9 Transmission pushbutton 21 Pushbutton to decrease engine speed
10 Light pushbutton 22 Pushbutton to increase engine speed
11 Interior lights pushbutton
Revised: 08.2004 1305 / 1505 / 1605 / 1705 Mobile
M+P-05C-0004
23 Display
24 Display control pushbutton
25 Program mode pushbutton
26 Pushbutton for decreasing menu values
27 Pushbutton for increasing menu values
28 Warning light, malfunction/defective fuse
29 Control light, information
30 Warning light, charge control
31 Control light, preselecting direction of travel
32 Warning light, engine oil pressure
33 Control light, high beam headlights
34 Control light, flashing direction indicators
35 Control light, brake
36 Control light, hazard warning flashers
37 Control light 1 to 4, preselecting
support pads
38 Control light A to C, special functions
1305 / 1505 / 1605 / 1705 Mobile Revised: 08.2004
Display Working parameters
After ignition the last selected function is shown on The following parameters can be shown on the
the display (23). display one after another by pressing + (27) or
- (26) button or they can be hidden.
In standard configuration the time, date and the
multifunction settings display are shown. 39 Multifunction settings display
40 Engine speed (rpm)
The actual values of four basic parameters are
41 Delta-P (pressure differential/
shown on the multifunction settings display
precision control, %)
(a number plus bar graph on the display) that can
be chosen from seven parameters and can be 42 Fuel level (%)
configured separately. 43 Temperature of the coolant (°C)
44 Engine torque (%)
45 Working hours, general (h)
46 Voltage (V)
47 Engine oil pressure (bar)
48 Charge air pressure (bar)
Display switch off
Revised: 08.2004 1305 / 1505 / 1605 / 1705 Mobile
1305M - 6066073 - 05B003-03
Warning symbols The warning symbols can be hidden by pressing

display control pushbutton (24).
If malfunctions occure, corresponding warning sym-
bols are shown on the display (23). Control light (29) comes on.
51 Low coolant level Low fuel level

52 High coolant temperature
53 Low engine oil pressure
54 Low break pressure
55 Air filter blocked
56 High hydraulic oil level
57 High hydraulic fluid temperature
58 Water in mesh strainer fuel filter
59 Low fuel level
1305 / 1505 / 1605 / 1705 Mobile Revised: 08.2004
In addition the following information symbols can be shown on the display.
60 Parking brake activated while selecting travel direction

61 Travel direction selected while starting the engine
62 Accelerator pedal pressed while driving with cruise control
Revised: 08.2004 1305 / 1505 / 1605 / 1705 Mobile
6 "STANDARD" Controls and display

The "program operation control" menu cannot be called up. The settings described in the instructions for
operation and maintenance can only be carried out by authorised TEREX-ATLAS engineers.
The F1 to F3 operating modes have been set as follows:
Operating mode Motor speed Delta-P

(rpm) (pressure difference/fine
controls) (%)
F1 1 600 100
F2 1 800 100
F3 2 000 100
1305 / 1505 / 1605 / 1705 Mobile Revised: 08.2004
1 Parking brake pushbutton

2 Cruise control pushbutton
3 Pushbutton pilot control deactivated
4 Swing axle lock pushbutton
5 Inching speed pushbutton
6 Transmission pushbutton
7 Windshield wiper pushbutton
8 Intermittent wipe / windshield washer operation pushbutton
9 Central lubrication pushbutton
10 Light pushbutton
11 Rotating beacon light pushbutton
12 Work-area lights pushbutton
13 Automatic idling system pushbutton
14 Pressure cut-in stage pushbutton
15 Overload warning device pushbutton
16 Operating mode pushbuttons F1
Revised: 08.2004 1305 / 1505 / 1605 / 1705 Mobile
19 Display
20 Pushbutton for decreasing menu values
21 Pushbutton for increasing menu values
22 Warning light, malfunction/defective fuse
23 Control light, information
24 Warning light, charge control
25 Control light, preselecting direction of travel
26 Warning light, engine oil pressure
27 Control light, high beam headlights
28 Control light, flashing direction indicators
29 Control light, brake
30 Control light, hazard warning flashers
31 Control light 1 and 2 preselecting support pads
32 Control light 3 and 4 preselecting support pads
33 Control light A special functions
34 Control light B special functions
35 Control light C special functions
1305 / 1505 / 1605 / 1705 Mobile Revised: 08.2004
Standard indication display
On switching on the ignition, the time, hours of operation and the multi-function display will be shown on
the display.
The multi-function display simultaneously shows the actual data for the following operating parameters (nu-
meric value and bar display):
• Motor speed (rpm)
• Coolant temperature (°C)
• Motor oil pressure (bar)
• Fuel level (%)
Warnings
The warnings described in the instructions for operation and maintenance of the excavator can be switched
off by pressing the +/- buttons simultaneously.
The indicator lamp i will light up.
Setting the time and the date
• Press the +/- buttons simultaneously.
• In the display the date is shown instead of the hours of operation. The digit indicating the hour will blink.
• Set the current hour by pressing the +/- buttons.
• Press the +/- buttons simultaneously. The figure set will be stored. The digit indicating the minutes will
blink.
• Set the minutes, day, month and year as described above.
• Once the year has been set the display will change to the standard display.
Revised: 08.2004 1305 / 1505 / 1605 / 1705 Mobile
Error messages
When an error is recognised, the time and the operating hour displays are switched off.
The top line of the display shows the five-digit error code on the left and the error number and the total
number of errors recognised on the right.
The warning light (1) will light up.
The error message can be confirmed and switched off by pressing the +/- (2) buttons simultaneously.
Any other error messages will be indicated and can be confirmed.
Once all of the error messages have been confirmed, the display will return to the standard display.
Please note
All of the error messages will be shown once again when the ignition is switched on. They can be then be
confirmed.
1305 / 1505 / 1605 / 1705 Mobile Revised: 08.2004
7 Control panel heating and air conditioning
1 Display air distribution

2 Display status information
3 Value select pushbutton - increase/decrease
4 Air distribution pushbutton
5 Blower pushbutton
6 Temperature pushbutton
7 Air conditioning pushbutton
8 Air recirculation pushbutton
Training Center Factory manual
Revised: 08.2004 1305 / 1505 / 1605 / 1705 Mobile
Chapter 3
Engine
Contents
1 EMR .............................................................................................................................. 2
1.1 Application of the EMR ................................................................................................. 2
1.1 Application of the EMR ................................................................................................. 2
2 System description........................................................................................................ 3
3 Basic equipment ........................................................................................................... 3
4 System functions........................................................................................................... 4
5 Pressure maintenance valves....................................................................................... 5
6 Technical data............................................................................................................... 6
Page 1 of 6
Factory manual Training Center
1305 / 1505 / 1605 / 1705 Mobile Revised: 08.2004
1 EMR
1.1 Application of the EMR
The Electronic Motor Regulator (EMR) serves the purpose of regulating rotary speed for DEUTZ diesel-
engines of the construction series 1012/1013 (1015) for application in agricultural and building machinery
as well as in aggregates. It is designed for application in rough environments under difficult environmental
conditions and has the respective protective classes.
The regulator performs all the functions of the mechanical regulator (Variable-speed control, torque limita-
tion, LDA-function) and also provides further functions.
1.2 Overview of system

The EMR consists mainly of the sensors, control unit and the actuator. Facilities in the engine as well as
vehicle/installation are connected to the EMR-control unit through separate, pre-fabricated cable-trees.
Cable-routing in the vehicle is done by the manufacturer of the vehicle/installation.
See the following graph for facilities in the engine and vehicle.
EMR (1) Ladeluftdrucksensor = Loading air

Vehicle equipment
EMR
control unit Engine equipment pressure sensor
control unit (2) Regelstangeweggeber/Stellglied =
Control rod-position
encoder/final control element
(3) Temperatursensor Kühlflüssigkeit =
Temprature sensor Cutting oil
(4) Drehzahlsensor Nockenwelle = Engine
speed sensor Camshaft
(16) 2. Drehzahlsensor optional = 2nd
speed sensor (optional)
(15) Hubmagnet optional = Lifting mana-
gement (optional)
(14) Öldruck optional = Oil pressure
sensor (optional)
(5) Energieversorgung = Power supply

(6) Drehzahl-Anzeige = Speed indication
(optional)
(7) Drehmoment-Anzeige = Torque indica-
tion (optional)
(8) Fahrpedal = Accelerator pedal
(9) Handgas = Hand throttle optional)
(10) Umschalter Funktionen = Change
over switch functions
(11) Schlüsselschalter Start-Stop =
Key switch start – stop
(12) Fehlerlampe = Error light
(13) Diagnoseschnittstelle CAN/Bus =
Diagnostic interface/CAN bus
Engine
Revised: 08.2004 1305 / 1505 / 1605 / 1705 Mobile
2 System description
The sensors mounted on the engine supply the the electronics in the control unit with all relevant physical
magnitudes.
The EMR activates a rotary magnet in accordance with this information through the present status of the
engine and the specifications (accelerator pedal etc.), which in turn, actiavtes the control rod of the injection
pump and thereby, doses the amount of fuel.
Through the position encoder of the control rod which, together with the rotary magnet, is positioned in a
housing (the “Actuator”), the precise position of the control rod is reported back and corrected where ne-
cessary.
The EMR is fitted with safety facilities and measures in the hardware and software in order to ensure emer-
gency-run functions (Limp home).
To shut off the engine, the EMR is de-energized through the ignition switch. A sufficiently strong spring in
the actuator presses the control rod to the zero-position in the de-energized state. Optionally, a lifting ma-
gnet can be additionally activated for shut-off.
The EMR is initially pre-programmed in an engine-neutral manner. On the test-field, the engine is tested,
set and programmed with the EMR. After this programming, the EMR is permanently assigned to the en-
gine and contains an engine-specific data-set.
The EMR is configured through the end-of-tape programming via the ISO 9141-interface for the various
application cases as well as customer wishes - e.g. in respect of a specific scope of function.
3 Basic equipment
In addition to the control unit, the following components are necessary as minimum equipment for the ope-
ration of the engine:
For the vehicle:

• Power supply (battery)
• Diagnostic interface (ISO 9141)
• Fault lamp
For the engine:

• Actuator (contains control rod-position encoder and operating magnet)
• Rotary speed-sensor (camshaft)
• Coolant temperature-transmitter (NTC)
• Cable-tree
Further components / Facilities may be required depending on the application case or desired functions.
Engine
1305 / 1505 / 1605 / 1705 Mobile Revised: 08.2004
4 System functions
The EMR offers a broad range of functions which can be activated through an application-dependent con-
figuration and the assignment of the inputs and outputs. It enables an exchange of signals also between
the engine (through the vehicle plug) and EMR. The signals may be analogue, digital or pulse-width mo-
dulated (PWM signals).
The functions used depends on the operational conditions of the engine. Accordingly, there are different
variations of the functions and the pin-assignment of the plugs.
The functions of the EMR relate to rotary-speed-regulation, volume-limitation (injection), monitoring,

vehicle and unit functions and communication/diagnostic interfaces.
The EMR offers a range of basic equipment which can be optionally expanded in all variations, see illustra-
tion below:
Engine
Revised: 08.2004 1305 / 1505 / 1605 / 1705 Mobile
5 Pressure maintenance valves

In case of poor performance, ignition failures etc., it is necessary to, first of all, measure the fuel-pressure
in the galery as determined by the pressure maintenance valve. The measurement shall be performed on
the connection of the hose coming from the fuel-filter and with a pressure connection which must be pre-
pared personally. (Double hollow screw with the respective connection to the manometer)
Position of the measurement station
Engine
1305 / 1505 / 1605 / 1705 Mobile Revised: 08.2004
6 Technical data
Type of motor Unit BF4M2012 BF4M2012C BF6M2012C

No. of cylinders 4 4 6
Bore/stroke mm 101/126 101/126 101/126
Piston capacity l 4,04 4,04 6,06
Compression ratio 19 19 19
Charge air cooling system sin con con
Max. rated speed min-1 2000 2000 2000
Power Kw /(PS) 67/(91) 88/(119) 105/(142)
for speed min-1 2000 2000 2000
Max. torque Nm 390 493 743
for speed min-1 1500 1500 1500
Lowest idling speed min-1 800 800 800
Engine
Revised: 08.2004 1305 / 1505 / 1605 / 1705 Mobile
Chapter 4
Vehicle engine
Contents
1 Instructions for repairs to the vehicle engine ................................................................ 2

2 Cross section vehicle engine ...................................................................................... 41
3 Cross section travel motion control valve ................................................................... 42
Page 1 of 42
1305 / 1505 / 1605 / 1705 Mobile Revised: 08.2004
1 Instructions for repairs to the vehicle engine
RDE 91 604-01-R/03.03
ersetzt/replaces 08.01
Variable displ. motor A6VM 28...200
Repair Instructions
Vehicle engine
Revised: 08.2004 1305 / 1505 / 1605 / 1705 Mobile
General repair instructions
Attention!
Observe the following notices when car-
rying out repair work at hydraulic aggre-
gates!
Close all ports of the hydraulic aggrega-

tes.
Replace all seals.

Use only ORIGINAL BRUENINGHAUS-
HYDROMATIK spare parts.
Check all seal and sliding surfaces for

wear.
Attention: rework of sealing area f. ex.
with abrasive
paper can damage surface.
Fill up hydraulic aggregates with medium

before start- up.
Vehicle engine
1305 / 1505 / 1605 / 1705 Mobile Revised: 08.2004
Seal kits and sub-assembly groups
Seal kit for drive shaft.
External sealing kit.
Housing
Pos. 2
Complete rotary group
Note: Pos. 1 - For port plate with differential piston
Pos. 2 - For port plate with synchronizing piston
Pos. 1
Port plate with control piston

Pos. 1 Pos. 2
Note: Pos. 1 - For port plate with differential piston
Pos. 2 - For port plate with synchronizing piston
Vehicle engine
Revised: 08.2004 1305 / 1505 / 1605 / 1705 Mobile
Seal kits and sub assembly groups
Solenoid
Cover with * throttle pin.

* Throttle pin "as to order requirement".
*
*
*
*
* Cover with flushing and boost pressure
valve and * throttle pin.
* Throttle pin "as to order requirement".
*
Vehicle engine
1305 / 1505 / 1605 / 1705 Mobile Revised: 08.2004
Component groups / Control components
e.g. HA
EP
"as to order requirement".
HA2
HD
Vehicle engine
Revised: 08.2004 1305 / 1505 / 1605 / 1705 Mobile
Component groups / Control components
e.g. HZ3 / EZ3
HA3 / HA3U
Vehicle engine
1305 / 1505 / 1605 / 1705 Mobile Revised: 08.2004
Replace seal nut
Replace seal nut.

setting First measure and record the setting
height X height X.
When tightening, hold the setting screw

in place, and then check setting height.
Vehicle engine
Revised: 08.2004 1305 / 1505 / 1605 / 1705 Mobile
Sealing of the drive shaft
Protecting the drive shaft.

Remove retaining ring and shim.
Screw in sheet metal screw into the holes

fitted with rubber.
Pull out seal with pliers.
Press in shaft seal ring and shim with

bush to stop.
Take note of press-in depth!
* Lightly grease the seal, dust lips and
shaft seal ring.
Install * mark for press-in depth of safety
ring.
Vehicle engine
1305 / 1505 / 1605 / 1705 Mobile Revised: 08.2004
Sealing of the control parts
Attention!
Spring load
1
1. Cover
1
2. Control part
Inspect
Drilling in housing, O-ring, groove.
2
Do not remove adjustment screw.
Inspect
O-ring, O-ring groove, housing
Assembly aid
Insert pin with grease.
Vehicle engine
Revised: 08.2004 1305 / 1505 / 1605 / 1705 Mobile
Sealing the hydraulic control
Example: A6VM ... HD control

Disassembly position:
Remove cover pos. 1
Pos.1
1
1. O-ring
2
2. Input flow of oil control
3. Throttle pin
Installation position differs according to
the control components
1. Input flow of oil control

2. High pressure /low pressure
1
5
3. High pressure /low pressure
4. Leakage oil
2 3 5. Control piston
Vehicle engine
1305 / 1505 / 1605 / 1705 Mobile Revised: 08.2004
Sealing the hydraulic control
Pos. 2
Example: A6VM... control - differential pi-
ston
Disassembly position: Remove cover
pos. 2.
x Attention! Spring load.
Dimension x: Note dimension (begin of
regulation).
1. Check of O-ring
1
2
*
1. High pressure - small control piston
side
2. Control pressure
3. High pressure - check valve
4. High pressure - check valve
3
4 * see service info
Vehicle engine
Revised: 08.2004 1305 / 1505 / 1605 / 1705 Mobile
Disassembly of the port plate
Differential piston:
x
Note dimension x
For disassembly of the port plate, swivel

always rotary group to zero position.
Piston rings to hang out of the cylinder
boring.
Qmin -screw
Remove Qmin -screw.

Swivel rotary group to 0°.
Vehicle engine
1305 / 1505 / 1605 / 1705 Mobile Revised: 08.2004
Synchronizing piston:
Note dimension x.
For disassembly of the port plate, swivel

always rotary group to zero position.
* Piston rings to hang out of the cylinder
boring.
Qmin -
Remove Qmin -screw and plug.
Swivel rotary group to zero position with

screw Qmin
Vehicle engine
Revised: 08.2004 1305 / 1505 / 1605 / 1705 Mobile
Port plate
Mark position. Loosen screws.
Removal
Check O-ring.
Stick new O-ring with some grease.
Do not swivel rotary group.
Piston rings to hang out from the cylinder
boring.
Stick control lens in sliding surface with

grease.
Assembly in reverse order.
Mount port plate.
Rotary group vertical.
Vehicle engine
1305 / 1505 / 1605 / 1705 Mobile Revised: 08.2004
Removing the positioning piston
Differential piston Synchronizing piston
Loosen fixing screw.

Use only socket wrench.
Vehicle engine
Revised: 08.2004 1305 / 1505 / 1605 / 1705 Mobile
Removing the positioning piston
Remove piston with piston ring
Differential piston
* Warm up fixation screw for positioning
*
plug via boring (screw glued - to turn out).
Use new screw.
Precote coating.
Note tightening torque! (see page 43).
Synchronizing piston
Remove screw.
Remove piston.
Note installation position.
Vehicle engine
1305 / 1505 / 1605 / 1705 Mobile Revised: 08.2004
Removing the rotary group
Screw in threaded pin into centre pin. Fix

the cylinder with disc and locknut.
Remove Qmax -stop screw.
Size 28: M4 x 60 mm
55: M5 x 80 mm
80: M6 x 90 mm
107: M6 x 100 mm
140: M8 x 110 mm
160: M8 x 110 mm
200: M8 x 110 mm
Press out rotary group!

If the bearings are used again do not hit
on the drive shaft.
Vehicle engine
Revised: 08.2004 1305 / 1505 / 1605 / 1705 Mobile
Or press-out with extraction device.
Vehicle engine
1305 / 1505 / 1605 / 1705 Mobile Revised: 08.2004
Exchanging the rotary group
pressed in
Complete rotary group
Setting of hydraulic part necessary.
Rotary group
1. Mechanical part: adjust drive shaft with
bearing.
2. Hydraulic part: adjustment
necessary *.
*
Rotary group: all parts
* Setting
Setting value, torque - see service infor-
mation.
Vehicle engine
Revised: 08.2004 1305 / 1505 / 1605 / 1705 Mobile
Exchanging the rotary group
Remove fixing screw (cylinder).

Remove cylinder.
Disassemble retaining plate.

Screws are glued. Warm it up to max. 120
°C and remove with Torx-tools.
Vehicle engine
1305 / 1505 / 1605 / 1705 Mobile Revised: 08.2004
Inspection notes
Free of corrosion, erosion or fretting; no

damage to splines or keyways.
Pistons
No scoring and no pitting.
1 2
Centre pin
No scoring and no pitting.
Retaining plate
No scoring and no evidence of wear
Cylinder block / control lens

1. Bores free of scoring; no evidence of
wear.
2. Faces smooth and even, free of
cracks and scoring.
Vehicle engine
Revised: 08.2004 1305 / 1505 / 1605 / 1705 Mobile
Inspection notes
Control housing
Sliding surface and side guides free of
scoring and no wear.
Visual check:
Bearing areas free of scoring; no evi-
dence of wear.
Vehicle engine
1305 / 1505 / 1605 / 1705 Mobile Revised: 08.2004
Rotary group assembly / see service information
Rotary group: mechanical part
Adjustment dimension * and bearing tor-

1 que
see service information.
2
*
Press on bearing.
Do not exceed bearing torque during
press-on.
BOJH
GG
RTT
GHED
000
000
BOJH
GG
RTT
GHED
Preload bearing with assembly sleeve and steady control of the torque.
Vehicle engine
Revised: 08.2004 1305 / 1505 / 1605 / 1705 Mobile
Rotary group assembly
Assemble safety ring.

Determine dimension * for adjustment
disc with final dimensions (crossover)
Install adjustment shim.

1 Assemble safety ring.
Drive shaft ready for assembly.
Vehicle engine
1305 / 1505 / 1605 / 1705 Mobile Revised: 08.2004
Insert retaining plate with piston and cen-

tre pin.
Use screw with Precote-coating.
(Tightening torque see page 36).
Make sure all parts are fitted in correctly.
Swivel cylinder block to zero position and

fix the cylinder with a threaded pin
(see page 19)
Vehicle engine
Revised: 08.2004 1305 / 1505 / 1605 / 1705 Mobile
Rotary group completely assembled rea-

dy for assembly.
Position assembly sleeve.
Warm up housing to 80 °C.
Vehicle engine
1305 / 1505 / 1605 / 1705 Mobile Revised: 08.2004
Insert rotary group into housing to seat

position.
Pull the drive shaft into housing to seat

position after rotary group assembly.
2 1
Fix zero position of cylinder

with Qmax -screw.
1. Disassemble cylinder fixing screw.
2. Insert O-ring.
Vehicle engine
Revised: 08.2004 1305 / 1505 / 1605 / 1705 Mobile
Rotary group adjustment (see service information)
Determine cylinder swivel range to max.

angle with screw.
* Disc
*
Place centering disc.
Mount measuring device.
Check dimension X.
Vehicle engine
1305 / 1505 / 1605 / 1705 Mobile Revised: 08.2004
Assembly of the port plate
1. Assemble port plate with differential

piston.
* Take care of assembly design!
Tighten fixing screws with torque.
2. Swivel rotary group to "starting
position".
3. Set Qmin -screw to dimension*.
4. Assemble plug.
5. Remove assembly sleeve.
Assemble cover.
Assemble control components.
Vehicle engine
Revised: 08.2004 1305 / 1505 / 1605 / 1705 Mobile
Assembly of the port plate
1. Assemble port plate with synchroni-

sing piston.
Take care of assembly design!
Tighten fixing screws with torque.
2. Swivel rotary group to "starting positi-
on".
3. Set Qmin -screw to dimension*.
4. Assemble plug.
5. Remove assembly sleeve.
Assemble shaft seal, disc and safety ring.

Press-in with assembly sleeve.
Lightly grease the seal, dust lips and
shaft seal ring.
Take care of press-in depth.
Vehicle engine
1305 / 1505 / 1605 / 1705 Mobile Revised: 08.2004
Assembly guidelines for tightening torques
1. Bolts (to N 08.001)
The values stated are valid for bolts with metric ISO threads to DIN 13 part 13, as well as head areas to
DIN 912 socked head cap screws, DIN 931 hexagon bolt or DIN 933 hexagon bolts with threads up to the
head.
Tensile strength class

Thread
8.8 10.9 12.9
Tightening torque MA in Nm
M3 1,1 1,6 1,9
M4 3,1 4,5 5,3
M5 6,1 8,9 10,4
M6 10,4 15,5 18
M8 25 37 43
M10 51 75 87
M12 87 130 150
M14 140 205 240
M16 215 310 370
M18 300 430 510
M20 430 620 720
M22 580 830 970
M24 740 1060 1240
Vehicle engine
Revised: 08.2004 1305 / 1505 / 1605 / 1705 Mobile
2. Plugs with internal hexagon and profile seal ring (to N 02.009).
G
EOLASTIC seal
Thread Tightening torque MA in Nm Thread Tightening torque MA in Nm

M8 x 1 5 G 1/8 A 10
M10 x 1 10 G 1/4 A 30
M12 x 1,5 20 G 3/8 A 35
M14 x 1,5 30 G 1/2 A 60
M16 x 1,5 35 G 3/4 A 90
M18 x 1,5 40 G1A 140
M20 x 1,5 50 G 1 1/4 A 240
M22 x 1,5 60 G 1 1/2 A 300
M26 x 1,5 70
M27 x 2 90
M30 x 1,5 100
M33 x 2 140
M42 x 2 240
M48 x 2 300
Vehicle engine
1305 / 1505 / 1605 / 1705 Mobile Revised: 08.2004
5. Plugs with internal hexagon, O-ring and UNF-, UN- threads in acc. with SAE J 514
(in acc. with N 02.106)
G
O-ring seal
Thread

7/16 - 20 UNF 15 M12 x 1,5 20
1/2 - 20 UNF 20 M14 x 1,5 30
9/16 - 18 UNF 25 M27 x 1,5 90
3/4 - 16 UNF 72
7/8 - 14 UN 127
1 1/16 -12 UN 147
1 3/16 -12 UN 173
1 5/16 -12 UN 198
1 5/8 -12 UN 320
1 7/8 -12 UN 390
Vehicle engine
Revised: 08.2004 1305 / 1505 / 1605 / 1705 Mobile
6. Oval head screw with inner TORX, thread pre-coated with "precote"
Standard
precote 80 - Red
Variant
precote 86 - Blue
I 2602493 M5 x 16
I 2602395 M6 x 20
* * with head bottom coating -
colourless
refer to parts list

Thread 10.9
M3 2,1
M4 4,7
M5 9,1
M6 15,8
M8 37,7
7. SEAL-LOCK - sealing nuts (in acc. with N 02.100)
Thread Tightening torque MA in Nm

M6 10
M6 x 0,5 11
M8 22
M8 x 1 24
M10 40
M10 x 1 44
M12 69
M12 x 1,5 72
M14 110
M14 x 1,5 120
M16 170
M16 x 1,5 180
Vehicle engine
1305 / 1505 / 1605 / 1705 Mobile Revised: 08.2004
A6V positioning piston

for A6V / A7V / A7F / A8V)
Tightening torque MA for threaded pin (1) Tightening torque MA for shaft bolts (2)
Connection: Positioning piston and positioning Connection: Positioning piston and piston for A6V
trunnion
M6 : 8,5 Nm M14 x 1,5 : 120 Nm
M8 : 14,0 Nm
M10 : 30,0 Nm
M12 : 52,0 Nm
Vehicle engine
Revised: 08.2004 1305 / 1505 / 1605 / 1705 Mobile
Safety regulations
General advice
• Make yourself familiar with the machine fittings.

• Only operate the machine if you are completely familiar with the operating and control elements as well
as the functioning of the machine.
• Use your safety equipment such as the helmet, safety shoes and ear protection.
• Make yourself familiar with your working field.
• Only operate the machine for its intended purpose.
Please observe the guidelines of the Professional Association and the machine manufacturer.
Before starting
• Observe the operating instructions before starting.

• Check the machine for obvious faults.
• Do not operate the machine with defective instruments, warning lights or control elements.
• All safety devices must be securely positioned.
• Do not carry any movable objects with you or if you do, please secure them to the machine.
• Keep oily and inflammable material away from the machine.
• Before entering the driver's cabin, check if persons or obstacles are beside or beneath the machine.
• Be careful when entering the driver's cabin; use the steps and handles.
• Adjust your seat before starting.
Vehicle engine
1305 / 1505 / 1605 / 1705 Mobile Revised: 08.2004
Safety regulations
Start
• When starting all operating levers must be in the "neutral position".

• Only start the machine from the driver's seat.
• Check the indicating instruments after start to assure that all functions are in order.
• Do not leave the machine unobserved when the motor is running.
• When starting with battery connection cables connect plus to plus and minus to minus. Always connect
the earth cable (minus) last and cut it off first.
Attention
• Exhaust gas is dangerous. Make sure that there is sufficient fresh air when starting in closed rooms!
Hydraulic equipment
1. Hydraulic equipment is subject to high pressure!
High pressure fluids (fuel or hydraulic oil) which escape under high pressure can penetrate
the skin and cause serious injury, so a doctor must be consulted immediately to avoid the
occurrence of serious infections.
2. When searching for leakages appropriate auxiliary devices must be used to avoid accidents.
3. Before carrying out any work on the hydraulic equipment, it is essential to lower the pressure to zero
and to lower the working arms of the machine.
4. When carrying out work on the hydraulic equipment, it is essential that the motor be stopped and that
the tractor be secured against rolling away (parking brake, shim)!
5. When connecting hydraulic cylinders and motors please ensure that flexible hydraulic hoses are pro-
perly connected.
6. When the ports are exchanged, the functions are vice versa (e.g. lift-up/lower) - risk of accidents!
7. Check flexible hydraulic hoses regularly and replace them in case of damage or wear! The new hoses
must comply with the technical requirements of the machine manufacturer!
Please dispose of oil, fuel and filters in an orderly manner!
Vehicle engine
Revised: 08.2004 1305 / 1505 / 1605 / 1705 Mobile
Operating instruction
Setting test
(Begin of regulation of Vgmax - Vgmin )
e.g. HD
X - 10 bar
Setting screw - commencement P
of control
Vg min
G
X
Operating
pressure
~ P/2
1:2
M1
Control pressure
Observe safety regulations!

Setting data as to production order
Blocked condition (travel mode and manual brake).
A6VM - HD Vg max – Vg min

• Pressure gauge "G" = 600 bar
• Pressure gauge "M1" = 600 bar
• Pressure gauge "X" = 60 bar
Commencement of regulation / setting
Example: 10 bar pilot pressure at X
Observe pressure gauge at M1!

Increase pressure value at X till half the pressure is generated from G → Commencement of regulation
Setting screw turned clockwise → Regulation commences sooner
Setting screw turned anti-clockwise → Regulation commences later
Vehicle engine
1305 / 1505 / 1605 / 1705 Mobile Revised: 08.2004
Operating instruction
Setting test
(Begin of regulation of Vgmin - Vgmax )
e.g. HA
Vg min X M1
Control
pressure
1:2
Set screw - Begin of control G

Operating
pressure
Observe safety regulations!
Setting data as to production order
Blocked condition (travel mode and manual brake)
Connect pressure gauge 600 bar at G and M1
Example 1:
Begin of regulation 200 bar
Increase service pressure slowly till pressure gauge at G = 200 bar
Positioning pressure gauge M1
1/2 of the service pressure = approx. 100 bar.
→ Commencement of control
Readjust positioning pressure at setting screw - start of control
Note:
Clockwise turning - commencement of regulation sooner
Anti-clockwise turning - commencement of regulation later
Example 2:
In systems with two or more motors, e.g. tracked vehicles, the following setting may be carried out additio-
nally. Remove safety cap from the setting screw Vg min - do not turn the setting screw. Record dimension X.
Increase service pressure slowly till pressure gauge indicates 200 bar at G.
Verification: Vg min "fixed" (lens plate is pressed against setting screw).
As of a service pressure of 200 bar the screw becomes "movable".
(lens plate strokes to Vg max).
→ Commencement of control
Attention!
Do not modify the setting data of Vg min screw.
Note: Readjustment at the setting screw - commencement of regulation
Vehicle engine
Revised: 08.2004 1305 / 1505 / 1605 / 1705 Mobile
2 Cross section vehicle engine
A6VM … HA1TA
Series 63
Vehicle engine with motion control valve Size 55...160
Cross section
High Return line Suction Case drain Pilot Control

pressure pressure pressure pressure pressure pressure
Vehicle engine
1305 / 1505 / 1605 / 1705 Mobile Revised: 08.2004
3 Cross section travel motion control valve
BVD … F
Series 41
Travel Motion Control Valve Size 20...25
Cross section
B B’
pressure pressure pressure pressure pressure pressure
S
Vor Festlegung Ihrer Konstruktion bitte verbindliche Einbauzeichnung anfordern.
Prior to finalising your design, please obtain a certified drawing.
Gext
Bosch Rexroth AG, Glockeraustraße 4, 89275 Elchingen, Germany Training document A’
www.boschrexroth.com RDE 95522-01-L/03.01 A G
L
Vehicle engine
Revised: 08.2004 1305 / 1505 / 1605 / 1705 Mobile
Chapter 5
Pumps
Contents
1 Instructions for the repair of a variable pump................................................................ 2

2 Study view of the variable pump ................................................................................. 33
Page 1 of 34
1305 / 1505 / 1605 / 1705 Mobile Revised: 08.2004
1 Instructions for the repair of a variable pump
RDE 92 500-02-R/05.03
Variable Pump A11VO Series 10 ersetzt / replaces 03.01
Repair Instructions
NG NG 40 - 40
/ Size 60 - 60
NG / NG
Size
7575
- 95- 95
NG /NG 130130
Size
Pumps
Revised: 08.2004 1305 / 1505 / 1605 / 1705 Mobile
Notice / Contents
NOTICE
Specifications, descriptions and illustrative material shown here in were as accurate as known at the time
this publication was approved for printing.
Modifications to a product may affect the service for which we incur no obligations.
Methods and devices are recommendations. We therefore assume no liability for the result.
BRUENINGHAUS HYDROMATIK sub-assemblies, on indication of the serial number ordered, are the ba-
sis for good repairs.
Adjustments and tests have to be carried out on the test bench under operating temperatures.
Protection of personnel and property has to be guaranteed by means of appropriate measures.
Expert knowledge, a pre-requisite for any service work, is obtained in our training courses.
CONTENTSPage
A11VO
Sectional view .......................................................................................................................................... 4-6

General repair instructions.......................................................................................................................... 7
Seal kits and sub-assemblies .................................................................................................................. 8-9
Sealing of the drive shaft .......................................................................................................................... 10
Sealing of the regulator housing .......................................................................................................... 11-12
Removing the port plate and the regulator........................................................................................... 13-15
Regulator ............................................................................................................................................. 16-18
Removing rotary group ........................................................................................................................ 19-21
Inspection instructions ......................................................................................................................... 22-24
Pump assembly ................................................................................................................................... 25-29
Assembly guidelines for tightening torques ......................................................................................... 30-32
Pumps
1305 / 1505 / 1605 / 1705 Mobile Revised: 08.2004
Sectional view
A11VO...LRDS
LR
LR
Pumps
Revised: 08.2004 1305 / 1505 / 1605 / 1705 Mobile
Sectional view
A11VO 130 HD2D

(with impeller)
Pumps
1305 / 1505 / 1605 / 1705 Mobile Revised: 08.2004
Sectional view
DRS
LRDU2 LR
EP
LR
LRDH
D
EP2D (HD2D)
EP/HD
Pumps
Revised: 08.2004 1305 / 1505 / 1605 / 1705 Mobile
General repair instructions
Attention!
Observe the following instructions when
carrying out repair work on hydraulic
aggregates!
Close all ports of the hydraulic

aggregates.
Replace all seals.

Use only ORIGINAL BRUENINGHAUS
HYDROMATIK spare parts.
Check all seal and sliding surfaces for

wear.
Attention!
Reworking the sealing area, e.g. with ab-
rasive paper, can damage the surface.
Before start-up fill up hydraulic aggrega-

tes with hydraulic oil or deaerate.
Pumps
1305 / 1505 / 1605 / 1705 Mobile Revised: 08.2004
Seal kits and sub-assemblies
Seal kit for drive shaft.
External seal kit.
Housing
Complete rotary group.
1. Hydraulic control, small.

1 2. Hydraulic control, large.
Pumps
Revised: 08.2004 1305 / 1505 / 1605 / 1705 Mobile
Seal kits and sub-assemblies
Port plate
Complete regulator
Impeller
Pumps
1305 / 1505 / 1605 / 1705 Mobile Revised: 08.2004
Sealing of the drive shaft
Protect the drive shaft.

Loosen retaining ring and remove it,
press away front cover.
1 Press in the shaft seal ring to the

correct position with a suitable
sleeve.
2 If the shaft has deep grooves,
insert a shim behind seal.
Fit new O-ring, ensure that it is correctly

located. Grease the O-ring as well as the
seal and dust lips of the shaft seal (see
service information).
Fit circlip.
Check to ensure that the circlip is correct-
ly located in the groove.
Pumps
Revised: 08.2004 1305 / 1505 / 1605 / 1705 Mobile
Sealing of the regulator housing
LRDS
Remove screws and press off the regula-

tor, while ensuring that the sealing surface
is not damaged.
1. Power control
1 2. Constant pressure control
3. Load-sensing valve
Please note:
3 Do not change position of adjustment
screws.
2 Remove complete set of threaded bush
with adjustment screws.
Pumps
1305 / 1505 / 1605 / 1705 Mobile Revised: 08.2004
Sealing of the regulator housing
Attention!
For control with measuring spring, for example HD2D, LRDU2, LRDH, EP2D
First remove control bush with measuring spring, then remove regulator housing!
LRDU2
LRDH
HD2D
Pumps
Revised: 08.2004 1305 / 1505 / 1605 / 1705 Mobile
Removing the port plate and the regulator
Remove protection cover.
Measure and note adjustment height "h".
Pumps
1305 / 1505 / 1605 / 1705 Mobile Revised: 08.2004
Remove regulator housing.
For control with measuring spring, for in-

stance: DRL, EP, LRDH - first remove
control bush with the measuring spring,
then remove the regulator housing.
Remove O-rings and measuring pistons

with bush and spring.
Design with impeller!

First remove the impeller.
Mark position of the connection plate.

Loosen connection plate fixation.
Pumps
Revised: 08.2004 1305 / 1505 / 1605 / 1705 Mobile
Lift the port plate with control plate.

Disassemble regulator.
1. Hydr. -small
2. Hydr. -large
2
1
3 4
1 5
2
1. Remove control plate. 1 Connection plate

2. Cylinder roller bearing. 2 Sleeve
3. Port "G" without valve
3 Valve poppet
4. Alternatively with valve
4 Valve sleeve
.
5 Seal ring
Pumps
1305 / 1505 / 1605 / 1705 Mobile Revised: 08.2004
Regulator
Disassemble regulator.
Þ * Do not change setting values.
LRDS *
*
*
LRDH
Pumps
Revised: 08.2004 1305 / 1505 / 1605 / 1705 Mobile
Regulator
DRS
LRDS
Pumps
1305 / 1505 / 1605 / 1705 Mobile Revised: 08.2004
Regulator
HD2D
LRDU2
Pumps
Revised: 08.2004 1305 / 1505 / 1605 / 1705 Mobile
Removing rotary group
130
Disc
Balancing
disc
Disc
Balancing disc
130 with impeller
Loosen fixing of the retaining segments.
Remove retaining segments with screws.
Pumps
1305 / 1505 / 1605 / 1705 Mobile Revised: 08.2004
Remove O-ring.
Remove cylinder with pistons.
Remove Qmin and Qmax screws after

noting down adjustment dimension "X".
Remove joint pin for swivel cradle.
Pumps
Revised: 08.2004 1305 / 1505 / 1605 / 1705 Mobile
Fully remove the cover

ring.
Press out the drive shaft.
Remove the swivel

cradle with bearing as
well as bearing case.
Pumps
1305 / 1505 / 1605 / 1705 Mobile Revised: 08.2004
Inspection instructionsl
Check!
Gears (1); Contact area shaft seal (2);
Gears (3); bearing seat (4).
Sliding surface (1 ) free of scoring.
1 Bearing 2 Bearing cup
Check!
Cage set (1);
Bearing cup set (2).
Check!
Contact area (*).
Check!
Socket for regulator (*).
Check!
Contact area of bearing (1).
Pumps
Revised: 08.2004 1305 / 1505 / 1605 / 1705 Mobile
Inspection instructions
Check!
Retaining ball (1)
Retaining plate (2).
Check!
Fixing segments
Check!
Slipper pads (1),
Axial backslash (2).
Check!
Cylinder boring (1),
Gears (2).
Check!
Cylinder contact area (1),
Contact area control plate (2).
Pumps
1305 / 1505 / 1605 / 1705 Mobile Revised: 08.2004
Inspection instructions
Check!
Fixing segments
Assemble the grinded side to the cradle!

.
Check!
Pull-down piston (*)
Adjustment by means of the release rod.
Pull-down piston
no Qmin-Stop
.
Pull-down piston
with Qmin-Stop
2 1
1 Check!
Positioning piston (1),
Boring - control bush (2).
Check!
Boring (*),
Contact area control plate (1).
Pumps
Revised: 08.2004 1305 / 1505 / 1605 / 1705 Mobile
Pump assembly
Insert bearing bells.
Clean threaded borings.
Installing bearings onto the swivel cradle

with a wire guide.
Fixing with auxiliary device.
Auxiliary devices e. g.
• clamp
• rubber rings
• grease
Place swivel cradle with bearing into

bearing shell.
Attention!
Installation position.
Pumps
1305 / 1505 / 1605 / 1705 Mobile Revised: 08.2004
Pump assembly
Remove auxiliary devices.

Check position of bearings.
Adjust guide wire. Install joint pins.

Install locking screws.
1 1. Auxiliary device-screw driver
Fit swivel cradle with threaded pin in zero

position.
1. Auxiliary device (2 threaded pins).
Install drive shaft.
Mount cover ring.
Pumps
Revised: 08.2004 1305 / 1505 / 1605 / 1705 Mobile
Pump assembly
Mount shims, springs and retaining ball.

Note:
Observe correct mounting position*.
For rotary group adjustment see service

information.
.
Place retaining plate with piston into cy-

linder.
Align gearing of retaining ball / cylinder.
Assembly hint:
Fix with O-ring via piston retaining
assembly.
Insert fixing segments.
Use screws with Precote.

Attention!
Observe the hardening time!
Tighten screws acc. to torque.
Pumps
1305 / 1505 / 1605 / 1705 Mobile Revised: 08.2004
Pump assembly
Hydraulic control rod - large. Hydraulic control rod - small.
Direction of rotation - Direction of rotation - Direction of rotation - Direction of rotation -

clockwise anti-clockwise clockwise anti-clockwise
Standard design Special design
Install control plate.

Attention!
Installation position (direction of rotation).
Pumps
Revised: 08.2004 1305 / 1505 / 1605 / 1705 Mobile
Pump assembly
Mount port plate and attach with screws.

Attention! Torque - screws (see page 29).
Remove threaded pin.

Install Qmin, Qmax- screws.
Attention!
Adjustment measurement.
Design with impeller!

Assemble impeller.
Install measuring piston with O-rings.
Install regulator.
Pumps
1305 / 1505 / 1605 / 1705 Mobile Revised: 08.2004
A11VO Tightening torques
Tightening torques for shaft bolts 10.9 * / Housing - port plate
Size Screw dimension Tightening torques shaft bolts port

plate
40 M14 205 Nm
60 M16 260 Nm
75 M16 260 Nm
95 M18 400 Nm
130 M18 400 Nm
160 M20 580 Nm
190 M20 580 Nm
200 M20 580 Nm
250 M24 1000 Nm
260 M22 780 Nm
Pumps
Revised: 08.2004 1305 / 1505 / 1605 / 1705 Mobile
1. Bolts (acc. to N 08.001)

The figures stated are valid for bolts with metric ISO threads acc. to DIN 13 part 13, as well as head areas
acc. to DIN 912 socked head cap screws, DIN 931 hexagon bolt or DIN 933 hexagon bolts with threads up
to the head.

Thread 8.8 10.9 12.9
M3 1,1 1,6 1,9
M4 3,1 4,5 5,3
M5 6,1 8,9 10,4
M6 10,4 15,5 18
M8 25 37 43
M10 51 75 87
M12 87 130 150
M14 140 205 240
M16 215 310 370
M18 300 430 510
M20 430 620 720
M22 580 830 970
M24 740 1060 1240
Pumps
1305 / 1505 / 1605 / 1705 Mobile Revised: 08.2004
Assembly instructions for tightening torques
2. Plugs with internal hexagon and profile seal ring (acc. to N 02.009).)
G
EOLASTIC seal

M8 x 1 5 G 1/8 A 10
M10 x 1 10 G 1/4 A 30
M12 x 1,5 20 G 3/8 A 35
M14 x 1,5 30 G 1/2 A 60
M16 x 1,5 35 G 3/4 A 90
M18 x 1,5 40 G1A 140
M20 x 1,5 50 G 1 1/4 A 240
M22 x 1,5 60 G 1 1/2 A 300
M26 x 1,5 70
M27 x 2 90
M30 x 1,5 100
M33 x 2 140
M42 x 2 240
M48 x 2 300
6. SEAL-LOCK - sealing nuts (acc. to N 02.100) )
Thread Tightening torque MA in Nm

M6 10
M6 x 0,5 11
M8 22
M8 x 1 24
M10 40
M10 x 1 44
M12 69
M12 x 1,5 72
M14 110
M14 x 1,5 120
M16 170
M16 x 1,5 180
Pumps
Revised: 08.2004 1305 / 1505 / 1605 / 1705 Mobile
2 Study view of the variable pump
A11VO … LE2S2
Series 10
Variable pump Size 130
Cross Section
M A,B G X2 X

pressure press pressure press. pressure press.
Vor Festlegung Ihrer Konstruktion bitte verbindliche Einbauzeichnung anfordern.

Prior to finalising your design, please obtain a certified drawing.
Bosch Rexroth AG, Glockeraustraße 4, 89275 Elchingen, Germany Training document

www.boschrexroth.com RDE 92500-44-L/03.03
S M1
Pumps
1305 / 1505 / 1605 / 1705 Mobile Revised: 08.2004
Pumps
Revised: 08.2004 1305 / 1505 / 1605 / 1705 Mobil
Chapter 6
Pilot Control Equipment
Contents
1 Dozer blade/support pads ............................................................................................. 2

1.1 Principle of hydraulic function ....................................................................................... 2
2 Folding jib, slewing, lifting/lowering, bucket/grab .......................................................... 3
2.1 Structure ....................................................................................................................... 3
3 Function ........................................................................................................................ 3
4 Sectional view pilot control equipment .......................................................................... 4
5 Diagram regulating piston ............................................................................................. 5
Page 1 of 6
1305 / 1505 / 1605 / 1705 Mobil Revised: 08.2004
1 Dozer blade/support pads
Symbol, hydraulic
1.1 Principle of hydraulic function

Hydraulic pilot-control devices of the type 2TH6 function on the basis of directly controlled pres-
sure-reduction valves. The pilot control equipments type 2TH6 are mainly composed of an opera-
tion lever (1), two pressure reducing valves and a housing (6). Each pressure reducing valve
consists of a variable piston (2), a variable spring (3), a restoring spring (4) and a tappet (5). When
the control level is not operated, it is kept in zero position by the restoring springs (4). Control
connections (1,2) are linked to tank connection T by means of the bore hole (8). On excursion of
control lever (1) the tappet (5) presses against restoring spring (4) and variable spring (3). Variable
spring (3) first displaces the variable piston (2) down, closing the link between the concerned con-
nection and the tank connection T. At the same time, bore hole (8) is used to link the concerned
connection to connection P. The variable control phase starts once the variable piston (2) has
found the balance between the force of the variable spring (3) and the force resulting from hydrau-
lic pressure in the concerned connection (connection 1, 2). The combined action of variable piston
(2) and variable spring (3) has the effect that pressure in the concerned connections is proportio-
nal to the stroke of tappet (5) and thus to the position of control lever (1). This pressure control
depending on the position of the control lever (1) and the properties of the control spring (3)
enables the proportional hydraulic activation of directional control valves as well as of control
valves for hydro-pumps and hydro-engines. A rubber collar (9) protects the mechanical compon-
ents in the housing against soiling through which the pilot-control devices 2TH6 are also suited to
unfavourable usage conditions.
Revised: 08.2004 1305 / 1505 / 1605 / 1705 Mobil
2 Folding jib, slewing, lifting/lowering, bucket/grab
Symbol, hydraulic
Unions
P Supply
T Tank
1, 2, 3, 4 Control unions
2.1 Structure
Pilot control equipment is mainly composed of an operation lever (5), four pressure adjusting val-
ves and a housing (10). Each pressure adjusting valve consists of a variable piston (6), a variable
spring (7), a restoring spring (8) and a tappet (9).
3 Function
When the control level is not operated, it is kept in zero position by the four restoring springs (8).
Control unions (1, 2, 3, 4) are linked to tank union T by means of the bore hole (11) . On excursion
of control lever (5) the tappet (9) presses against restoring spring (8) and variable spring (7).
Variable spring (7) first displaces the variable piston (6) down, closing the link between the con-
cerned union and the tank union T. At the same time, bore hole (11) is used to link the concerned
union to union P. The variable control phase starts once the variable piston (6) has found the ba-
lance between the force of the variable spring (7) and the force resulting from hydraulic pressure
in the concerned union (union 1, 2, 3 or 4). The combined action of variable piston (6) and variable
spring (7) has the effect that pressure in the concerned unions is proportional to the stroke of tap-
pet (9) and thus to the position of control lever (5). Rubber collar (12) protects the mechanical
components of the hydraulic pilot control equipment against pollution from the outside.
1305 / 1505 / 1605 / 1705 Mobil Revised: 08.2004
4 Sectional view pilot control equipment
Readjusting spring
Regulating piston
Tappet
Lever
1
2
3
4
1
2
3
4
Pilot Control Equipment 4TH6
Sectional view
T
03 P Witt BRM/VMK2 Atl
N
5
Diagram
Regulating piston
Chapter 6
Revised: 08.2004
5
Training Center

4
3
2
T T T T
Diagram regulating piston
PE PE PE PE
PST PST PST

Factory manual
PST
Regulating piston in Regulating piston in Regulating valve in Regulating valve
1305 / 1505 / 1605 / 1705 Mobil
the starting position the pressure control range a neutral position interconnected
N 03 P Witt BRM/VMK2 Atl T
Page 5 of 6
1305 / 1505 / 1605 / 1705 Mobil Revised: 08.2004
Revised: 08.2004
1305 / 1505 / 1605 / 1705 Mobile
Chapter 7
Control block
Contents
1 Function of the control block ......................................................................................... 2

2 Control block construction........................................................................................... 26
2.1 1305 control block, Picture 1....................................................................................... 27
2.4 1505 / 1605 control block, Picture 1............................................................................ 30
Page 1 of 32
1305 / 1505 / 1605 / 1705 Mobile Revised: 08.2004
1 Function of the control block

Modern hydraulic system for wheeled and crawler excavators
2
Nov. 03; P. Witt; BRM/VMK2; Atlas Terex
Control block
Revised: 08.2004 1305 / 1505 / 1605 / 1705 Mobile
1 Loop LUVD system
(example: 13 ton wheeled excavator)
1M7 + 5M7 + 1M7

(control)
GFB + A2FE
(slew drive)
A6VM + MHB
(travel drive)
A11VO
(travel and implement hydraulics)
TH6
Nov. 03; P. Witt; BRM/VMK2; Atlas Terex (pilot control device)
Control block
1305 / 1505 / 1605 / 1705 Mobile Revised: 08.2004
1 Loop LUVD system
1 2 3 4 5 6
3; P. Witt; BRM/VMK2; Atlas Terex
1 - Turn
2 - Drive
3 - Shovel
4 - Boom
5 - Shaft
6 - Outrigger
Control block
Revised: 08.2004 1305 / 1505 / 1605 / 1705 Mobile
1 Loop LUVD system
Applications
• Compact- and standard excavators
• Drag-line excavators
• Spider excavators
Features
• Only one variable displacement pump for all functions
• Easy installation and assembly
• Load independent movements
• Excellent fine control
• High efficient swing control
• Torque control plus priority for slew circuit
Control block
1305 / 1505 / 1605 / 1705 Mobile Revised: 08.2004
LUVD system
Q[%]
100
50
0
1 2
A1 A2
Q = f (A)
∆p1 = ∆p2
Nov 03; P Witt; BRM/VMK2; Atlas Terex
1 - Fine metering
2 - Spool stroke
• Commencement of movement and fine control range independent of pressure and flow rate
• The consumers do not influence one another
Control block
Revised: 08.2004 1305 / 1505 / 1605 / 1705 Mobile
Flow distribution
80 Consumer I
60 Qobjective = 80,0 l/min
Qactual = 61,5 l/min
40 ratio 0,77
20
t
Q
80
Consumer II
60 Qobjective = 50,0 l/min
Qactual = 38,5 l/min
40 ratio 0,77
20
t
Q
100
Pump
80 Qmax = 100,0 l/min
60
40
20 t
Control block
1305 / 1505 / 1605 / 1705 Mobile Revised: 08.2004
LUDV principle
(flow distribution independent of load pressure)
qV = f (.p, A)
F1 F2
F1 < F2
P1 < P2
Cover
QV1 A1 > A2
Q V2
∆ p1 = Pp - P1’
P1
∆ p2 = Pp - P2’
P2 p2 = P2’ = P1’
∆ p1 = ∆ p2 = ∆ p
∆ p = const.
∆p3
A1 und A2
P1'(P2') P2'
∆ p3 = P2 - P1
∆p1 ∆p2 qV1 = f (A1)
A1 A2 qV2 = f (A2)
qV1 A1
qV2 = A2
Control block
Revised: 08.2004 1305 / 1505 / 1605 / 1705 Mobile
LUDV control features
• Good fine control qualities

• Consistent commencement of control (independent of pressure and flow rate)
• Direct response characteristic
• Losses low, resulting in economical use, even when operating with partial loads
• Parallel operation of several consumers independent of load, also in the case of a saturation deficit
Control block
1305 / 1505 / 1605 / 1705 Mobile Revised: 08.2004
LUDV M7-20 control block
Rated quantity:
20
Flow rate:
240/300 l/min
Pressure:
400/420 bar
Applications:
• excavators
• cranes
• drilling machines
• forestry machines
Control block
Revised: 08.2004 1305 / 1505 / 1605 / 1705 Mobile
LUDV excavator systems
Left Right Shaft Shovel Boom
5M7-22 and
5M7-20
new version
30 bar
to swing pilot pressure

unit
Control block
1305 / 1505 / 1605 / 1705 Mobile Revised: 08.2004
Input element
(5) (3)
(6) (2)
LS
LS
(9)
P
T
(7/8)
(4) P
(1) (7)
(1) Primary pressure control valve (diagram) (2) LS attenuation (3) unloading valve piston (4) unloading
valve spring (5) LS centre nozzle (6) LS drain valve (7/8)
tank or radiator lead pre-stress (p1<p2) (9) LS pressure cut-off valve with / without pressure connection
setting
P2
T
(8) (1)
(2)
(4)
LS
Q= ca. ... l/min
MLS (3)
(5)
p (9)
P1
K
(6)
(7)
Q= 0,7 l/min
p LS T
Control block
Revised: 08.2004 1305 / 1505 / 1605 / 1705 Mobile
Input section circuit diagram
6,0 bar
T
(8) (1)
(2)
(4)
LS Q= ca. ... l/min
MLS (3)
(5)
p (9)
3,5 bar
K
(7) (6)
Q= 0,7 l/min
p LS T
Control block
1305 / 1505 / 1605 / 1705 Mobile Revised: 08.2004
1 3
A B
LS
T P T
a b
5 4
1 - Pressure control Power supply

2 - Pressure balance
3 - Load holding valve
4 - Shuttle valve
5 - Lifting limit
Control block
Revised: 08.2004 1305 / 1505 / 1605 / 1705 Mobile
A B
LS
T P T
a b
Control block
1305 / 1505 / 1605 / 1705 Mobile Revised: 08.2004
M7 section with drive feed pistons
LS signal
Tank Pump Tank
1 - Lifting limiter
2 - Pressure feed valve
7 - Lifting limiter
8 - PST-shuttle valve
9 - Drive feed piston
Control block
Revised: 08.2004 1305 / 1505 / 1605 / 1705 Mobile
M7 section with drive feed pistons
LS signal
Tank Pump Tank
Opens at 15.7 … 16.9 bar Closes at 9 …15 bar
Control block
1305 / 1505 / 1605 / 1705 Mobile Revised: 08.2004
M7 section with regeneration pistons for extending shaft cylinders
3 (open) 4 (open) 5
LS signal
A B
2 6
1 7
a b
13 Tank 12 11 Pump 10 9 Tank 8
1 - Lifting limiter
7 - Lifting limiter
9 - Control cross sections
10 - Piston valve
11 - Orifice gauge
12 - Flap valve
Control block
Revised: 08.2004 1305 / 1505 / 1605 / 1705 Mobile
M7 section with pilot-controlled pressure balance for the boom function
3 4 5
LS signal
A B
2 6
1 7
a Tank 9 Pump Tank b

10 8
1 - Lifting limiter
4 - Pilot-controlled pressure balance
7 - Lifting limiter
9 - Piston valve
Control block
1305 / 1505 / 1605 / 1705 Mobile Revised: 08.2004
Pilot-controlled LUDV pressure balance
Arm Boom
Low Pressure position High Pressure
pc
High
pc = LS-system = p’
High
pc
Low
pc
p' High
A1 A2 Meter in
orifice
pump line
ov. 03; P. Witt; BRM/VMK2; Atlas Terex
Control block
Revised: 08.2004 1305 / 1505 / 1605 / 1705 Mobile
Low Pressure position High Pressure position
pc
High
pc
High
= LS-system = p’
pc
High p'
pc
Low
A1 A2 Meter in
orifice
pump line
v. 03; P. Witt; BRM/VMK2; Atlas Terex
Control block
1305 / 1505 / 1605 / 1705 Mobile Revised: 08.2004
Low Pressure position High Pressure position
pc = LS-system = p’
High
pc pc
Low High
Meter in
orifice
A1 A2
Witt; BRM/VMK2; Atlas Terex

pump line
Control block
Revised: 08.2004 1305 / 1505 / 1605 / 1705 Mobile
M7 boom section
pressure balance bypass
Control block
1305 / 1505 / 1605 / 1705 Mobile Revised: 08.2004
M7 boom section
pressure balance bypass
Control block
Revised: 08.2004 1305 / 1505 / 1605 / 1705 Mobile
LUDV excavator systems

DTS slewing gear
Nov 03; P Witt; BRM/VMK2; Atlas Terex 02 03 BRM/VMK2 38 0037
Control block
1305 / 1505 / 1605 / 1705 Mobile Revised: 08.2004
2 Control block construction
Control block
Revised: 08.2004 1305 / 1505 / 1605 / 1705 Mobile
2.1 1305 control block, Picture 1

,
100 Housing 211 Throttle pin

110 Plate 219 Valve seat
120 Socket head cap screw 220 Piston
160 Piston 221 Spring plate
161 Piston 222 Pressure spring
162 Piston 225 Screw plug
164 Pressure spring 235 Cone
165 Pressure spring 236 Supporting ring
166 O-ring 237 Pressure spring
167 Screw plug 239 Screw plug
168 Screw plug 271 Nozzle
170 Cone 275 Screw plug
171 Pressure spring 276 Screw plug
172 Screw plug 300 Housing
182 Pressure valve 325 Socket head cap screw
183 Sealing set for item 182 620 Socket head cap screw
190 Screw plug 681 Pressure valve
191 Sealing set for item 190 682 Sealing set
200 Pressure control valve 802 Housing
202 Valve 810 Plate
203 Sealing set for item 202 900 Sealing set for items 238, 259 and 251
210 Valve seat 920 Sealing set for items 803 and 804
Control block
1305 / 1505 / 1605 / 1705 Mobile Revised: 08.2004
130 Sealing set

131 Spring plate
132 Pressure spring
134 Cap
135 Socket head cap screw
136 Sealing set
141 Flap valve
142 Flap valve
157 Cap
241 Piston
242 Piston
243 Piston
244 Piston
245 Piston
292 Pressure spring
294 Reducer
295 O-ring
296 Vent screw
298 Piston
299 Ring
Control block
Revised: 08.2004 1305 / 1505 / 1605 / 1705 Mobile
300 Housing
331 Spring plate
332 Pressure spring
334 Cap
341 Flap valve
360 Piston
362 Screw plug
365 Pressure spring
370 Cone
371 Pressure spring
373 Screw plug
400 Pressure control valve
401 Sealing set for item 400
408 Pressure balance control
441 Piston
472 Nozzle
473 Nozzle
474 Nozzle
475 Screw plug
477 Screw plug
490 Flap valve
910 Sealing set for items 330, 336, 363, 372, 450 and 451
Control block
1305 / 1505 / 1605 / 1705 Mobile Revised: 08.2004
2.4 1505 / 1605 control block,

, Picture 1
100 Housing 211 Throttle pin

110 Plate 219 Valve seat
120 Socket head cap screw 220 Piston
160 Piston 221 Spring plate
161 Piston 222 Pressure spring
162 Piston 225 Screw plug
164 Pressure spring 235 Cone
165 Pressure spring 236 Supporting ring
167 Screw plug 239 Screw plug
168 Screw plug 271 Nozzle
170 Cone 275 Screw plug
171 Pressure spring 276 Screw plug
172 Screw plug 300 Housing
182 Pressure valve 325 Socket head cap screw
183 Sealing set for item 182 620 Socket head cap screw
190 Screw plug 681 Pressure valve
191 Sealing set for item 190 682 Sealing set for item 681
200 Pressure control valve 802 Housing
201 Sealing set for item 200 810 Plate
202 Valve 900 Sealing set for items 238, 259 and 251
203 Sealing set for item 202 920 Sealing set for items 803 and 804
210 Valve seat
Control block
Revised: 08.2004 1305 / 1505 / 1605 / 1705 Mobile
2.5 1505 / 1605 control block, Picture 2
130 Sealing set

131 Spring plate
132 Pressure spring
134 Cap
136 Sealing set
141 Flap valve
142 Flap valve
157 Cap
241 Piston
242 Piston
243 Piston
244 Piston
245 Piston
292 Pressure spring
294 Reducer
295 O-ring
296 Vent screw
298 Piston
299 Ring
Control block
1305 / 1505 / 1605 / 1705 Mobile Revised: 08.2004
2.6 1505 / 1605 control block, Picture 3

,
300 Housing
331 Spring plate
332 Pressure spring
334 Cap
341 Flap valve
360 Piston
362 Screw plug
365 Pressure spring
370 Cone
371 Pressure spring
373 Screw plug
401 Sealing set for item 400
408 Pressure balance control
441 Piston
472 Nozzle
473 Nozzle
474 Nozzle
475 Screw plug
477 Screw plug
490 Flap valve
910 Sealing set for items 330, 336, 363, 372, 450 and 451
Control block
Revised: 08.2004 1305 / 1505 / 1605 / 1705 Mobile
Chapter 8
Main rotation connection
Contents
1 Rotation connection and rotary transmission lead-through.............................................2

2 Maintenance of the rotary connection.............................................................................4
Page 1 of 8
1305 / 1505 / 1605 / 1705 Mobile Revised: 08.2004
1 Rotation connection and rotary transmission lead-through
29
28
27 26
25
30
4 15
14 13
5
32 3 1 20
10
19
31 8
21
2
18
9
17
7 13 16
6
11 21
22
12
23
24
Overview:
Rotary connection Items 8-15
Rotary transmission lead-through Items 16-32
1. Spherical head 2. Lock

3. Cap screw 4. Cap screw
5. Cap screw 6. Hexagon head cap screw
7. Hexagon nut 8. Inner part
9. Outer part 10.Rotation set
11.Sliding disc 12.Circlip
13.Lip seal 14.Sealing ring
15.Screw plug 16.Outer part
17.Hub 18.Rotomatic ring
19.Sliding disc 20.Circlip
21.Lip seal 22.Stop disc
23.Flange 24.Cap screw
25.Disc 26.Cylinder pin
27.Stircomatic sealing ring 28.Terminal block
29.Cap screw 30.Counter-ring
31.Inner part 32.Protective hose
Training Center Manual de taller
Revised: 08.2004 1305 / 1505 / 1605 / 1705 Mobile
The branch circuit connections are indicated:
Rotary connection:
Connection 1 = steer
2 = steer
3 = drive
4 = drive
5 = support
6 = support
7 = overflow oil
Rotary transmission lead-through:
Connection 1 = gear shifting

2 = service brake (1 circuit front)
3 = service brake (2 circuit rear)
4 = gear change
5 = regulator bypass
6 = jointed cross shaft axle locking device
1305 / 1505 / 1605 / 1705 Mobile Revised: 08.2004
2 Maintenance of the rotary connection

2.1 Screw off the spherical head (1) and remove the
lokking device (2).
2
1
2.1
2.2 Remove the cap screws (24) and the flange (23) with
the stop disc (22).
23
24 22
2.2
2.3 Pull off the outer part (16).

16
2.3
2.4 Screw out the securing screws (6).
6
6
6
2.4
Revised: 08.2004 1305 / 1505 / 1605 / 1705 Mobile
2.5 Remove the lip seals (21).

21
2.5
2.6 Remove the rotomatic rings (18).
18
2.6
2.7 Replace the rotomatic rings (18).
18
2.7
2.8 Replace the lip seals (21).
21
2.8
1305 / 1505 / 1605 / 1705 Mobile Revised: 08.2004
2.9 Mark the outer part on the inner part. Have the circlip
(12) rebound.
12
2.9
2.10 Remove the sliding disc (11).
11
2.10
2.11 Separate the outer part from the inner part by means
of placing it lightly on the floor.
2.11
2.12 Remove the lip seals (13).
13
2.12
Revised: 08.2004 1305 / 1505 / 1605 / 1705 Mobile
2.13 Remove the rotating sealing sets (10):

10
1. bearing rings
2.13
2. sealing rings
10
2.13
2.14 Clean the outer part and the inner part and examine
them to ensure that they are not damaged.
Replace the rotation sealing set (10):
10
1. sealing rings
2.14
2. bearing rings
10
2.14
1305 / 1505 / 1605 / 1705 Mobile Revised: 08.2004
2.15 Oil the inner part and press the outer part onto it. If ne-
cessary, knock slightly.
2.15
2.16 Screw out the cap screws (29) and remove the termi-
28 nal block (28).
29
2.16
2.17 Exchange the stircomatic sealing (27).

27
The remaining assembly procedure takes place in reverse

order.
2.17
Revised: 08.2004 1305 / 1505 / 1605 / 1705 Mobile
Chapter 9
Slewing gear gears and motor
Contents
1 Gearbox ........................................................................................................................ 3
2 Disassembly Gearbox ................................................................................................... 6
3 Assembly Gearbox...................................................................................................... 12
4 AF 10 FD slewing gear motor ..................................................................................... 25
Page 1 of 32
1305 / 1505 / 1605 / 1705 Mobile Revised: 08.2004
Revised: 08.2004 1305 / 1505 / 1605 / 1705 Mobile
1 Gearbox
1.1 Introduction
For disassembly; assembly procedure of the gearbox, spare parts drawing and parts list of
the respective gearbox-type is required.
The safety instructions and the appropriate accident prevention instructions have absolutely to be
observed!
Exclusively install original spares.
Drain the oil from the gearbox.

For this purpose use suitable containers.
Make sure that no dirt or foreign bodies are allowed to enter the gear box.
Replace damaged parts and all seals with new L+S parts.
Oil all moving parts and seals prior to assembly.
In the event the paint coat of the gear-box has been damaged as a result of disassembly / assembly work
touch up or renew the paint coat as necessary to protect the gear against corrosion.
Carry out a test run of the gearbox.
Copyright
The copyright on drawings and pictures remains with us.
A drawing (picture) must only be used for the purposes it has been transferred to the recipient. Drawings
and pictures must not be handed over disclosed to third parties without our express consent in writing.
Any reproduction of a drawing in whole or part is prohibited.
Contraventions will be prosecuted.
Note!
The photos may show other drive types than the described one.
1305 / 1505 / 1605 / 1705 Mobile Revised: 08.2004
1.2 Tightening Torques
Standard-tightening torque MA in Nm for unlubricated shoulder stud (µ = 0,13 to 0,17)

with standard thread without additional details
(LSN 945 0201)
Screw M 6 M 8 M 10 M 12 M 14 M 16 M 20 M 24 M 27 M 30 M 33 M 36 M 39 M 42
8.8 Ld. 8,5 21,1 42,2 73,6 114,8 176,6 358 618 903 1216 1687 2129 2757 3394
10.9 Ld. 12,4 30,4 60,8 104,0 166,8 255,1 510 873 1285 1736 2364 3021 3924 4836
Ld. = torque wrench
1.3 Tool and Accessories

• Torque Wrench
• Bearing Puller
• Tools for Snap Rings
• Plastic Hammer
• Roller bearing grease K3N 30 DIN 51502
• LOCTITE 7061
• LOCTITE 270
• LOCTITE 586
1.4 Lube Oil; Weight

Weight approx. 80 kg
Gear lube oil volume approx. 3 liters
Lube oil CLP 220 LSN 1410-7
or
Shell Spirax A90LS
Revised: 08.2004 1305 / 1505 / 1605 / 1705 Mobile
1.5 Drawings
331
334
390
198
126
31
18
10
49 390 334 332 30
48 19
11
44
169
199
114
29 402
158
7 135
403 117
4 404
139
108
102 103
200
120 121
126 128 125
113
106
GFB 9 T2 3012
331
334
390
198
126
31
18
10 390 334 332
49 30
48 19
11
44
169
199
114
116
402
29 158
7 135
403 117
4 404
139
108
102 103
200
120 121
126 128 125
113
106
GFB 9 T2 3026
1305 / 1505 / 1605 / 1705 Mobile Revised: 08.2004
2 Disassembly Gearbox
For oil inlet resp. oil outlet use the supplied oildrain valve
consisting of item 402; 403; 404.
Oil drain pan to be used!
fig. 1
Remove motor mounting bolts (items 199).
fig. 2
Remove hydraulic motor (item 198) with o-ring (item 126).
fig. 3
Remove sun gear shaft (item 114).
fig. 4
Revised: 08.2004 1305 / 1505 / 1605 / 1705 Mobile
Remove completely pre-assembled 1st planet stage.
fig. 5
Remove ring gear fastening screws (item 169).
fig. 6
Remove ring gear (item 102) and o-ring (item 126).
fig. 7
Remove snap rings (item 30).
fig. 8
1305 / 1505 / 1605 / 1705 Mobile Revised: 08.2004
Pull planet gears (item 11).
fig. 9
Remove socket head cap screw (item 158).
Attention!
Socket head cap screw is sticked with LOCTITE 270.
fig. 10
Remove with a suitable device spring dowel sleeve

(item 135) and disk (item 117).
fig. 11
Remove planet carrier main stage (item 108).
fig. 12
Revised: 08.2004 1305 / 1505 / 1605 / 1705 Mobile
Remove support disk (item 200).
fig. 13
Take off cartridge (item 103).
fig. 14
Remove lower inner ring with roller cage of tapered roller

bearing (item 120) from output shaft (item 106).
fig. 15
Remove Nilos ring (item 128) from output shaft (item 106).
fig. 16
1305 / 1505 / 1605 / 1705 Mobile Revised: 08.2004
Remove support disk (item 113) from output shaft

(item 106).
Attention!
Support disk (item 113) is sticked with LOCTITE 270.
fig. 17
Remove upper inner ring with roller bearing cage of tapered

roller bearing (item 120) out of cartridge (item 108).
fig. 18
Remove radial shaft sealing ring (item 125) with a suitable
device out of cartridge (item 103).
fig. 19
Remove snap rings (item 31).
fig. 20
Revised: 08.2004 1305 / 1505 / 1605 / 1705 Mobile
Take off support disks (item 48) and shims (item 49).
fig. 21
Remove snap ring (item 29).
fig. 22
Take off planet carrier (item 7) from sun gear (item 4).
fig. 23
1305 / 1505 / 1605 / 1705 Mobile Revised: 08.2004
3 Assembly Gearbox
Clean all parts before assembly of the gearbox.
ATTENTION!
The LOCTITE setting time equals 24 hours at ambient
temperature of 20°C.
Note!
fig. 24
Evenly apply coat of LOCTITE 270 to contact surface of
„pinion“ from support disk (item 113).
fig. 25
Mount support disk (item 113) on output shaft (item 106).
Observe correct installation position of „chamfer“ at support
disk.
fig. 26
Grease Nilos ring (item128) with grease (K3N 30

DIN 51502) and mount it on the output shaft (item 106).
fig. 27
Revised: 08.2004 1305 / 1505 / 1605 / 1705 Mobile
After cooling-off with nitrogen, insert outer ring of lower

tapered roller bearing (item 120) into cartridge (item 103)
(check for proper axial seat).
fig. 28
Insert new radial shaft sealing ring (item 125) and mount
them with an adequare device for proper axial seat.
Observe correct mounting position of sealing lip!
fig. 29
After cooling-off with nitrogen, insert outer ring of upper

tapered roller bearing (item 120) into cartridge (item 103)
(check for proper axial seat).
fig. 30
Fill mounting space between sealing lip with roller bearing

grease (K3N 30) DIN 51502).
fig. 31
1305 / 1505 / 1605 / 1705 Mobile Revised: 08.2004
Heat lower inner ring with roller cage of tapered roller

bearing (item 120) to approx. 120°-130°C and mount onto
output shaft.
Allow a cooling time of approx. 15 minutes before contin-
ning assembly.
fig. 32
Grease roller cage of tapered roller bearing (item 120) with

roller bearing grease (K3N 30 DIN 51502)..
fig. 33
Mount pre-assembled cartridge (item 103) on output shaft

(item 106).
fig. 34
Heat upper inner ring with roller cage of tapered roller
bearing (item 120) to approx. 120°-130°C and mount onto
output shaft (item 106)
Allow cooling time of approx. 15 minutes before continning
assembly.
fig. 35
Revised: 08.2004 1305 / 1505 / 1605 / 1705 Mobile
Setting of taper roller bearings

• Rotate the cartridge (item 103) either clock- or anti-
clockwise
• with the output shaft, being fixed at standstill position
• and a load of 75 kN on the inner bearing ring (item 121)
• Degrease load of the inner ring (item 121)
• Check dimension X according scetch
• Check dimension Y from planet carrier (item 108)
• Support ring (item 200) to be grinded to measure
b = X-Y+0,25+0,05
fig. 36
Mount the grinded (by measure „b“) support disk

(item 200).
fig. 37
Insert planet carrier (item 108).
fig. 38
Mount spring dowel sleeve (item 135) into disk (item 117).
Insert spring dowel sleeve into the suitable boring of output
shaft (item 106).
fig. 39
1305 / 1505 / 1605 / 1705 Mobile Revised: 08.2004
Degrease thread of socket had cap screw (item 158) (e.g.

with LOCTITE 7061).
Evenly apply coat of LOCTITE 270 to thread of socket had
cap screw (item 158).
fig. 40
Insert socket head cap screw (item 158) into threaded hole
of output shaft (item 106) and tighten them to a proper
torque.
fig. 41
Mount a new o-ring (item 126) on the fit of cartridge

(item 103).
Grease o-ring.
fig. 42
Assembly of cylindrical roller bearing (item 19) main

stage
Push cylindrical roller bearing (item 19) directly out of the
transport packing into locating hole of planet gear.
Attention!
Make sure that the snap ring is in the right position of the
snap ring groove.
fig. 43
Revised: 08.2004 1305 / 1505 / 1605 / 1705 Mobile
Heat pre-assembled planet gears (item 11+19) to

approx. 120°-130°C.
fig. 44
Observe during assembly of the pre-assembled planet

gears that the larger radius on the bearing bore is orienta-
ted towards the planet carrier.
fig. 45
Mount pre-assembled planet gears onto the planetary pins

of planet carrier (item 108).
fig. 46
Secure the planet gears with new snap rings (item 30).
fig. 47
1305 / 1505 / 1605 / 1705 Mobile Revised: 08.2004
Mount ring gear (item 102) on the fit of cartridge (item 103).
fig. 48
Insert ring gear mounting bolts (item 169) into threaded

holes of cartridge (item 103).
Tighten them to a proper torque.
fig. 49
Insert sun gear (item 4) into internal teeth of planet carrier

(item 7).
fig. 50
Secure with new snap ring (item 29).
fig. 51
Revised: 08.2004 1305 / 1505 / 1605 / 1705 Mobile
Use nitrogen to cool down (–180°C) the planet bolts

(item 44) and mount them into cavity of the planet carrier
(item 7).
fig. 52
Assembly of cylindrical roller bearing (item 18)

prestage
Install a new circlip (is supplied with cylindrical roller
bearing).
fig. 53
Push cylindrical roller bearing (item 18) directly out of trans-

port packing into the locating hole of the planet gear
(item 10).
fig. 54
Insert 2nd new circlip (is supplied with cylindrical roller

bearing).
Mount 1x support disk (item 48) and 1x shim (item 49) onto
each planet bolt (item 44).
fig. 55
1305 / 1505 / 1605 / 1705 Mobile Revised: 08.2004
Heat pre-assembled planet gears (item 10+18) to

approx. 120°-130°C and mount them onto the planetary
bolts of planet carrier (item 7).
fig. 57
Secure the planet gears with new snap rings (item 31).
fig. 58
Install completely pre-assembled 1st planet stage into

swing drive.
(For gearbox type GFB 9 T2 3026 note for this fig. 71)
fig. 59
Revised: 08.2004 1305 / 1505 / 1605 / 1705 Mobile
Install sun gear shaft (item 114).
fig. 60
Insert a new screw plug (item 139) into the threaded hole of
cartridge (item 103) and tightem them with a suitable tool to
proper torque.
fig. 61
Mount a new o-ring (item 126) on the fit of hydraulic motor

(item 198).
Grease o-ring.
fig. 62
Mount hydraulic motor (item 198) into the fit of ring gear
(item 102).
fig. 63
1305 / 1505 / 1605 / 1705 Mobile Revised: 08.2004
Insert motor mounting bolts (item 199) into threaded holes

of ring gear (item 102) tightem them to a propertorque.
fig. 64
Remove the plugs, for mounting the extensions (item 390),

at the hydraulic motor.
fig. 65
Degrease thread of the extension resp. threaded hole at

the hydraulic motor (with e.g. LOCTITE 7061).
fig. 66
Evenly apply coat of LOCTITE 586 to thread of extension
(item 390).
fig. 67
Revised: 08.2004 1305 / 1505 / 1605 / 1705 Mobile
Insert extensions (item 390) into suitable thread holes of

hydraulic motor (item 198).
(Use for tighten the extensions screw plugs G1/2).
fig. 68
Mount vent (item 331) with a new seal ring (item 334).
fig. 69
Mount dipstick (item 331) with a new seal ring (item 334).
fig. 70
Getriebeausführung GFB 9 T2 3026
At gearbox size GFB 9 T2 3026 a additionaly locating ring

(item 116) must be mounted.
fig. 71
1305 / 1505 / 1605 / 1705 Mobile Revised: 08.2004
For oil inlet resp. oil outlet use the supplied oildrain valve
consisting of item 402; 403; 404.
Oil drain pan to be used!
fig. 72
Revised: 08.2004 1305 / 1505 / 1605 / 1705 Mobile
4 AF 10 FD slewing gear motor
1 - 2 pressure control valves adjustable independently of one another for pHDA / pHDB
2 - Electrical operation for releasing the brake (signal input)
1305 / 1505 / 1605 / 1705 Mobile Revised: 08.2004
A10FD slewing gear motor: Atlas Terex circuit diagram
2 4
1 - Tachometer
2 - Two-point pressure control
3 - Anti-cavitation valve
4 - Brake lifting valve
Revised: 08.2004 1305 / 1505 / 1605 / 1705 Mobile
A10FD slewing gear motor
5
3
1 - High-pressure connections
2 - Oil overflow connection
3 - Brake aeration Electrical signal input
4 - Two-stage pressure control valve
5 - Drain connection
1305 / 1505 / 1605 / 1705 Mobile Revised: 08.2004
Slewing gear motors
1 - PG: external cutting-off pressure

2 - Electrical signal input to release the brake
Please note concerning cutting-off pressure:

The constant-current characteristic indicates that the brakes are released at > 15 bar. Due to the nature of
the equipment a target pressure of approx. 35 bar is recommendable. (authorised: approx. 70 bar)
Revised: 08.2004 1305 / 1505 / 1605 / 1705 Mobile
A10FD slewing gear motor: Setting the two-point pressure control
1 - Remove the fixing nut 1

2 - Set the low pressure setting by means of turning the top section. Secure the setting!
3 - Remove the fixing nut 2
4 - Set the higher pressure setting by means of turning the outer screws. Secure!
1305 / 1505 / 1605 / 1705 Mobile Revised: 08.2004
A10FD slewing gear motor
or A10FD
1 - Anti-vibration damper valve: blocked!

2 - Anti-cavitation valve
Revised: 08.2004 1305 / 1505 / 1605 / 1705 Mobile
Swing drive motors
1 - Pressure relief valve with damping

2 - Anti cavitation valves
3 - Antireaction valve
1305 / 1505 / 1605 / 1705 Mobile Revised: 08.2004
Revised: 08.2004 1305 / 1505 / 1605 / 1705 Mobile
Chapter 10
Pressure setting tables / setting regulations
Contents
1 Pressure setting table 1305, part 1 ............................................................................... 3

5 Pressure setting table 1605/1705, part 1 ...................................................................... 7
6 Pressure setting table 1605/1705, part 2 ...................................................................... 8
7 Setting regulations ........................................................................................................ 9
7.1 Test ports ...................................................................................................................... 9
7.2 Bleeding the equipment .............................................................................................. 11
7.3 Fuel admission pressure............................................................................................. 12
7.4 Pilot control ................................................................................................................. 13
7.5 LS regulator, Dp setting .............................................................................................. 14
7.6 Pressure cut-off........................................................................................................... 16
7.7 Secondary valves........................................................................................................ 17
7.7.1 Raising the pressure P................................................................................................ 17
7.7.2 Setting the “fold out/fold in” secondary valve .............................................................. 18
7.7.3 Setting the “open/close bucket” secondary valve ....................................................... 18
7.7.4 Setting the “lift/lower” secondary valve ....................................................................... 19
7.7.5 Setting the “extend/retract centring actuator” secondary valve................................... 20
7.7.6 Setting the “grab turn” secondary valve ...................................................................... 21
7.7.7 Setting the “drive forwards/reverse” secondary valve ................................................. 21
7.7.8 Setting the pressure P ................................................................................................ 22
7.8 “Slew” secondary valve............................................................................................... 23
7.8.1 Setting the “slew left/right” secondary valve ............................................................... 23
7.8.2 Setting the brake pressure.......................................................................................... 25
Page 1 of 50
1305 / 1505 / 1605 / 1705 Mobile Revised: 08.2004
7.9 Setting the TC valve ................................................................................................... 28

7.10 Reverse current throttles ............................................................................................ 29
7.10.1 “Fold in” reverse current throttle device...................................................................... 29
7.10.2 “Lower” reverse current throttle device....................................................................... 31
7.11 Lifting cylinder open-circuit guard............................................................................... 32
7.11.1 Setting the switch-on of the locking piston ................................................................. 32
7.11.2 Adjusting the “lower” reverse-current throttle device .................................................. 34
7.11.3 Secondary valves ....................................................................................................... 36
7.12 Open-circuit guard for the articulated cylinder............................................................ 38
7.12.1 Basic setting for the locking piston ............................................................................. 38
7.12.2 Secondary valve ......................................................................................................... 41
7.13 Checking/adjusting the cardan shaft speed................................................................ 42
7.14 Checking/adjusting the “drive” pilot control pressure.................................................. 44
7.15 Centring actuator shut-off device with no oil overflow ................................................ 46
7.15.1 Checking/adjusting the secondary valve .................................................................... 46
7.15.2 Checking/adjusting the control valve .......................................................................... 48
Revised: 08.2004 1305 / 1505 / 1605 / 1705 Mobile
1 Pressure setting table 1305, part 1
* Checking and setting are carried out at max. engine speed

** Checking and setting are carried out at min. engine speed
*** Checking is carried out with a manual pump
**** Setting at 1680 rpm engine speed
Index Figure Tolerance Unit
1 ENGINE SPEEDS
2 Min. idling speed 950 -30 min-1
3 Max. idling speed 2150 -40 min-1
4 Speed for automotive driving 1480 min-1
F1-speed 1680 min-1
F2-speed 1890 min-1
F3-speed 2100 min-1
5 PRIMARY VALVES
6 Pump 1 350 +10 bar
7 Pump 2
* 8 Pressure cut-off 345 +5 bar
* 9 Pressure activation setting
* 10 Pressure activation setting/drive M
* 11 Pressure activation setting/drive R
* 12 Pilot pump 35 bar
* 13 Pressure control valve-emergency connection
* 14 Control commencement
* 15 Fan pump
* 16 Steering pump 3 200 +5 bar
17 LS control unit (delta P)
* 18 Pump 2 23 +/-0 bar
19 delta p shifting (50%) ∆p 12 bar
20
21 SECONDARY VALVES
*** 22 Lifting cylinder – lift – no-leakage stop-RBS 1 390 +20 bar
23 section 1 390 +20 bar
** 24
**** 25 Lower 1 390 +20 bar
**** 26 Articulated cylinder (retract-extend) 1 390 +20 bar
*** 27 Articulated cylinder RBS 3 410 +10 bar
**** 28 Shovel-grab cylinder 1 390 +20 bar
* 29 Slewing motor – motor 80/265 +10/+20 bar
* 30 - TC plate 250 +5/-5 bar
**** 31 Drive motor - mobile 400 +25 bar
32
**** 33 Turn grab section 210 +20 bar
34 section for SWE and swivel range grab shovel 210 +20 bar
*** 35 - Motor 75 bar
*** 36 Adjusting cylinder - extend – oil leakage-free stop 435 +20 bar
**** 37 - section 365 +20 bar
**** 38 - retract 440 +20 bar
** 39
** 40
** 41
*** 42 Steering cylinder 200 bar
43
44
45
2126.445.00.01.000
1305
Pressure chart 0000000 Sheet
1
1305 / 1505 / 1605 / 1705 Mobile Revised: 08.2004

46 JOINTED CROSS SHAFT AXLE LOCKING DEVICE
48 VARIABLE SPEED MOTOR
**** 49 Pressure regulator (commencement of regulation) 250 +20 bar
50 OIL LEAKAGE-FREE STOP
**** 51 Valve for minimal lowering (commencement of opening) 3 +2 bar
52 SUPPLY PRESSURE VALVES (no tank initial tension)
* 53
* 54 Return 7 bar
* 55 Radiator safety valve 3,5 bar
56
57
58
59
* 60
* 61
* 62
63 MANOMETRIC SWITCH
** 64 Automatic idling
65 SPEED
* 66
* 67 Slewing 9 +1 min-1
* 68 Cardan shaft q min. (gearbox setting 1) 570 min-1
* 69 Cardan shaft q max. (gearbox setting 1) 266 min-1
* 70 Cardan shaft (28 km/h) q min. (gearbox setting 1) 3 770 min-1
* 71 Cardan shaft (28 km/h) q max. (gearbox setting 1) 3 266 min-1
72 POWER BRAKES (hydr.)
** 73 Storage loading valve on 152 bar
74 off 185 bar
** 75 Foot brake 100 bar
* 76 VST pressure accelerator 3 23 +1 bar
77 Foot brake accumulator 65 bar
78 COMPRESSED AIR VALVES
79 - Pressure reduction valve 0.5 bar
80 - Tyre pressure 6.5 bar
81
10
9
8
7
6
5
4
3
2
1
Ind. Change Change no. Date Name
2126.445.00.01.000 Processed Date Name

1305 Plätschke
2
Revised: 08.2004 1305 / 1505 / 1605 / 1705 Mobile

1 ENGINE SPEEDS
F1-speed 1680 min-1
F2-speed 1890 min-1
F3-speed 2100 min-1
5 PRIMARY VALVES
6 Pump 370 +10 bar
7 Pump 2
* 8 Pressure cut-off 1 350 +5 bar
* 15 Fan pump
17 LS CONTROL UNIT (delta P)
* 18 Pump 2 23 +/-0 bar
20
21 SECONDARY VALVES
**** 22 Lifting cylinder – lift – no-leakage stop-RBS 1 390 +20 bar
23 - section 1 390 +20 bar
24
**** 25 -lower 1 390 +20 bar
* 29 Slewing motor – motor (fixed setting) 80/265 +10/+20 bar
* 30 - TC plate 230 +5/-5 bar
32
34 section for SWE and swivel range grab shovel 210 +20 bar
35 - Motor 75 bar
** 36 Adjusting cylinder - extend – leakage-free lock 435 +20 bar
**** 37 - section 385 +20 bar
**** 38 - retract 440 +20 bar
** 39
** 40
** 41
*** 42 Steering cylinder 3 240 bar
43
44
45
2132.445.00.01.000
1505
1
1305 / 1505 / 1605 / 1705 Mobile Revised: 08.2004

* 53
* 54 Return 7 bar
* 55 Radiator safety valve 3.5 bar
56
57
58
59
* 60
* 61
* 62
65 SPEED
* 66 min-1
* 68 Cardan shaft q min (gearbox setting 1) 565 min-1
* 69 Cardan shaft q max (gearbox setting 1 ) 345 min-1
* 70 Cardan shaft (28 km/h) q min. (gearbox setting 1) 3 770 min-1
* 71 Cardan shaft (28 km/h) q max. (gearbox setting 1) 3 345 min-1
74 off 185 bar
81
10
9
8
7
6
5
4
3
2
1

1505 Plätschke
2
Revised: 08.2004 1305 / 1505 / 1605 / 1705 Mobile
5 Pressure setting table 1605/1705, part 1

1 ENGINE SPEEDS
F1-speed 1680 min-1
F2-speed 1890 min-1
F3-speed 2100 min-1
5 PRIMARY VALVES
6 Pump 370 +10 bar
7 Pump 2
* 8 Pressure cut-off 1 350 +5 bar
* 15 Fan pump
17 LS CONTROL UNIT (delta P)
* 18 Pump 2 23 +/-0 bar
20
21 SECONDARY VALVES
*** 22 Lifting cylinder – lift – no-leakage stop-RBS 1 390 +20 bar
23 - section 1 390 +20 bar
** 24
**** 25 -lower 1 390 +20 bar
* 29 Slewing motor – motor (fixed setting) 80/265 +10/+20 bar
* 30 - TC plate 230 +5/-5 bar
32
34 - section for SWE and swivel range grab shovel 210 +20 bar
35 - Motor 75 bar
*** 36 Adjusting cylinder - extend – leakage-free lock 435 +20 bar
**** 37 - section 365 +20 bar
**** 38 - retract 440 +20 bar
** 39
** 40
** 41
*** 42 Steering cylinder 3 240 bar
43
44
45
2142.445.00.01.000
1605
1
1305 / 1505 / 1605 / 1705 Mobile Revised: 08.2004
6 Pressure setting table 1605/1705, part 2

* 53
* 54 Return 7 bar
* 55 Radiator safety valve 3.5 bar
56
57
58
59
* 60
* 61
* 62
65 SPEED
* 66 min-1
* 68 Cardan shaft q min. (gearbox setting 1) 565 min-1
* 69 Cardan shaft q max. (gearbox setting 1) 345 min-1
* 70 Cardan shaft (export) q min. (gearbox setting 1) 3 770 min-1
* 71 Cardan shaft (export) q max. (gearbox setting 1) 3 345 min-1
74 off 185 bar
81
10
9
8
7
6
5
4
3
2
1

1605 Plätschke
2
Revised: 08.2004 1305 / 1505 / 1605 / 1705 Mobile
7 Setting regulations
CAUTION
High pressures will be used while settings are being carried out. Please undertake cor-
responding safety measures, e.g. wear safety goggles.
7.1 Test ports
M3
M1
M2
M6
M7
M4
M5
M8
M1 Fuel admission pressure M5 LS

M2 Pilot control M6 Valve A
M3 Drive pilot control M7 Valve B
M4 P M8 Lower pilot control
1305 / 1505 / 1605 / 1705 Mobile Revised: 08.2004
M9
M10
M9 Fold cylinder
M10 Fold pilot control
Revised: 08.2004 1305 / 1505 / 1605 / 1705 Mobile
7.2 Bleeding the equipment
Prior to initial operation of the equipment or after the pump has been replaced it is essential to
bleed the pump.
CAUTION
If air is not removed from the hydraulic pump it may be damaged during operation since
there is no guarantee for sufficient lubrication of the pump.
CAUTION
Make sure that the hydraulic leads have been depressurised.
1. Screw the hydraulic lead off on the screw connection (1) of the hydraulic pump (2).
2. Fill up the hydraulic pump with hydraulic oil until the top of the screw connection (1).
3. Screw the hydraulic lead onto the screw connection (1) of the hydraulic pump (2) again.
1305 / 1505 / 1605 / 1705 Mobile Revised: 08.2004
7.3 Fuel admission pressure
M1
1. Remove the banjo screw (1) from the “fuel admission pressure” test port (M1), screw on a sui-
table adaptor and connect the pressure gauge.
2. Start up the motor.
3. Measure the fuel admission pressure at the maximum motor speed. The result must be
between 5 bar and 5.5 bar.
4. Switch off the motor.
5. Remove the pressure gauge and the adaptor and close the “fuel admission pressure” test port
(M1) with a banjo screw (1).
Revised: 08.2004 1305 / 1505 / 1605 / 1705 Mobile
7.4 Pilot control
M2
1. Connect the pressure gauge to the “pilot control” (M2) test port.
3. Set at the maximum motor speed.
4. Set the required pressure by means of screwing the adjusting screw (1) in or out.
6. Remove the pressure gauge.
1305 / 1505 / 1605 / 1705 Mobile Revised: 08.2004
7.5 LS regulator, ∆p setting
M3
M4
M5
1. Jack up the excavator.
2. Connect pressure gauges to the “P” (M4), “LS” (M5) and “pilot control drive” (M3) test ports.
WARNING
Risk of accident through turning parts.

The cardan shaft and the wheels of the excavator will be turning.
1 2
5. Use the “creep speed” (1) button to switch on the regulator bypass (Qmax) (the LED will light
up green).
6. Use the “gear switch” button (2) to switch into second gear (on-the-road gear) (the LED on the
right will light up yellow).
Revised: 08.2004 1305 / 1505 / 1605 / 1705 Mobile
7. Use the accelerator to adjust to 18 bar on the “drive pilot control” (M3) test port and maintain
this during the following setting.
8. Set the ∆p setting to 23 bar on the adjusting screw (6) of the LS regulator while driving.
10. Remove the pressure gauges.
1305 / 1505 / 1605 / 1705 Mobile Revised: 08.2004
7.6 Pressure cut-off
M4
1
1. Connect the pressure gauge to the “P” (M4) test port.
4. Operate the “fold out” function as far as it will go and maintain in this position.
5. Measure the pressure of the pressure-cut-off device on the pressure gauge and set the
stipulated setting by means of turning the adjusting screw (1) in or out.
Revised: 08.2004 1305 / 1505 / 1605 / 1705 Mobile
7.7 Secondary valves
Prior to setting the secondary valves, the pressure P must be raised by means of adjusting the
primary valve of the pump and the pressure cut-off device; see section 7.7.1.
Once the respective secondary valves have been set the pressure P is to be adjusted to the
stipulated setting by means of adjusting the primary valve of the pump and the pressure cut-off
device; see section 7.7.8.
7.7.1 Raising the pressure P
3
M4
2
3. Set the motor speed at approx. 1700 min-1.
4. Operate the “fold out” function as far as it will go and maintain in this position. The “fold out”
pressure is indicated.
5. Screw in the adjusting screw (1) of the “fold out” secondary valve by approx. one turn.
CAUTION
The pressure on the test port “P” (M4) may not exceed 460 bar.
6. Screw in the adjusting screw (2) of the pressure cut-off device by approx. one turn.
7. Use the adjusting screw (3) of the primary valve of the pump to set the pressure at 20 bar
above the highest secondary pressure setting.
1305 / 1505 / 1605 / 1705 Mobile Revised: 08.2004
7.7.2 Setting the “fold out/fold in” secondary valve
1 2
2. Setting the respective secondary valve is carried out by means of turning the respective
adjusting screw for “folding out” (1) or “folding in” (2) in or out.
7.7.3 Setting the “open/close bucket” secondary valve
1 2
adjusting screw for “open bucket” (1) or “close bucket” (2) in or out.
Revised: 08.2004 1305 / 1505 / 1605 / 1705 Mobile
7.7.4 Setting the “lift/lower” secondary valve
1 2
adjusting screw for “lift” (1) or “lower” (2) in or out.
NOTE
Should it not be possible to reach the pressure stipulated for the secondary valve, check
the setting of the open-circuit guard on the lifting cylinder, see section 7.11.
1305 / 1505 / 1605 / 1705 Mobile Revised: 08.2004
7.7.5 Setting the “extend/retract centring actuator” secondary valve
1 2
adjusting screw for “retract centring actuator” (1) or “extend centring actuator” (2) in or out.
NOTE
Should it not be possible to reach the pressure stipulated for the secondary valve, check
the setting of the secondary valve in the overflow oil free stop of the centring actuator,
see section 7.15.
Revised: 08.2004 1305 / 1505 / 1605 / 1705 Mobile
7.7.6 Setting the “grab turn” secondary valve
1 2
adjusting screw for “turn anti-clockwise” (1) or “turn clockwise” (2) in or out.
7.7.7 Setting the “drive forwards/reverse” secondary valve
adjusting screw for “drive forward” (1) or “reverse” (2) in or out.
1305 / 1505 / 1605 / 1705 Mobile Revised: 08.2004
7.7.8 Setting the pressure P
2
M4
3
2. Operate the “fold out” function as far as it will go and maintain in this position. The “fold-out”
pressure is indicated.
3. Use the adjusting screw (1) of the “fold out” secondary valve to set the pressure as stipulated.
CAUTION
The pressure P may not exceed 460 bar.
5. Use the adjusting screw (2) of the primary valve of the pump to set the pressure as stipulated.
6. Use the adjusting screw (3) of the pressure cut-off device to set the pressure as stipulated.
Revised: 08.2004 1305 / 1505 / 1605 / 1705 Mobile
7.8 “Slew” secondary valve
7.8.1 Setting the “slew left/right” secondary valve
1
1
M4
4. Screw the adjusting screw of the TC valve (1) right in.
1305 / 1505 / 1605 / 1705 Mobile Revised: 08.2004
2 3
2 3 5
Links = Rechts =
Schwenken links Schwenken rechts
Adjusting is carried out on the “slew left” (2) or “slew right” (3) valves respectively as follows
(steps 5 to 9):
5. Fasten the excavator superstructure (e.g. with a slew stop).
6. Loosen the fastening nut (4) of the respective valve (“slew left” is shown here).
CAUTION
Make sure that the superstructure is firmly attached before you operate the “slew left”
or “slew right” functions.
7. Set the pressure of the secondary valve as stipulated by means of turning the outer screw (5)
of the respective valve (“slew left” is shown here) while operating the respective function (in
this case “slew left”).
8. Secure the screw (5) with a fastening nut (4). While doing so make sure that the screw setting
(5) is not altered.
9. Check the pressure once again while operating the respective function (in this case “slew left”)
and if necessary, repeat steps 6 to 9.
Once the valves have been set, the TC valve must be adjusted.
10. For adjusting the TC valve, see section 7.9.
Revised: 08.2004 1305 / 1505 / 1605 / 1705 Mobile
7.8.2 Setting the brake pressure
M4
3 4
1 2
CAUTION
Make sure that the pressure tubes (1) and (2) have been depressurised.
2. Take the two pressure tubes (1) and (2) off the valves (3) and (4) and close off with welsh
plugs.
1305 / 1505 / 1605 / 1705 Mobile Revised: 08.2004
3 4
3 4 6
Links = Rechts =
1 2 Schwenken links Schwenken rechts
Adjusting is carried out on the “slew left” (3) or “slew right” (4) valves respectively as follows
(steps 4 to 8):
6. Loosen the fastening nut (5) of the respective valve (“slew left” is shown here).
CAUTION
7. Set the brake pressure as stipulated by means of turning the outer screw (6) of the respective
valve (“slew left” is shown here) while operating the respective function (in this case “slew
left”).
8. Secure the screw (6) with a fastening nut (5). While doing so make sure that the screw setting
(6) is not altered.
9. Check the pressure once again while operating the respective function (in this case “slew left”)
and if necessary, repeat steps 5 to 8.
Revised: 08.2004 1305 / 1505 / 1605 / 1705 Mobile
CAUTION
Make sure that the pressure tubes (1) and (2) have been depressurised.
12. Remove the welsh plugs from the pressure tubes (1) and (2).
13. Connect the pressure tubes (1) and (2) to the valves (3) and (4).
1305 / 1505 / 1605 / 1705 Mobile Revised: 08.2004
7.9 Setting the TC valve
1
1
M4
CAUTION
5. The TC valve is adjusted by means of screwing the adjusting screw (1) in or out while
operating the “slew left” or “slew right” functions.
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7.10 Reverse current throttles
7.10.1 “Fold in” reverse current throttle device
NOTE
The figures indicated apply for assembled tools.
NOTE
The respective reverse current throttle device on the open-circuit guard of the articulat-
ed jib cylinder must be completely open, see section 7.12.
1
2
1. Remove the sealing cap (1).
4. Extend the jib fitting (fully retract the connecting rod of the articulated cylinder).
5. Switch the “fold in” function as far as it goes.
6. The connecting rod of the articulated cylinder must be fully extended after three seconds.
1305 / 1505 / 1605 / 1705 Mobile Revised: 08.2004
Should it be necessary to make an adjustment, proceed as follows (steps 7 to 10):
7. Loosen the fixing nut (3):
8. Set the speed by means of screwing the adjusting screw (2) in or out.
9. Secure the adjusting screw (2) with a fastening nut (3). While doing so make sure that the
adjusting screw setting (2) is not altered.
10. Check the speed again (steps 4 to 6) and if necessary, repeat steps 7 to 10.
11. Screw the sealing cap (1) on again.
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7.10.2 “Lower” reverse current throttle device

The reverse current throttle device for “lower” is adjusted on the open-circuit guard of the lifting
cylinder, see section 7.11.2.
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7.11 Lifting cylinder open-circuit guard
7.11.1 Setting the switch-on of the locking piston
M6 2
M7
A
3
1 B
M8
1. Connect the pressure gauges to the test ports (M6) and (M7) of the valves (A) and (B).
2. Connect the pressure gauge to the “lower pilot control” (M8) test port.
CAUTION
Lower the jib equipment onto the ground..
CAUTION
Make sure that the equalising line (1) has been depressurised.
3. Screw off the equalising line (1) and close the connections with welsh plugs.
4. Loosen the fastening nuts (3) on the valves (A) and (B).
5. Turn in the adjusting screws (2) on the valves (A) and (B) by one turn.
Revised: 08.2004 1305 / 1505 / 1605 / 1705 Mobile
8. Lift up the boom approx. 2 m above the track level.
9. Operate the “lower” function until the pressure on the test port for “lower pilot control” (M8) is
9 bar.
10. Maintain this pressure and turn out the adjusting screw (2) on valve (A) until the static pressure
on the test port (M6) begins to drop.
NOTE
The pressure on the test port (M7) will now begin to rise.
11. Screw the adjusting screw (2) out of the valve (B) until the boom begins to lower.
Check the setting as follows:
12. Fully extend the lifting cylinder.
13. Now lower the boom.
14. During the lowering procedure, check to see whether both of the locking pistons open
simultaneously in the fine control range (same pressures on the (M6) and (M7) test ports).
A pressure difference of 30 bar is permissible here.
15. Should it be necessary to make an adjustment, this is done by means of adjusting the
adjusting screw (2) on valve (B).
17. Secure the adjusting screws (2) on the valves (A) and (B) with fastening nuts (3). On doing so
make sure that the adjusting screws are not shifted.
CAUTION
Lower the jib equipment onto the ground.
CAUTION
Make sure that the welsh plugs have been depressurised.
18. Remove the welsh plugs and screw on the equalising line (1) again.

1305 / 1505 / 1605 / 1705 Mobile Revised: 08.2004
7.11.2 Adjusting the “lower” reverse-current throttle device
NOTE
The setting is carried out with attached tools.
2
M6
M7 3
A
1 B
1. Connect the pressure gauges to the test ports (M6) and (M7) of the valves (A) and (B).
CAUTION
CAUTION
3. Loosen the fastening nuts (3) on the valves (A) and (B).
6. Lift up the boom as far as it will go.
Revised: 08.2004 1305 / 1505 / 1605 / 1705 Mobile
7. Switch the “lower” function right on.
8. Set the adjusting screws (2) of the valves (A) and (B) so that the lowering speed of the boom
is equal to the lifting speed. A maximum pressure difference of 5 bar is permissible here.
10. Secure the adjusting screws (2) on the valves (A) and (B) with fastening nuts (3). On doing so
make sure that the adjusting screws are not shifted.
CAUTION
CAUTION
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7.11.3 Secondary valves
4
1 M6
2 M7 5
It is not necessary to adjust the secondary valves (1) and (2) since these have been set in the
factory.
Should a check/setting nevertheless be carried out, the procedure is as follows:
CAUTION
Both valves must be checked and if necessary adjusted.
CAUTION
CAUTION
2. Connect the manual pump with the pressure gauge onto the test port (M6) or (M7) of the
secondary valve to be adjusted, (1) or (2).

Revised: 08.2004 1305 / 1505 / 1605 / 1705 Mobile
5. Fully extend the lifting cylinder.
7. Build up pressure with the manual pump until the pressure no longer rises.
The pressure indicated is the setting of the respective secondary valve (1) or (2).
8. Should an adjustment be made, loosen the fastening nut (5) and set the pressure stipulated
with the adjusting screw (4). Secure the adjusting screw (4) with the fastening nut (5). On
doing so make sure that the adjusting screw (4) is not shifted.
CAUTION
CAUTION
10. Remove the manual pump with the pressure gauge.
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7.12 Open-circuit guard for the articulated cylinder
7.12.1 Basic setting for the locking piston
NOTE
The setting is carried out without tools.
M9
1
2
M10
4
3
CAUTION
1. Loosen the fixing nut (1).
2. If necessary unscrew the adjusting screw (2) until no more resistance is felt.
3. Secure the adjusting screw (2) with the fastening nut (1).
Revised: 08.2004 1305 / 1505 / 1605 / 1705 Mobile
4. Connect the pressure gauges to the “fold cylinder” (M9) and “fold pilot control” (M10) test
ports.
CAUTION
Connect the pressure gauges in such a manner that a reading can be taken beyond the
slewing range of the jib equipment.
NOTE
It must be possible to read the pressure gauge on the “fold pilot control” test port (M10)
from the cabin, otherwise longer instrument leads will need to be used.
CAUTION
Make sure that the superstructure has been firmly attached.
8. Raise and extend the jib.
9. Operate the “fold in” function so that a pressure of 14 bar ± 0.5 bar is indicated and maintained
on the “fold pilot control” test port (M10) during the folding procedure.
10. While a pressure of 14 bar ± 0.5 bar is being indicated and maintained on the “fold pilot control”
test port (M10) during the folding procedure, read the pressure on the “fold cylinder” (M9) test
port. This reading must be 200 bar ± 10 bar.
If necessary, the pressure must be adjusted as follows (steps 11 to 15):
11. Lower the jib equipment onto the ground.
12. Loosen the fixing nut (3).
1305 / 1505 / 1605 / 1705 Mobile Revised: 08.2004
13. Adjust the pressure by means of turning the adjusting screw (4) in (increasing the pressure)
or out (reducing the pressure).
14. Secure the adjusting screw (4) with the fastening nut (3). On doing so make sure that the
adjusting screw (4) is not shifted.
15. Check the setting (steps 7 to 10) and if necessary repeat steps 11 to 15.
16. Lower the jib equipment onto the ground.
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7.12.2 Secondary valve
M9
1
2
It is not necessary to adjust the secondary valve since it has been set in the factory.
Should a check/setting nevertheless be carried out, the procedure is as follows:
2. Lift up the jib and extend it fully (fully retract the connecting rod of the articulated cylinder).
4. Connect a manual pump with a pressure gauge to the test port (M9).
5. Build up pressure with the manual pump until the pressure no longer rises.
The pressure indicated is the pressure setting for the secondary valve.
6. Should an adjustment be made, loosen the fastening nut (1) and set the pressure stipulated
with the adjusting screw (2). Secure the adjusting screw (2) with the fastening nut (1). On
doing so make sure that the adjusting screw (2) is not shifted.
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7.13 Checking/adjusting the cardan shaft speed
2
5 3
NOTE
Prior to checking/adjusting the cardan shaft speed, the drive pilot control pressure must
be checked and if necessary adjusted, see section 7.14.
1. Make a mark (1).
2. Jack up the excavator.
WARNING
Risk of accident through turning parts.

The cardan shaft and the wheels of the excavator will be turning.
Revised: 08.2004 1305 / 1505 / 1605 / 1705 Mobile
4 5 6
5. Use the “creep speed” (4) button to switch off the regulator bypass (Qmax) (the LED will not
light up).
6. Use the “gear switch” button (5) to switch into first gear (off-the-road gear) (the LED on the left
will light up green).
7. Push the accelerator right down and use the “tempomat” button (6) to activate the tempomat
function (LED will light up green).
8. Take your foot off the accelerator.
9. Measure the speed with a gauge (2) and compare it to the target setting on the setting chart.
10. If necessary adjust the speed with the setting screw (3).
11. Switch off the tempomat function (6) by means of operating the brake pedal or the parking
brake (LED will not light up).
1305 / 1505 / 1605 / 1705 Mobile Revised: 08.2004
7.14 Checking/adjusting the “drive” pilot control pressure
M3
1
2
1. Connect the pressure gauge to the “drive pilot control” (M3) test port.
3. Push the brake pedal and lock it.
5. Use the “gear switch” button (3) (LED on the right will light up yellow) to switch into second
gear (on-the-road gear).
6. Select the direction of drive (forward or reverse).
7. Push the accelerator as far as it will go.
8. Check the pilot control pressure on the pressure gauge.
Revised: 08.2004 1305 / 1505 / 1605 / 1705 Mobile
Should it be necessary to adjust the pressure, proceed as follows (steps 9 to 12):
9. Loosen the fixing nut (1) on the accelerator.
10. Screw the adjusting screw (2) in or out until the stipulated pilot control pressure is indicated
with the accelerator pushed as far as it will go.
11. Secure the adjusting screw (2) with the fastening nut (1). On doing so make sure that the
adjusting screw (2) is not shifted.
12. Check the pressure and if necessary repeat the adjustment procedure (steps 9 to 12).
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7.15 Centring actuator shut-off device with no oil overflow
7.15.1 Checking/adjusting the secondary valve
3
1
The secondary valve (1) has been set in the factory.
Check/adjust the secondary valve (1) as follows:
CAUTION
CAUTION
Make sure that the hydraulic leads (2) and (3) have been depressurised.
1. Screw off the hydraulic lead (2) to the cylinder and connect a manual pump with a pressure
gauge instead.
2. Screw off the hydraulic lead (3) to the fuel tank.
3. Build up pressure with the manual pump until hydraulic oil is forced out of the open connection
for the hydraulic lead (3).
4. Take the pressure reading.
Revised: 08.2004 1305 / 1505 / 1605 / 1705 Mobile
5. If necessary adjust the pressure to the stipulated setting with discs on the secondary valve (1)
6. Remove the manual pump.
7. Remove the hydraulic leads (2) and (3).
1305 / 1505 / 1605 / 1705 Mobile Revised: 08.2004
7.15.2 Checking/adjusting the control valve
3
1 2
CAUTION
CAUTION
Make sure that the hydraulic line (1) has been depressurised.
1. Install a test port with a pressure gauge in the “pilot control” hydraulic lead (1).
4. Lift up the boom as far as it will go.
5. Operate the “lower” function until the pilot control pressure is 3 bar. Maintain this pressure.
8. Adjust the control screw on the control valve (3) so that the boom just begins to lower itself
slowly.
CAUTION
Revised: 08.2004 1305 / 1505 / 1605 / 1705 Mobile
CAUTION
Make sure that the hydraulic line (1) has been depressurised.
10. Remove the test port with the pressure gauge.
1305 / 1505 / 1605 / 1705 Mobile Revised: 08.2004
Revised: 08.2004 1305 / 1505 / 1605 / 1705 Mobile
Chapter 11
Cylinders
Contents
1 Construction of the cylinders......................................................................................... 2

1.1 Jointed cross shaft axle lock cylinder............................................................................ 2
1.2 Blade cylinder ............................................................................................................... 3
1.3 Shovel tilting cylinder 1305 ........................................................................................... 4
1.4 Shovel tilting cylinder 1505 / 1605 ................................................................................ 5
1.5 Articulated cylinder 1305............................................................................................... 6
1.6 Articulated cylinder 1505 / 1605.................................................................................... 7
1.7 Adjusting cylinder 1305................................................................................................. 8
1.8 Adjusting cylinder 1505 / 1605...................................................................................... 9
1.9 Lifting cylinder ............................................................................................................. 10
Page 1 of 10
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1 Construction of the cylinders

1.1 Jointed cross shaft axle lock cylinder
1 Cylinder pipe
2 Piston rod
3 Flap valve
4 Shift cylinder
5 Piston valve
6 Stripper
7 Lip seal
8 O-ring
9 Cap screw
10 Screw plug
11 Screw plug
12 Screw plug
20 Disc
21 Sealing set for items 6-8 and 14-18
Cylinders
Revised: 08.2004 1305 / 1505 / 1605 / 1705 Mobile
1.2 Blade cylinder
1 Cylinder pipe 26 Piston guiding ring

2 Piston rod 27 O-ring
3 Piston 28 Bearing ring
4 Cylinder nut 29 O-ring
5 Piston valve 30 Bearing ring
6 Pin 31 O-ring
7 Valve seat 32 Pressure spring
8 Valve seat 33 Groove nut
9 Valve cone 34 Threaded pin
10 Screw plug 35 Swing support
11 Screw plug 36 Tone circlip
17 Stripper 37 Lubricating nipple
18 Lip seal 38 Set of valves
19 Rod guidance ring 39 Sealing set for items 17-31
20 O-ring
21 Bearing ring
22 O-ring
23 Turcon Glyd ring
24 O-ring
25 Bearing ring
Cylinders
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1.3 Shovel tilting cylinder 1305
1 Cylinder pipe 19 Lubricating nipple

2 Circlip 20 Swing support
3 Swing support 21 Circlip
4 Lubricating nipple 22 Sealing set for items 5-9, 11 and 14-17
5 Oil control ring
6 Lip seal
7 Guide bush
8 Rod sealing
9 Guide ring
10 I-Plus socket head cap screw
11 Cylinder nut
12 PUR profile ring
13 Piston
14 Guide ring
15 Compact piston packing
16 Guide ring
17 PUR profile ring
18 Piston rod
Cylinders
Revised: 08.2004 1305 / 1505 / 1605 / 1705 Mobile
1.4 Shovel tilting cylinder 1505 / 1605
1 Cylinder pipe with bearing 21 Piston rod

2 Circlip 22 Circlip
3 Swing support 23 Swing support
4 Lubricating nipple 24 Lubricating nipple
5 Screw plug 25 Sealing set for items 6-10, 13 and 17-20
6 Oil control ring
7 Lip seal
8 Guide bush
9 Rod seal
10 Guide ring
12 Cylinder nut
13 PUR profile ring
14 Piston
15 Stopper
16 I-Plus threaded pin
17 Guide ring
19 Guide bush
20 PUR profile ring
Cylinders
1305 / 1505 / 1605 / 1705 Mobile Revised: 08.2004
1.5 Articulated cylinder 1305
1 Cylinder pipe with bearing 21 Piston rod

2 Circlip 22 Lubricating nipple
3 Swing support 23 Swing support
4 Screw plug 24 Circlip
5 Lubricating nipple 25 Sealing set for items 6-10, 13 and 17-20
6 Oil control ring
7 Lip seal
8 Guide bush
9 Rod seal
10 Guide ring
12 Cylinder nut
13 PUR profile ring
14 Piston
15 Stopper
17 Guide ring
19 Guide bush
20 PUR profile ring
Cylinders
Revised: 08.2004 1305 / 1505 / 1605 / 1705 Mobile
1.6 Articulated cylinder 1505 / 1605
1 Cylinder pipe with bushing 21 Guide ring

2 Bearing bush 80/95 X 74 22 Connecting rod with bushing
3 Oil control ring 23 Bearing bush 80/95 X 74
4 Lubricating nipple 24 Oil control ring
5 Oil control ring 25 Lubricating nipple
6 Lip seal 26 PUR profile ring
7 Guide bush 27 Bearing ring
8 Rod seal 28 Guide bush
9 Guide ring 29 Sealing set for items 3, 5-9, 12, 19-21,
10 I-Plus socket head cap screw 24, 26-28
11 Cylinder nut
12 PUR profile ring
13 Snap ring
14 Damping ring
15 Pressure spring
16 Piston
17 Stopper
19 Driving band
Cylinders
1305 / 1505 / 1605 / 1705 Mobile Revised: 08.2004
1.7 Adjusting cylinder 1305

2 Oil control ring
3 Cylinder cap
4 Compact sealing set
5 Ring
6 Cylinder nut
7 O-ring
8 Back ring
9 Cylinder pipe
10 Bearing bush
11 Oil control ring
12 Lubricating nipple
13 Connecting rod
14 PUR profile ring
15 Piston
16 Stopper
18 Guide ring
19 Guide ring
21 Sealing set for items 2, 4, 7, 8, 14, 18-20
Cylinders
Revised: 08.2004 1305 / 1505 / 1605 / 1705 Mobile
1.8 Adjusting cylinder 1505 / 1605
1 Cylinder pipe with bearing 21 Guide bush

2 Bearing bush 22 PUR profile ring
3 Oil control ring 23 Piston rod
4 Lubricating nipple 24 Oil control ring
5 Oil control ring 25 Bearing bush
6 Lip seal 26 Lubricating nipple
7 Guide ring 27 Sealing set for items 3, 5-9, 12, 19-22, 24
8 Rod seal
9 Guide ring
11 Cylinder nut
12 PUR profile ring
13 Snap ring
14 Damping ring
15 Pressure spring
16 Piston
17 Stopper
19 Guide ring
Cylinders
1305 / 1505 / 1605 / 1705 Mobile Revised: 08.2004
1.9 Lifting cylinder
1 Cylinder pipe with bearing

2 Oil control ring
3 Bearing bush 80/95 X 64
6 Oil control ring
7 Lip seal
8 Guide bush
9 Rod seal
10 Guide ring
12 Cylinder nut
13 PUR profile ring
14 Piston
15 Stopper
17 Guide ring
19 Guide bush
20 PUR profile ring
21 Piston rod with bearing
22 Oil control ring
23 Bearing bush 80/95 X 64
24 Sealing set for items 6-10, 13 and 18-20
Cylinders
Revised: 08.2004 1305 / 1505 / 1605 / 1705 Mobile
Chapter 12
Hydraulic accessories
Contents
1 Claw support - 4 supports ............................................................................................. 2

1.1 Operable at the same time............................................................................................ 2
1.2 Check valve, pilot-operated .......................................................................................... 3
1.3 Integral check................................................................................................................ 4
2 Pilot control block.......................................................................................................... 5
3 Power shift gear ............................................................................................................ 6
4 Power brake system ..................................................................................................... 7
4.1 Structure ....................................................................................................................... 7
4.2 SETTING REGULATION .............................................................................................. 9
4.2.1 Shut-off valve ................................................................................................................ 9
4.2.2 Foot brake..................................................................................................................... 9
5 Axle blocking............................................................................................................... 11
5.1 Functional description ................................................................................................. 11
5.2 Putting into operation and de-aeration........................................................................ 12
5.3 Trouble-shooting ......................................................................................................... 12
5.4 Repair Guide (see picture 3)....................................................................................... 13
5.5 Pendulum axle lock cylinder ....................................................................................... 14
6 Multi-function valve ..................................................................................................... 15
7 Pipe break safety device............................................................................................. 17
7.1 Function description RBS ........................................................................................... 18
7.2 Pipe-break safety device 1305.................................................................................... 20
7.3 Pipe-break safety device 1505 / 1605......................................................................... 22
Page 1 of 24
1305 / 1505 / 1605 / 1705 Mobile Revised: 08.2004
1 Claw support - 4 supports

1.1 Operable at the same time
1 Outrigger cylinder
2 Check valve, pilot-operated
3 Integral check
4 Main screw connection
5 Check valve, self-unblocking
Revised: 08.2004 1305 / 1505 / 1605 / 1705 Mobile
1.2 Check valve, pilot-operated
1 to the check valve

2 from the check valve
3 Control line from the minor cylinder
side
4 Piston valve with TurconGlyd ring -
has to be mounted with a mounting
device
A Connection - major cylinder side
B Connection - plate valve
1305 / 1505 / 1605 / 1705 Mobile Revised: 08.2004
1.3 Integral check
1 Guide piece
2 Spring
3 Valve unit
P Connection - control block
R Connection - minor cylinder side
Revised: 08.2004 1305 / 1505 / 1605 / 1705 Mobile
2 Pilot control block
Y18
Y17
Y24
Y54
Y19
Y16
Y15
1 Pressure regulating valve 50 Ring Function

2 Sealing set or items 1, 6, 7, 13-17 51 Disc Y15 Backwards
3 Socket head cap screw 54 Control lever Y16 Forwards
4 Hexagon nut 55 Filter insert Y17 Creeping speed
5 Housing 56 O-ring Y18 Swing axle
8 Spring plate 57 Small filter element Y19 VST switch-off
9 Pressure spring 58 Screw plug Y24 free
10 Spring plate 59 Pressure accumulator Y54 Automatic speed control
11 Piston 62 O-ring
12 Valve body 63 Check valve
18 Pressure control valve 64 Solenoid valve
19 Sealing set for items 18, 20-22, 28-30 65 Trip coil
32 Hexagon nut 66 Sealing set for item 64
33 Threaded pin 67 Switch
34 Ball valve installation set 68 Sealing ring
35 Sealing set for items 34, 37-43,47-49 69 Shuttle valve
36 Connection plate 71 O-ring
45 Ball 72 O-ring
46 Spindle
1305 / 1505 / 1605 / 1705 Mobile Revised: 08.2004
3 Power shift gear
1 Housing
2 Emergency lock
4 Trip coil
6 Magnetic pipe
8 Tappet
9 Piston
10 Spring
12 Screw plug
13 Protective cap
16 Piston
17 Spring plate
20 Adjusting screw
21 Spring
23 Sealing set for items 3, 5, 7, 11, 14
Revised: 08.2004 1305 / 1505 / 1605 / 1705 Mobile
4 Power brake system

4.1 Structure
1 Compact brake block

2 Pedal
3 Base plate
4 Accumulator
5 Prong head
6 Activation rod
7 Adjustment screw
1305 / 1505 / 1605 / 1705 Mobile Revised: 08.2004
BR1 BR2
DS1
S1 S2
P Steering pump
N to steering unit
BR1 to the brake cylinders 1st circuit
BR2 to the brake cylinders 2nd circuit
X Measurement connection
DS1 Pressure switch brake pressure
DS2 Pressure switch function control 100 bar
S1 Pressure accumulator
S2 Pressure accumulator
Revised: 08.2004 1305 / 1505 / 1605 / 1705 Mobile
4.2 SETTING REGULATION

Verification / Setting
Connect manometer (0 - 400 bar) to the measurement
connection XIV, XV.
4.2.1 Shut-off valve
Start engine.
The accumulator pressure of 185 bar is displayed immedia-

tely.
By activating the pedal-operated brake valve several times,
the accumulated pressure plunges to the set value of 152
bar and then rises again to 185 bar.
The setting of 152 bar is done on the adjustment screw (1).
1
Screw-out adjustment screw:
• charge pressure lesser 2
Screw-in adjustment screw:
• charge pressure higher
4.2.2 Foot brake

Arrest pedal-operated brake valve.
A brake pressure of 120 bar must be displayed. Adjustment
is performed on the thread rod (2).
Thread rod (2) in the bushing of the idler fork:

• Screw-in: Brake pressure lesser
• Screw-out: Brake pressure higher
Pedal-operated brake valve released.

Connect manometer (0 -6 bar) to the measurement
connection XV.
A brake pressure of 0.5 bar must be displayed.

Adjustment is performed on the adjustment screw (7)
(see page 11).
Attention: This adjustment is for industrial machines with
drum brakes only.
1305 / 1505 / 1605 / 1705 Mobile Revised: 08.2004
Power brake valve
Measurement connections:
XIV Shut-off valve

XV Foot brake
Pressure switch:
DS1 Pressure switch brake lights
DS2 Pressure switch function control
DS3 Pressure switch swinging axles
Venting:
Shut-off valve – Connect mini-measure-
ment hose with measurement connection
(XIV).
Keep end of hose in an adequate contai-
ner.
Foot brake – Connect mini-measurement

hose with measurement
connection (XIV).
Keep end of hose in an adequate
container.
(Slightly activate plate valve)
Revised: 08.2004 1305 / 1505 / 1605 / 1705 Mobile
5 Axle blocking
5.1 Functional description
Design as plunger-cylinder with integrated shut-off valve.

The shut-off valve is designed as leak-oil free ball valve which is capable of being opened through a control
piston.
Area relations Ψ = 16 : 1
Pilot-opening pressure PSt = 30 bar
The control line is connected to the connecting line of both supporting cylinders, i.e. the pilot-opening
pressure with which the shut-off valve in the cylindrical head is loaded for unlocking, is at the same time,
the pre-load pressure for the cylinder during swinging, i.e. only one line to the cylinder
is required.
Points to be observed:
The pressure in the tank line must be smaller than 2 bars in the locked state. The axle-seating should be
even, hardened and greased.
The screwing areas for the cylinder on the undercarriage must be even to avoid extra tensions on the
cylinder housing during screwing.
(1)
(2)
Picture 3: Swinging axle cylinder with shut-off valve
1305 / 1505 / 1605 / 1705 Mobile Revised: 08.2004
5.2 Putting into operation and de-aeration
To put into operation, all components must be filled with mineral oil and de-aerated.
This will be performed as follows:

• The screw plug (pos. 10) is removed on the swinging axle cylinder.
• The rod is pressed downwards until the axle seat.
ATTENTION! Depending on the type of cylinder, the check-valve element pos. 3 may protrude
more or less far into the oil fill-up boring. The valve element shall not be damaged while the rod
is being pressed down.
• The rod may as well be pressed down hydraulically.
• Fill the cylinder space with oil and screw-in screw-plug once again MA = 180 Nm.
• To de-aerate the two cylinders, screw-out the de-aeration screw pos. 11 and fill-up with oil until no fur-
ther air-bubble is let out.
• Screw-in the de-aeration screw but do not tighten same. The screw shall remain slightly loosened.
• Exert control-pressure on the cylinder and tighten de-aeration screw (MA = 28 Nm), as soon as bubble-
free oil flows out. This concludes the de-aeration process.
Extreme cleanliness shall be observed during the entire de-aeration process.
5.3 Trouble-shooting
a) Should the supporting effect of a cylinder recede in the stiff state of an axle, the rod-sealing pos.7 as
well as the leak-proof of the check-valve element pos. 3 shall be verified, if necessary, the parts shall
be renewed.
b) Should the swinging axle be incapable of being placed in a labile position after several switching, the
following shall be verified:
• In case of a very high cylinder load, unlocking cannot be performed against the inner cylinder pressure
(see function description).
• The system must be de-aerated (see Initial Operation and de-aeration).
• Should the re-establishment of the axle-function through de-aeration fail, it should be verified if suf-
ficient control-pressure is available (see function description).
• Should no defect be determined in the face of the aforementioned points, then the control piston pos. 5
of the shut-off valve must still be verified for smooth-running (see Repair Guide).
Revised: 08.2004 1305 / 1505 / 1605 / 1705 Mobile
5.4 Repair Guide (see picture 3).

a) Replacement of the rod-sealing
• Remove screw-plug pos. 10.
• Press-out rod pos. 2 downwards.
ATTENTION! Do not damage surface of rod.
• Lift out grooved ring pos. 7 with rounded tool.
ATTENTION! Do not damage puncture surface.
• Lead-in new grooved ring by pressing it together in a kidney-form and press into the groove.
(Picture 4 and 5).
• Check stripper pos. 6 for damages and replace if necessary.
• Grease-in sealings.
• Re-position rod.
b) Repairing the check-valve

• Remove screw-plugs pos. 9.
• Remove screw-plug pos. 4.
• Remove screw-plug pos. 5. Control piston must be smooth-running in the check-valve element as well
as in the switch-cylinder.
• Press check-valve element pos. 3 outwards from the inside through the fill-in bore pos. 10.
• Check sealing pos. 8, 14, 15, 16 and 17 for damages and replace if necessary.
• The check-valve element pos. 3 cannot be further dismantled.
• Assemble in reversed order.
• Grease-in sealings for assembly..
• Tightening torque for cylinder-head screws pos. 9 MA = 16 Nm.
ATTENTION! Use only cylinder-head screws with tensile strength 12.9!
De-aeration shall be performed prior to initial operation in accordance with item 2.
ATTENTION! All verifications and repairs shall be performed with the maintenance of extreme
cleanliness.
Picture 4: Grooved ring pressed together in a

kidney form
Picture 5: Positioning the grooved ring in the closed groove
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5.5 Pendulum axle lock cylinder
1 Cylinder pipe
2 Piston rod
3 Flap valve
4 Shift cylinder
5 Piston valve
6 Stripper
7 Lip seal
8 O-ring
9 Cap screw
10 Screw plug
11 Screw plug
12 Screw plug
20 Disc
21 Sealing set for items 6-8 and 14-18
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6 Multi-function valve
Turn grab
Shearing unit
Comfort unit
Comfort unit Turn grab Shearing unit
Control pressure VST 6 - 25 bar Volume flow QA1+QB1 60 l/min

Secondary valves DV1+DV2 210 bar QA2+QB2 250 l/min
DV3+DV4 380 bar QH 20-300 l/min
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7 Pipe break safety device
AL AL
St St
L L
VSt VSt
Z Z
P T
VSt
Subject to alterations!
1305 / 1505 / 1605 / 1705 Mobile Revised: 08.2004
7.1 Function description RBS
The pipe rupture safeguard is flanged on the cylinder with the Z-connection. By this means, it is installed
between the consumer cylinder and the control valve. Its duty is to prevent the uncontrolled drop of a load
in case of a pipe rupture or hose-connection. The permissible speed surge or drop is stipulated in ISO
8643. At the same time, it should also be possible to lower the load in a controlled manner after a pipe
rupture. This function is fulfilled by the RBS 427.063.949.9.
As a result of its thin construction form in the direction of the cylinder, it is capable of being adapted without
problems in most applications. The connection from the control block (Connection St) can be optionally
mounted right or left on the side. To lift the load and thereby, run-out the cylinder, the volume flow is led
through the St-connection into the cylinder. A generously dimensioned check-valve guarantees a flow with
minimum loss. The lowering of the load is performed through the increase of the pilot-controlled pressure
which also opens the outlet side of the main control valve. To prevent an uncontrolled speed surge of the
load in case of hoserupture, the cylinder pressure must rest on the valve spool of the pipe-rupture safe-
guard. This can only be guaranteed if the opening pressure of the main valve spool is lesser than the
opening pressure of the pipe-rupture safeguard. The necessary adaptation is done with the aid of the ad-
justing screw on the spring cap of the pipe-rupture safeguard. Here too, the maximum displacement of the
valve spool which generates the desired maximum lowering speed, can be limited.
The pipe-rupture safeguard is designed in a pressure-compensated manner. This has the advantage that
the dynamic pressures which are eventually built up before the main control valve do not have a closing
effect on the valve spool of the pipe-rupture safeguard. The opening crosssection of the pipe-rupture safe-
guard is thereby, dependent only on the pressure of the pilotcontrol system. To protect the cylinder against
non-permissible high pressure, the pipe-rupture safeguard is fitted with a pressure relief valve. Since this
opens up in the St connection, it is also designed in a pressure-compensated manner. Most often, RBS is
flanged to two parallel-operated cylinders. To prevent an uneven distribution of the load on the cylinders
and thereby, nonpermissible pressure e.g. on the boom, both cylinders must open up at the same pilot-
control pressure (to be set through the adjustment screw on the spring cap, s.o.). In spite of that, different
pressures may occur particularly upon the fast movement of the cylinder. To keep this as low as possible
a compensation line (Connection AL) is provided. The pipe-rupture safeguards which function parallel to
each other are connected to one another through this line which is limited in its cross-section as a result of
legal provisions. Pressure differences are thereby minimised.
Revised: 08.2004 1305 / 1505 / 1605 / 1705 Mobile
Pipe break safety device 1", ST = SAE ¾"

Qmax = 350 I/min Pmax = 410 bar
ST MST L VSt
ST
AL
Z MZ
Pressure valve pressure depending on the pilot control
410
Pressure valve opening point (bar)
400
390
380
370
360
7,3 7,6 7,8 8 8,3 8,5
Pilot control opening point (bar)
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7.2 Pipe-break safety device 1305
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1 Housing
2 Valve tappet
3 Spring cap
4 Bushing
5 Valve cone
6 Valve cone
7 Screw plug
8 Spring plate
9 Connecting plate
10 Adjustment
11 Screw plug
12 Disc
13 Screw plug
14 Screw plug
15 Screw plug
16 Pressure valve
17 Distance sleeve
18 Separator
19 Nut
20 Intermediate flange, complete
21 Spring
22 Spring
23 O-ring
24 Bearing ring
25 O-ring
26 O-ring
27 O-ring
28 O-ring
29 O-ring
30 O-ring
31 O-ring
32 O-ring
33 TURCON STEP SEAL
34 Screw plug
35 Screw plug
36 Screw plug
37 Screw plug
38 Ball
39 Cap screw
40 Hexagon head cap screw
41 Hexagon nut
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7.3 Pipe-break safety device 1505 / 1605
Revised: 08.2004 1305 / 1505 / 1605 / 1705 Mobile
1 Housing
2 Valve tappet
3 Spring cap
4 Bushing
5 Valve cone
6 Valve cone
7 Screw plug
8 Spring plate
9 Connecting plate
10 Adjustment
11 Screw plug
12 Disc
13 Screw plug
14 Screw plug
15 Screw plug
16 Pressure valve
17 Distance sleeve
18 Separator
19 Nut
20 Intermediate flange, complete
21 Spring
22 Spring
23 O-ring
24 Bearing ring
25 O-ring
26 O-ring
27 O-ring
28 O-ring
29 O-ring
30 O-ring
31 O-ring
32 O-ring
33 TURCON STEP SEAL
34 Screw plug
35 Screw plug
36 Screw plug
37 Screw plug
38 Ball
39 Cap screw
40 Hexagon head cap screw
41 Hexagon nut
1305 / 1505 / 1605 / 1705 Mobile Revised: 08.2004
Revised: 08.2004 1305 / 1505 / 1605 / 1705 Mobile
Chapter 13
Air conditioner system
Contents
1 Use................................................................................................................................ 2
2 Technical Data .............................................................................................................. 2
3 Functions on the control elements ................................................................................ 3
3.1 Overview ....................................................................................................................... 3
3.1.1 Control .......................................................................................................................... 3
3.2 Detailed description of the functions ............................................................................. 4
3.2.1 Air distribution ............................................................................................................... 4
3.2.2 Fan................................................................................................................................ 4
3.2.3 Temperature plate......................................................................................................... 4
3.2.4 Switch for the air conditioner......................................................................................... 4
3.2.5 Radio button for fresh air and ambient air..................................................................... 4
3.3 Description of the functions in the background ............................................................. 5
3.3.1 Auxiliary heating............................................................................................................ 5
3.3.2 Pressure switch in the refrigeration cycle ..................................................................... 5
3.3.3 Temperature sensor...................................................................................................... 5
3.3.4 Combustion engine ....................................................................................................... 5
3.3.5 Ignition key (terminal 15) and switching on the control unit .......................................... 5
3.3.6 Switching off the ignition ............................................................................................... 5
4 Air conditioning of the cabin.......................................................................................... 6
4.1 Pane defrosting............................................................................................................. 6
4.2 Heating.......................................................................................................................... 6
4.3 Operation of the air conditioner..................................................................................... 6
5 Heating air conditioner .................................................................................................. 7
5.1 Place of installation ....................................................................................................... 7
6 Description of the cooling cycle components................................................................ 9
6.1 Capacitor for the 13-1705 excavator models ................................................................ 9
6.2 Dryer with push button collector.................................................................................. 10
6.3 Compressor ................................................................................................................ 10
7 Safety information ....................................................................................................... 11
8 Maintenance ............................................................................................................... 12
9 Error diagnosis ............................................................................................................ 13
Page 1 of 14
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Air conditioner system 6062747

with control element 6064232
1 Use
The heating air conditioner 6062747 was designed specifically for the purpose of conditioning the air of
the driver cabin of the Atlas Excavator Generation 13-1705.
2 Technical Data
Heating air conditioner 6062747
Thermal output : 13 kW
Refrigerating capacity : 5 kW
Refrigerant : R134a
Nominal voltage : 24 V
Power reception : 13 A max.
Operating voltage : 24 V (20....28 V)
Operating over-pressure : max. 27 bar
Air current max. : 1050 m3/h (blowing freely)
Fan : has 4 levels
Refrigerant : R134a - 1150+50 grams
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3 Functions on the control elements

A control element, which has been set to this heating air conditioning device supports the simplifies the
regulation of the complete unit.
3.1 Overview
Display field, air distribution

Toe space
Roof, toe space
Roof space
Bar chart, status LED‘s
Air distribution
Fan level
Heating
Backs the setting of the selected function
Regulation of the selected function

Air distribution
Fan level
Temperature adjustment
Function keys
Air distribution
Fan level
Temperature control
Compressor of the air conditioner: on/off
Fresh air, ambient air
3.1.1 Control
The air conditioning and ambient air keys can be switched on or off independent from the other functions
(alternating switches).
After selecting a function by pressing the respective key (temperature, air valves and ventilator), the keys
[+] and [-] are used to set the value of the function.
The LED bar chart always shows the value of the currently selected function. The luminous fields for the
air distribution are started independently from the current function.
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3.2 Detailed description of the functions
You can enable the individual functions by using the jogging mode.
3.2.1 Air distribution

Is used for the selection of the ventilation types. Normally, three operating modes can be used: Toe space;
toe space and roof space; roof space. The main operating modes are shown in the display field. The mixed
air valves can be moved to a 4 different positions. The intermediate positions are shown on the bar chart.
3.2.2 Fan
The air current can be set in four different levels. The selected fan level is shown in the bar chart. The fan
can also be switched off (the LED bar is dark).
3.2.3 Temperature plate

The temperature can be set to 8 levels from low to high. The selected temperature is shown in the bar chart.
3.2.4 Switch for the air conditioner

Is used to switch the cooling and dehumidification function on or off. If the air conditioner is switched on,
the control light in the control panel is lit. When the air conditioner is switched on, the air valves are moved
automatically to the central position.
3.2.5 Radio button for fresh air and ambient air

It is used to select between fresh air (fresh air from the outside) or ambient air (cabin air). If the case of
ambient air, the control light in the control panel is lit.
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3.3 Description of the functions in the background

3.3.1 Auxiliary heating
If the auxiliary heating is switched on, the water valve is opened completely. The mixed air valves are mo-
ved to their central position, the fan level 2 is activated and set to fresh air. These functions are provided
without the support of the control unit. If the ignition – terminal 15 – is switched on, the bar chart blinks
alternatively; if the ignition is switched off, all display elements stay dark.
The signal of the auxiliary heating has always priority. As long as this continues, no control functions are
perceived by the control unit when the ignition is switched on (this is shown by the alternatively blinking of
the LED bar).
3.3.2 Pressure switch in the refrigeration cycle

After a high pressure of approximately 30 bar the compressor is separated from the power flux through the
magnetic transmission. (the current feeding of the compressor is switched off)
3.3.3 Temperature sensor

Under a temperature of approximately 2 °C the compressor is separated from the power flux through the
magnetic transmission. (Hysteresis: Off at approximately 2°, On at approximately 8°)
3.3.4 Combustion engine

If the combustion engine is switched off, the compressor is separated from the power flux through the mag-
netic transmission.
3.3.5 Ignition key (terminal 15) and switching on the control unit
A lamp test of the LED bar is started, after the ignition is switched on (without any signal of the auxiliary
heating). The last settings of the control unit are restored and the actuators are triggered accordingly.
3.3.6 Switching off the ignition

After the ignition is switched off, all the current operating parameters (air valves, ventilator, temperature,
ambient air, air conditioner and function) are stored in a non-volatile memory (EEProm), and the servo mo-
tors are moved to their end position.
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4 Air conditioning of the cabin

4.1 Pane defrosting
In order to achieve the maximum capacity for the pane defrosting, do the flowing settings:
• temperature pre-selection, maximum warm
• fresh air operation
• fan level, 4
• position of the mixed air valve, 2
• open front nozzles or rear nozzles and turn them to the panes
4.2 Heating
• if necessary, pre-select the temperature on the operating panel
• if necessary, pre-select the fan level on the operating panel, however the minimum position should be
position 2. Otherwise there can be condensation on the panes
• open foot nozzle
• if necessary, adjust front nozzles or rear nozzles
4.3 Operation of the air conditioner

The air conditioner is controlled from the operating panel. If the air conditioner is switched on, the control
light in the control panel is lit. When the air conditioner is switched on, the air valves are moved automati-
cally to the central position. The air conditioner works only is the motor is running. Adjust the fan level ac-
cording to your needs, however the minimum position should be position 1, otherwise there will be no
cooling.
The following settings are necessary to achieve the maximum cooling in the cabin:
• ambient air mode
• fan level, 4
• open all nozzles
The air conditioner can dehumidify the cabin air in wet and cold days. (use the heating and the air condi-
tioner at the same time). The cooling is compensated with the vehicle heating. This will enable a more com-
fortable cabin climate and avoid the condensation of the window panes.
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5 Heating air conditioner

5.1 Place of installation
The heating device 6062747 is located in the toe space of the cabin, under the seat console. The air dis-
tribution elements, air nozzles are visible in the driver cabin.
The heating air conditioner can be accessed only from below.
1 Water valve with a servomotor 2 Wire harness

3 24V relay 4 Thermostat with a 24V relay
5 Air filter 6 Fan
7 Evaporator 8 Expansion valve
9 Heater 10 Cover air filter
11 Condensation water run-off
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A Air intake (fresh air) B Air intake (circulating air)

C Air exit, C column, right D Air exit, C column, left
E Air exit, side window F Air exit, front windscreen
G Air exit, floor
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6 Description of the cooling cycle components

6.1 Capacitor for the 13-1705 excavator models
1 Refrigerant entry 2 Refrigerant exit

3 Fastening points 4 Direction of air
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6.2 Dryer with push button collector
1 Dryer 2 Push button connection

3 Inspection glass, view from the top 4 Refrigerant entry
5 Refrigerant exit
6.3 Compressor
1 Refrigerant entry (S) - exterior

2 Refrigerant exit (D) - interior
3 Pulley with a magnetic coupling; V-belt - 13 mm
4 Fastening points
Revised: 08.2004 1305 / 1505 / 1605 / 1705 Mobile
7 Safety information
Please pay attention to the following information for your own safety:
The general rule is:
• Please let the maintenance and repair works to be done only by the professional personnel.
• Do not stuck your hands into the device and do not place anything into the ventilator of the evaporator
and the condenser.
• The motor must be stopped for maintenance procedures.
• Disable the battery before opening the air conditioner.
• In emergency cases, switch the air conditioner off by switching the ventilator switch to the „Off“ state.
• ATTENTION There is a danger of injury at the slats of the opened condenser / evaporator.
Maintenance works at the refrigeration cycle:
• The system must be emptied before any of the maintenance works at the refrigeration cycle. This can
be done only by the PROFESSIONAL PERSONNEL with VERIFIABLE EXPERT KNOWLEDGE IN
AIR CONDITIONING TECHNOLOGY.
• Do not heat refrigerant bottles with open fire.
• Do not discharge refrigerants into the open.
• Fluid refrigerants must not touch the skin or the eyes.
• Protection goggles are necessary when dealing with refrigerants.
• ATTENTION – Danger of explosion! Please do not carry out soldering or welding works directly on the
parts in closed refrigeration cycle or in its near environment. Heating raises the pressure in the system
and could lead to an explosion.
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8 Maintenance
The air conditioner must be switched on at least once in a month for a short time. The operation is neces-
sary for lubricating the compressor.
The following maintenances need to be done at the beginning, middle and end of a cooling period:
• Check the V-belt tension and the compressor fastening
• Check the refrigerant level (make sure that the refrigerant flows through the inspection window of the
liquid container without any bubbles, while the motor is running and the capacity of the air conditioner is
at maximum (ambient temperature is approximately 20 °C).
• Cleaning the condenser (the slats must be cleaned carefully, without high pressure, otherwise they
would bend).
An annual inspection should be done in your workshop at the beginning of each cooling period.
The heating device, air conditioner has been equipped with one ambient air and fresh air filter. Depending
on the level of dirt accumulation, the filters must be cleaned or replaced.
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9 Error diagnosis
Fault Cause Remedy

Equipment does not Insufficient air flow - capacitor Clean the plates
cool sufficiently Insufficient air flow - evaporator Replace the air filters
Too little refrigerant in the system Fill up the equipment until the flow in the
inspection glass shows no bubbles
Expansion valve blocked Clean the expansion valve or replace it
Filter dryer partially blocked, recognisable Replace the dryer
by the formation of ice on the dryer
Air in the cooling cycle on raised pressure Empty the equipment and refill
levels and the formation of bubbles on the
inspection glass
Water valve has a leak (heating pipes are Replace the water valve
both warm / hot)
The compressor The compressor ball bearing is defect Replace the compressor
emits a loud noise The magnetic coupling is defect Replace the compressor
Insufficient oil in the compressor Fill up refrigerator oil
Whistling sounds V-belt is worn or not suitable Replace the V-belt
from the V-belt (a 13-mm V-belt should be used!)
V-belt too loose Tighten the V-belt
Equipment does not Electrical connections interrupted Check the connections on the magnetic
cool coupling, the switch, the relay, the ther-
mostat and the control device.
Air temperature thermostat defect Replace the air temperature thermostat
Thermostat and relay defect Replace the thermostat
Fuse defect Replace the fuse
Relay defect Replace the relay
The compressor switches off due to ex- Clean the capacitor
ceeding the max. operating pressure
(pressure switch no transmission)
Filter dryer blocked (suction pressure va- Replace the filter dryer
cuums / formation of ice on the dryer)
Too little refrigerant in the system Suction off the refrigerant until there are
(should be 1150+50 gr.) hardly any bubbles
The compressor switches off due to ex- Check to see whether the equipment
ceeding the min. operating pressure has a leak and if necessary fill up refri-
(pressure switch no transmission) gerant
The magnetic coupling on the compressor Replace the compressor
is defect
The V-belt is broken Replace the V-belt
The evaporator is iced up Check the thermostat and the air filter
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Revised: 08.2004 1305 / 1505 / 1605 / 1705 Mobile
Chapter 14
Power shift transmission
Contents
1 Technical data .......................................................................................................................... 4

2 Specification ............................................................................................................................. 5
3 Valve block for Gearbox control ............................................................................................... 6
4 Operation ................................................................................................................................. 7
4.1 General .................................................................................................................................... 7
4.2 Driving and switching gears ..................................................................................................... 7
4.3 Parking brake ........................................................................................................................... 7
4.3.1 General ..................................................................................................................................... 7
4.3.2 Parking ...................................................................................................................................... 8
4.4 Towing away ............................................................................................................................ 8
5 Maintenance ............................................................................................................................. 9
5.1 Type of oil ................................................................................................................................. 9
5.2 Checking the oil level ............................................................................................................... 9
5.3 Oil change and oil fill-up quantity ........................................................................................... 10
6 Charts ..................................................................................................................................... 11
7 INSTRUCTIONS FOR REPAIR ............................................................................................. 20
7.1 General instructions ............................................................................................................... 21
7.2 Important information on working safety ................................................................................ 22
7.3 Designation of statutory units ................................................................................................. 23
7.4 Tightening torques ................................................................................................................. 24
7.5 Gear structure ........................................................................................................................ 25
7.6 Instructions for commencement of operation, operating and maintenance ........................... 26
7.7 Installation overview and instructions on filling up with oil ..................................................... 27
7.8 Instructions on moving or towing away the vehicle in an emergency .................................... 28
7.9 Examples of tooth contact for Gleason-type gear teeth ......................................................... 29
7.10 RList of tools for assembling and disassembling ................................................................... 31
7.11 2 HL 100 switch protection ..................................................................................................... 37
7.12 Shift protection device ............................................................................................................ 38
Page 1 of 120
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8 Dismantling ............................................................................................................................. 39
8.1 Removing the clutch ............................................................................................................... 39
8.2 Removing and dismantling the planetary drive ...................................................................... 47
8.3 Switching off and removing and dismantling the spur wheel .................................................. 48
8.4 Dismantling the shift protection device ................................................................................... 54
8.5 Dismantling the drive output, axle drive housing and differential ........................................... 55
9 ASSEMBLY ............................................................................................................................ 61
9.1 Axle drive housing, drive output and differential ..................................................................... 61
9.1.1 Thickness of the adjusting disc in order to achieve perfect tooth bearings ............................. 61
9.1.2 Installing the driving pinion ...................................................................................................... 62
9.1.2.1 Set the rolling moment of the driving pinion bearing = 2.5 … 3.5 Nm .................................... 66
9.1.3 Completing and installing the differential................................................................................. 69
9.1.3.1 Adjusting the tooth profile clearance and the initial bearing tension ...................................... 73
9.2 Installing the helical gear and the shut-off device .................................................................. 74
9.3 Completing and installing the pinion cage .............................................................................. 77
9.3.1 Adjusting the switch-off device ................................................................................................ 79
9.4 Pre-assembling and installing the coupling (on-the-road gear) .............................................. 80
9.4.1 Checking the imperviousness and functioning of the coupling (Illustration 188…190) ........... 87
9.5 Installing the brakes (off-the-road gear) ................................................................................. 88
9.6 Mounting the drive housing .................................................................................................... 92
9.7 Checking that the brakes do not leak and that they function (off-road gear),
see illustrations 216 and 217 .................................................................................................. 95
9.8 Pre-assembling and installing the shift protection .................................................................. 96
9.8.1 Installing the lubrication oil pump .......................................................................................... 100
9.9 Installing the screw plugs and the oil lines ........................................................................... 102
9.10 Dismantling the drive output ................................................................................................. 104
9.11 Mounting the drive output ..................................................................................................... 107
9.12 Gear switch protection .......................................................................................................... 112
9.12.1 Dismantling, see also picture chart on pages 38 and 120!.................................................... 112
9.12.2 Assembly, see also picture chart on pages 38 and 120........................................................ 115

Revised: 08.2004 1305 / 1505 / 1605 / 1705 Mobile
2 HL-100

1305 / 1505 / 1605 / 1705 Mobile Revised: 08.2004
1 Technical data
Driving power P max. = 110 kW
Driving torque: T max. = 770 Nm
Speed: n max. = 4500 min-1
Hydromotor max q max. = 160 cnP/U
Gear transmission:
Gearbox ratio 3.17
Off-the-road gear i = 4.42
On-the-road gear i = 1.39
Gearbox ratio 3.85

Off-the-road gear i= 5.35
On-the-road gear i= 1.39
Gearbox control:
the following data applies for oil temperatures
from 30 °C to 40 °C
Control pressure on connection P1 or P2 at lowest/ p = 30 to 35 bar
highest diesel idling speed
Momentary pressure peaks for cold starting p max. = 40 bar

(oil temperature below -5 °C)
Remaining pressure in the P1 or P2 control line p max. = 1.0 bar
connected to the tank
Remaining pressure in the overflow oil line p max. = 1.0 bar

(drive housing)
Oil quantity - gearbox control Q min = 5.5 l/min at p = 24 bar counter-pressure

Q max = 25 l/min
Shift protection device:

Switch-back takes place at a gear speed of approx. 800 min-1.
Shut-down device for:

Towing away the machine
Emergency release device of the parking brake
The fuel flow between the drive input and output is cut off.
Brakes:
Parking brake
Gear mass:
Separate installation 125 kg
Direct installation depending on the axle design 150 to 220 kg

Revised: 08.2004 1305 / 1505 / 1605 / 1705 Mobile
2 Specification
The gears comprise a 2-gear planetary power shift transmission, a two-shaft pinion drive with a drive pinion
flange for the front and rear axle or a secondary set of bevel wheels for direct installation on a ZF axle.
The power shift for a planetary system comprises a rotating multiple-disc clutch on top of which is a multi-
ple-disc brake housed in a casing. They are both applied with spring power and are hydraulically released.
The power shift devices also function as parking brakes. On braking, the brake piston presses on the brake
discs with reduced force - resulting from the spring power and the opposing opening pressure of the brake
valve - and thus tensions the planetary drive.
The large-volume, dynamically-loaded brake absorbs the brake energy since the clutch remains engaged
during the braking procedure and is only subjected to static friction.
During the braking procedure the hydrostatics and the transmission brake function jointly.
The shut-down device therefore fulfils statutory requirements in respect of the emergency release device
of the parking brake in order to be able to move the vehicle out of a dangerous area in the event of a power
failure or a lack of control pressure.
The shifting safety device prevents a switch-back at high speeds and hence prevents the hydro-motor from
overspeeding. Should the vehicle be put into the off-the-road gear at high speed, this gear will remain blok-
ked and will only be automatically activated or released when the switch-back point has been reached.
Switch-back takes place at approximately 75% of the maximum speed in the off-the-road gear.
Shifting into a higher gear is not contingent on speed. The speed protection device takes effect in both di-
rections of drive. The shifting safety device does not prevent possible overspeeding during thrust driving
of the vehicle. Wheel brake valves have been installed on the hydromotor for this purpose. An electrical
design by means of inductive reactor and an electronics system is available as an alternative to a hydraulic
switch protection device. These signals may also be used for indicating the speed.
A cut-off device has been provided for between the planetary drive and the pinion drive (standstill shift).
Operation by means of a stop lever attached to the gearbox casing for the controller position ON/OFF. This
claw clutch cuts off the supply of power between the power shift part and the drive output, thus enabling
the vehicle to be towed up to the final speed without any particular limitations concerning the distance
covered.
The parking brake does not function when the clutch is disengaged.
The cut-off device may only be operated in an emergency to remove the vehicle from the danger zone in
the event of a power failure or if the gears have no control pressure.
The opening pressure of the brake valve is to be determined in accordance with the respective weight of
the vehicle, so that braking as stipulated in accordance with EG guidelines 71/320/EWG is achieved.
Securing the gearbox against insufficient control pressure (p < 24 bar) is carried out
by means of a pressure switch or a hydraulic monitoring switch.
It is essential to ensure that the drive valve switches into NEUTRAL.
Driving by means of the hydrostatic system is therefore ineffective. This also applies to operating the
parking or emergency brake.

1305 / 1505 / 1605 / 1705 Mobile Revised: 08.2004
3 Valve block for Gearbox control
1 Brake switch valve

2 Emergency locking / hand brake in the event of a power failure
3 Gear shift valve
4 On-the-road supply M 16 x 1.5
5 Pump pressure supply M 16 x 1.5
6 Adjusting screw pressure control valve
7 Petrol tank supply M 16 x 1.5
8 Integral check adjusting screw
9 Pressure switch supply M 10 x 1
10 Off-the-road supply M 16 x 1.5
11 Test port 1/4"
12 Hydraulic accumulator supply M 33 x 1.5

Revised: 08.2004 1305 / 1505 / 1605 / 1705 Mobile
4 Operation
4.1 General
Detailed regulations for operating the vehicle are to be found in the vehicle manufacturer's operating and
maintenance manual.
4.2 Driving and switching gears

The engine is always to be switched on when the vehicle is in neutral.
Once the engine has been switched on and the direction of drive and the gear have been selected, the
vehicle can be set in motion by accelerating.
Changing into a higher gear is not contingent on speed.
Should the vehicle be put into the off-the-road gear at high speed, this gear will remain blocked and will
only be automatically activated or released when the switch-back point has been reached.
Switch-back takes place at approximately 75% of the maximum speed in the off-the-road gear.
All of the gears can be used for reversing.
4.3 Parking brake

4.3.1 General
When the parking brake is applied, the control pressure in the gearbox drops to the opening pressure set,
so that the degree of ability to hold or the degree of dynamic braking required by law is achieved.
The gear brake only covers the parking brake function.

This means that the vehicles need to be fitted with a dual circuit brake system in order to comply with na-
tional and international brake directives.
On driving with ZF gears and ZF axles, it is essential to ensure that, when excavating, the vehicle is only
braked by means of the service brake. The circuitry system must ensure that the service brake (parking
brake) cannot be put on in this operating mode.
The hydrostatic braking of the vehicle in the thrust range is carried out by means of the brake valve provi-
ded for on the hydraulic motor. The minimum slow-down through resistance to moving and hydrostatics
should be approximately 12%.
When the parking brake is operated it is essential to ensure that operating the accelerator would not have
any effect (drive valve in NEUTRAL).
This also applies if the control pressure drops to an unacceptable level (< 24 bar).
The circuitry system must ensure that the vehicle is automatically put into the on-the-road gear when the
parking brake is activated.
When the brake has been released the vehicle can be driven again in the pre-selected gear.

1305 / 1505 / 1605 / 1705 Mobile Revised: 08.2004
4.3.2 Parking
We recommend that, on leaving the vehicle, the service brake be operated in addition to the parking brake.
This security is particularly necessary when the vehicle is parked on an upward or downward slope on
which the parking brakes do not hold sufficiently.
4.4 Towing away

Maximum towing speed in accordance with permissible final speed (the gear oil level required is also
necessary for tow operation).
It is only possible to operate the lever of the cut-off device manually and when the vehicle is standing still
(do not use any auxiliary tools).
Engage the lever (I) in the "OFF" position with screw (II)!
OFF ON
"OFF" is only possible if there is no torque between the drive input and the drive output. On switching on
"ON" it may be necessary to slightly turn the driven shaft so that the shifting claws can engage.
ATTENTION:
No braking force on the parking brake in the case of lever position "OFF" on the shut-down device.

Revised: 08.2004 1305 / 1505 / 1605 / 1705 Mobile
5 Maintenance
5.1 Type of oil
For the type of oil see Chapter 18 on "Maintenance"
5.2 Checking the oil level

On checking the oil level it is essential that the safety regulations stipulated in accordance with §6
of the Accident Prevention Regulations for driving gear in Germany or the respective regulations
of any other country be observed. The vehicle is to be prevented from rolling, for example, by
means of blocks.
• Weekly oil check

• Carry out oil checks when the diesel engine is stationary.
• Do not check the oil level before the diesel engine has been switched off for 5 minutes.
The level of oil in accordance with the oil level test boring!
Vertical fitting position Horizontal fitting position
I = Oil drain screw M26x1.5

II = Oil filler screw and oil level check screw M26x1.5
III = Ventilator - multi-disc brake

1305 / 1505 / 1605 / 1705 Mobile Revised: 08.2004
5.3 Oil change and oil fill-up quantity

The first oil change is carried out after 100 hours of operation.
The following oil changes are carried out after 2,000 hours of operation, but at least once a year.
• Oil changes must be carried out as follows:

• Switch off the engine
• Open the oil drain screw (I) with the O-ring and let the used oil drain off when the gears are at operating
temperature and the vehicle is in the vertical position.
• Clean the oil drain screw and the sealing area on the housing and mount again with a new O-ring.
• Loosen the oil filler screw and clean the sealing area on the housing.
• Fill the oil in accordance with the ZF lubrication chart into the oil charging hole (II) up to the overflow
level.
• Check the oil level after approximately 2 minutes and top up if necessary.
• Mount the oil filler screw with a new O-ring and screw it in.
• OIL QUANTITY: Vertical gears installed approx. 2.9 litres

Horizontal gears installed approx. 3.2 litres
The figures indicated are approximate values!

Revised: 08.2004 1305 / 1505 / 1605 / 1705 Mobile
6 Charts
Construction 2 HL-100
SEPARATE INSTALLATION
Chart-1
1 Hydraulic motor construction

2 Storage for cut-off pressure multiple disk brakes
3 Multiple disk clutch
4 Multiple disk brake
5 Planetary drive
6 Cut-off device
7 Switch control
8 Rotor pump for the control pressure switch control and for gear lubrication
9 Spur pinion
10 Disk springs for the multiple disk brake and the multiple disk clutch
11 Choker valve
12 Drive
13 Pinion end

1305 / 1505 / 1605 / 1705 Mobile Revised: 08.2004
Measuring points and connections 2 HL-100
SEPARATE INSTALLATION AND AXLE ATTACHMENT

VERTICAL AND HORIZONTAL FITTING POSITION
Chart-7
The marked positions (e.g. M) correspond to the positions in the gearbox diagram.
SEPARATE INSTALLATION AND AXLE ATTACHMENT

VERTICAL FITTING POSITION
VIEW X
SEPARATE INSTALLATION
HORIZONTAL FITTING POSITION VIEW Y

Revised: 08.2004 1305 / 1505 / 1605 / 1705 Mobile
CONNECTIONS:
P1 ROAD SPEED DELIVERY CONNECTION M16X1.5
P2 CROSS-COUNTRY SPEED DELIVERY CONNECTION M16X1.5
N INDUCTANCE TRANSMITTER CONNECTION (OPTIONAL) M18X1.5
E OIL LEAKAGE CONTROL CIRCUIT M14X1.5
MEASURING POINTS:
J ROAD SPEED M14X1.5
M CROSS-COUNTRY SPEED M14X1.5
L PUMP PRESSURE FOR GEAR SAFETY DEVICE M10X1
AND GEAR LUBRICATION
PIPES:
B HOSE PIPE FROM THE GEAR SAFETY DEVICE TO THE MULTIPLE DISK BRAKE
K HOSE PIPE FROM THE GEAR SAFETY DEVICE TO THE MULTIPLE DISK CLUTCH
S SUCTION PIPE FOR THE ROTOR PUMP (ACTUATION PRESSURE GEAR SAFETY DEVICE AND
GEAR LUBRICATION)

1305 / 1505 / 1605 / 1705 Mobile Revised: 08.2004
Gearbox diagram 2 HL-100

GEARBOX WITH GEAR SAFETY DEVICE-CROSS-COUNTRY SPEED
LEGEND:
GEAR BOX
GEAR SAFETY DEVICE
SYSTEM PRESSURE
GEAR SAFETY DEVICE ACTUATING PRESSURE
LUBRICATION OIL
RETURN TO THE TANK
BREATHING
OIL LEAKAGE CONTROL CIRCUIT
SUCTION PIPE
SYMBOLS:
✉ MEASURING POINT
● GEAR INTERFACE
X BREATHER
PIPES:
B PRESSURE PIPE FROM THE GEAR SAFETY DEVICE TO THE MULTIPLE DISK BRAKE
K PRESSURE PIPE FROM THE GEAR SAFETY DEVICE TO THE MULTIPLE DISK CLUTCH
S SUCTION PIPE FOR THE ROTOR PUMP (ACTUATION PRESSURE GEAR SAFETY DEVICE AND
GEAR LUBRICATION)
MEASURING POINTS:
J ROAD SPEED
M CROSS-COUNTRY SPEED
L PUMP PRESSURE FOR GEAR SAFETY DEVICE
CONNECTIONS:
P1 ROAD SPEED DELIVERY CONNECTION
P2 CROSS-COUNTRY SPEED DELIVERY CONNECTION
E OIL LEAKAGE CONTROL CIRCUIT
N INDUCTANCE TRANSMITTER CONNECTION (OPTIONAL)

Revised: 08.2004 1305 / 1505 / 1605 / 1705 Mobile
1 = Gear box 2 = Gear safety device

3 = Check valve 4 = Gear piston
5 = Shuttle check valve 6 = Leakage check valve
7 = Pressure-control valve 8 = Lubrication oil pump with a change-over for the
gear oil supply and the actuating pressure of the
gear safety device
9 = Gauze filter 10 = Pinion end
Filter surface approx. 125 cm²
Filter fineness approx. 200 my
11 = Disconnection device 12 = Oil supply, gear box
13 = Multiple disk brake 14 = Oil supply, gear control
15 = Hydraulic motor 16 = Multiple disk clutch
17 = Multiple disk brake breather 18 = One-way restrictor
19 = Storage

1305 / 1505 / 1605 / 1705 Mobile Revised: 08.2004
STRUCURAL COMPONENTS FOR GEAROX CONTROLS 2 HL-100

CHART 9
PLEASE NOTE: THE STRUCTURAL COMPONENTS FOR THE GEARBOX CONTROLS ARE NOT
WITHIN THE SCOPE OF ZF SUPPLY!
TANK
3
LEGEND:
CONDUCTO ELÉCTRICO
CONDUCTO HIDRÁULICO
1 VALVE BLOCK GEARBOX CONTROLS 2 SLEWING DUCT

3 NOMINAL WIDTH 10 mm 4 GEAR CHANGE VALVE
5 ACCUMULATOR 6 FASCHIA
7 BRAKE VALVE 8 PUSH BUTTON PARKING BRAKE
9 INDICATOR LAMP 10 TOGGLE SWITCH
11 MANOMETRIC SWITCH 12 RELAY
13 CONTROL SWITCH 14 PILOT CONTROL VALVE
15 TOGGLE SWITCH PARKING BRAKE 16 CHECK VALVE
17 PILOT CONTROL PUMP 18 TANK LINE GEARBOX CONTROL VALVE
BLOCK
19 RETURN FILTER 20 TANK POWER LINE
21 PILOT CONTROL 22 NOMINAL WIDTH 15 mm
23 PRESSURE CONTROL VALVE 30+5 bar (A) 24 BRAKE VALVE 7 to 15 bar (B)
A) FOR CONSUMERS WITH A CONTROL PRESSURE EXCEEDING 35 bar, A PRESSURE

REDUCTION VALVE IS TO BE INSTALLED INSTEAD OF A PRESSURE CONTROL VALVE
B) PRESSURE SETTING DEPENDENT ON THE WEIGHT OF THE VEHICLE

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2 HL-100 Determining gear control oil quantity

Chart-14
1 Gear control group of
valves
2 Storage
3 Rotary transmission
leadthrough
4 Control line for road or
cross-country speed
min NW 10
5 Panel
6 End of control line for
P1 and P2 gear
connections
8 Stop valve
9 Measuring vessel
10 Manometer
11 Check valve
12 Control pump
13 Filter
30 + 5 bar
15 Brake valve
16 Brake on-off valve
17 Gear shift valve
Procedure for setting the pressure and determining the quantity of oil
Gauges for oil viscosity of 110 cSt (equivalent to sea 20W at 30 °C)
• Put the brake on-off valve and the gear shift valve into the shift positions indicated. Insert the pressure control
valve and the manometer at the end of the P1 control line and close the stop valve for the measuring vessel.
• Setting the actuating pressureSet the pressure control valve for the actuating pressure in the case of the low
engine idling speed at at least 30 bars. Max. permissible pressure: 35 bars in the case of high engine idling
speed.
• Determining the quantity of oil on maintaining the actuating pressure setOpen the stop valve. Set the pressure
control valve at the end of the P1 control line at 24+1 bars. The required quantity of oil in the measuring vessel is
at least 5.5 l/min. in the case of low engine idling speed.
A. The pressure control valve simulates the power for releasing the clutch or the brakes, and it is located on the piston
due to the spring pre-stress. The valve is only required for measuring the quantity of oil.
Note: Should other consumers be connected to the control circuit, a preferred flow divider may become necessary to
ensure the minimum quantity of oil (5.5 l/min.) for the gear control.

1305 / 1505 / 1605 / 1705 Mobile Revised: 08.2004
Chart-15
Fault finding 2 Hl-100
Problem Cause Remedy
The vehicle does not move in 1. and Actuating pressure is lower than 26 bars Set the actuating pressure:
2. gear. +/- 10 %, it is not possible to drive. 30 bars + 5 bar.
The parking brake valve does not switch on Replace the group of valves (as an emergen-
receiving a power supply. cy measure, operate the valve mechanically.
No power supply to the brake valve. Fault in the wiring or switch.
Release device open. Set the release device at "ON" and secure it
with a screw.
Pressure switch does not transmit signals. Replace the pressure switch or check cable
connections.
The vehicle does not move in 1. or Gear switch valve does not switch on Replace the group of valves for the gear con-
2. gear. receiving a power supply. trol.
No power supply to the gear switch valve. Fault in the wiring or switch.
Switching down from 2. to 1. gear at No lubrication oil pressure. Replace the gear safety device or the whole
any speed. gearbox.
No lubrication oil in the gear sump. Bring the oil in the gearbox up to the right le-
vel.
Brake valve of the hydraulic motor is Piston clear of the brake (gear) not ventila- Ventilate the brake (gear) at the breather.
actuated while switching gears ted.
(usually from 1. to 2.) The pressure switch opens while switching
gears.
This stops the stream of oil from the pump to
the hydraulic motor.
Insufficient stream of control oil to the gear Check the control pump, the control leads
(5.5l/min.in comparison to 24 bars + 1 bar). and the actuating pressure safety valve.
The pressure switch opens while switching Check the actuating pressure.
gears. This stops the flow of oil from the
pump to the hydraulic motor.
Holding load of the parking brake in- Non-operation pressure during parking brake Check the non-operation pressure during the
sufficient. function too high. parking brake function.
Noise when switching from 1. to 2. No lubrication oil in the gear sump. Bring the oil in the gearbox up to the right le-
gear. vel.
No lubrication oil pressure despite sufficient Check the suction pipe of the lubrication oil
quantity pump or replace the gear safety device or
the whole gearbox.
Gear temperature too high Too much oil. Check the level of oil.
(> 110 °C)
Oil level rises during operation. Leakage from the hydraulic motor to the ge- Check the sealing of the hydraulic motor
arbox. This fills up the gearbox. shaft and the gears. If necessary, replace the
hydraulic motor or the gearbox.
Leakage from the piston clearances of the Replace the gearbox.
clutch or the brake to the gears.
Leakage from the gear safety device to the Replace the gear safety device or the whole
gearbox. gearbox.
If the gearbox is installed on the axle there Replace the axle with the gearbox.
may be a leakage from the axle to the gear-
box.
(Usually if there is a leakage from the piston
of the service brake).
Brakes (1) or clutch (2) scraping. Residual pressure on the clutch or brake too Check the control system and the tank pipe
high (max. 1.0 bar) of the group of valves.
Gears block during switching Piston clearing of the brake (gear) not venti- Ventilate the brake (gear) at the breather.
(usually from 1. to 2.) ª. lated.
Stream of control oil to the gears insufficient Check the control pump, control leads and
(5.5l/min. in comparison to 24 bar + 1 bar) actuating pressure safety valve. Check the
actuating pressure.

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Chart-16
Axles for automobiles, utility vehicles

and machines TE-ML 05 lubrication chart
Construction Authorized lubricants for service fill-ups
Axles and central axial drives Gear oil with and without limited slip additives
Wheel heads and semi-axles - API GL-5
Axle parts
- MIL-L-2105D
- SÄE 80W-90 / 85W-90 / 85W-140 /90
Authorized commercial products: Pages 2 and 3
Axles and central axle drives with Gear oil with limited slip additives
wet multi-disc brakes and / or - API GL-5
multi-disc locking differentials
- MIL-L-2105D
- SÄE 80W-90 / 85W-90 / 85W-140 / 90
Authorized commercial products: Page 3
Semi-axle (planetary end drive output) for Gear oil with and without limited slip additives
T-7100/T-7200 - API GL-5
- MIL-L-2105D -
SÄE 85W-140/90 / 85W-90 / 85W-140 / 90
Authorized commercial products: Pages 2 and 3
When using multigrade gear oils, the basic oil and the EP additives may not comprise more than
2 weighted % of the dissolved additives (VI improver, pour point depressant, etc.).
A lithium based saponification multi-purpose lubricant, NLGI category 2 is to be used at lubrication points.
Instructions for lubricant suppliers: any adjustments to the composition of authorized products or to the
trademark and any differences in quality at home and abroad are to be reported immediately.

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7 INSTRUCTIONS FOR REPAIR
INFORMATION ON THE INSTRUCTIONS FOR REPAIR

These instructions for repair only contain details of the dismantling and assembly of one model.
Qualified specialists will easily be able to recognise any work to be carried out on other models which
deviates from these instructions.
The perspective illustrations in the respective spare-parts list may also be referred to.

Revised: 08.2004 1305 / 1505 / 1605 / 1705 Mobile
7.1 General instructions

Any work carried out is to be done properly and professionally. Gearboxes removed from vehicles must
therefore be cleaned prior to being opened.
It is essential that tools stipulated are used.
The special tools have a 10-digit reference number and can be ordered from the ZF in Passau.
All of the parts are to be cleaned after having been dismantled.

This applies in particular to corners, pockets and angles on casings and covers.
Old sealing material is to be fully removed.
Lubrication oil drillings, nuts and pipes are to be checked to ensure that they are not blocked. They must
be free of any deposits, impurities and preservatives.
The latter applies in particular to new parts.
Any parts which are inevitably damaged on being disassembled must be replaced,
e.g. rotary shaft lip seals, O-rings, lip seals, cup leather, protective caps, etc.
Parts such as rolling bearings, stop discs, synchronous parts, etc. which are in the driving range and are
subject to normal wear and tear are to be checked by a specialist who is to decide on whether they can be
used again or not.
Heating plates, heating elements or heating furnaces are to be used to heat up bearings, etc. Never use a
direct flame for heating. Another possibility would be to put the bearing in a container filled with oil which
is then heated up with a flame.
Ball bearings, covers, flanges and similar fittings should be heated up to approximately 90°C to 100°C.
Shrunk-on parts must be driven once they have cooled down to ensure that the equipment is perfect.
Both parts must be lubricated before shafts, bearings, etc. are pressed in or set.
All of the settings, test data and tightening torques are to be maintained on assembly.
The units are oiled subsequent to any repair work carried out.
The procedure to be undertaken and the types of oil authorized can be seen in the operating instructions
or the lubricating instructions and the respective list of lubricants.
The oil check and oil drain stoppers are to be closed with the tightening torques stipulated subsequent to
filling up oil.

1305 / 1505 / 1605 / 1705 Mobile Revised: 08.2004
7.2 Important information on working safety

Persons carrying out repair work on units are always responsible for work safety themselves.
It is essential that currently-valid safety regulations and statutory requirements are observed in order to
avoid injury to persons and damage to products when repair and maintenance work is being carried out.
It is essential that these products be properly maintained by professionally-trained, specialised

members of staff.
The party carrying out repair work is responsible for any such training measures.

Revised: 08.2004 1305 / 1505 / 1605 / 1705 Mobile
7.3 Designation of statutory units

Note: linear density in kg/m; areal density in t/m²
Term Symbol New Old Translation Comments

Masse m kg (kilogram) kg
Mass
Mass
Masa
Kraft F N (Newton) kp lkp = 9,81 N
Force
Force
Fuerza
Arbeit A J (Joule) kpm 0,102 kpm = U = 1 Nm
Work
Travail
Trabajo
Leistung P KW (Kilowatt) PS (DIN) 1 PS = 0,7355 KW
Power 1 KW = 1,36 PS
Puissance
Potencia
Drehmoment T Nm (Newtonmeter) kpm 1 pkm = 9,81Nm T (Nm) =
Torque F (N)*r(m)
Couple
Par de torsión
Kraftmoment M Nm (Newtonmeter kpm 1 pkm = 9,81Nm M (Nm) =
Moment (Force) F (N)*l(m)
Moment (Force)
Momento de fuerza
Druck (Über-) pü bar atü 1,02 atü = 1,02 kp/cm² = 1 bar
Pressure (Overpress) = 750 torr
Pression (Sur-)
Presión (sobrepresión)
Drehzahl n min-1
Speed
Nombre de Tours
Revoluciones
Conversion table
25,40 mm = 1 in (inch)
1 kg (kilogram) = 2,205 Ib (pounds)
9,81 Nm (1 kpm) = 7,233 ibf x ft (pound force foot)
1,356Nm (0,138kpm) = 1 Ibf x ft (pound force foot)
1 kg / cm = 5,560 Ib / in (pound per inch)
1 bar (1,02 kp/cm²) = 14,233 psi (pound force per squar inch Ibf/in^ )
0,070 bar (0,071 kp/cm²) = 1 psi (Ibf/in²)
1 litre = 0,264 Gallon (Imp.)
4,456 litres = 1 Gallon (Irnp.)
1 litre = 0,220 Gallon (US)
3,785 litres = 1 Gallon (US)
1609,344 m = 1 Mile (Landmeile)
0 °C (centigrade) = + 32 °F (Fahrenheit)
0 °C (centigrade) = 273,15 Kelvin

1305 / 1505 / 1605 / 1705 Mobile Revised: 08.2004
7.4 Tightening torques

Tightening torques for screws (in Nm) in accordance with ZF standard 148
Coefficient: µ ges. = 0.12 for screws and nuts without any reworking, as well as phosphatized nuts.
Tightening manually!
Unless otherwise indicated, refer to the following list for tightening torques:
Metric ISO standard thread BIN 13, Sheet 13

Dimensions 8,8 10,9 12,9
M4 2,8 4,1 4,8
M5 5,5 8,1 9,5
M6 9,5 14 16,5
M7 15,5 23 27
M8 23 34 40
M10 46 68 79
M12 79 117 135
M14 125 185 215
Ml 6 195 280 330
Ml 8 280 390 460
M20 390 560 650
M22 530 750 880
M24 670 960 1120
M27 1000 1400 1650
M30 1350 1900 2250
M33 1850 2600 3000
M36 2350 3300 3900
M39 3000 4300 5100
Metric ISO fine thread BIN 13, Sheet 13

Dimensions 8,8 10,9 12,9
M8x1 24,5 36 43
M9x1 36 53 62
M 10x1 52 76 89
M 10 x 1,25 49 72 84
M 12 x 1,25 87 125 150
M 12x1,5 83 122 145
M 14 x 1,5 135 200 235
M 16x1,5 205 300 360
M 18x1,5 310 440 520
M 18x2 290 420 490
M 20 x 1,5 430 620 720
M 22 x 1,5 580 820 960
M 24 x 1,5 760 1090 1270
M 24x2 730 1040 1220
M 27 x 1,5 1110 1580 1850
M 27x2 1070 1500 1800
M 30x1,5 1540 2190 2560
M 30x2 1490 2120 2480
M 33 x 1,5 2050 2920 3420
M 33x2 2000 2800 3300
M 36x1,5 2680 3820 4470
M 36x3 2500 3500 4100
M 39x1,5 3430 4890 5720
M 39x3 3200 4600 5300

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7.5 Gear structure
Power flow
a = 1. gear
b = 2. gear
c = braking effect
1 Drive gearbox with integrated on-off valves

2 Hydraulically-released disk springs
3 Multiple disk brake
4 Multiple disk clutch
5 Planetary drive
6 Cut-off device
7 Inductive transmitter for electro-hydraulic speed control device
8 Hydraulic speed control device
9 Emergency steering pump
10 Directly-attached axle construction
Gear structure
The 2 HL 100 and 2 HL 110 axle transmission gear-boxes comprise a planetary-structured two-speed power shift gear and
a helical gear wheel in a two-shaft arrangement.
The power shift device for the planetary drive comprises a case-fortified multiple disk brake (3) and a rotating multiple disk
clutch (4), both of which are operated by means of disk springs (2) and are hydraulically released. Locking the brake and
the clutch will block the planetary drive (5) so that it assumes the function of an emergency and parking brake.
A mechanically-operated dog clutch (6) is located between the planetary drive and the spur pinion. The power flow in the
clutch can be cut off with this cut-off device, enabling the machine to be towed away without any particular restrictions.
Depending on the type of vehicle, hydraulic motors with constant or adjustable working volumes can be used as a drive.
Gear drive
The gear drive is adapted to the respective machine. For an open circuit a purely hydraulic drive is preferred and for a closed
circuit the drive is electro-hydraulic. Both drives comprise a respective speed control device which stalls activated switch-
backs until the vehicle has reached the corresponding speed. This protects the hydraulic motor against over-speeding.
The clutch for the axle transmission gearbox can also be automated in combination with the electro-hydraulic drive. Hydro-
static drive and gear shifting will then be carried out automatically.
In the case of automatic shifting the shift points have been selected in such a manner that the best possible power is
achieved for the machine.

1305 / 1505 / 1605 / 1705 Mobile Revised: 08.2004
7.6 Instructions for commencement of operation, operating and

maintenance
Fill up with the right quantity of the oil type stipulated prior to commencing with operation. On filling up for
the first time, please note that some of the hollows have not yet been filled with oil, so that the level of oil
will need to be checked again after a short distance has been driven.
OIL QUANTITY: Gearbox installed vertically approx. 3,4 litres (*)

Gearbox installed horizontally approx. 3,8 litres (*)
Permissible oils:
see the operating instructions.
When checking the oil level it is essential to observe the safety regulations stipulated in accordance with §
6 of the Accident Prevention Regulations for power units!
On initial operation, it is essential that the machine be switched into the off-the-road gear with the control
pump running for approx. 2 minutes in order to prevent the drive from running dry. The same measure is
to be undertaken when replacing the gearbox or the hydraulic motor.
The gearbox control system is de-aerated with the control pump running. Ventilating is carried out with a
bleeder screw on the transmission brake - on doing so change gears several times.
When the parking brake is operated it is essential to ensure that operating the accelerator would not have
any effect (drive valve in NEUTRAL).
This also applies if the control pressure drops to an unacceptable level (< 24 bar).
The first oil change is carried out after 100 hours of operation.
Subsequent oil changes are carried out after 2000 hours of operation, but at least once a year.
Note on (*): The filler or control screws are mandatory

see installation overview on page 27.

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7.7 Installation overview and instructions on filling up with oil

Gearbox:
1 filling up with oil and checking
Instructions on filling up with oil
2 draining off oil
Separate installation,
vertical installation
Separate installation,
horizontal installation

1305 / 1505 / 1605 / 1705 Mobile Revised: 08.2004
7.8 Instructions on moving or towing away the vehicle in an emergency

There is a claw clutch between the planetary drive and the pinion drive.
When moving the vehicle or towing it away in an emergency, the flow of power between the drive output
(pinion drive) and the hydraulic engine will be cut off
Remove the adjusting screw, put the control lever in the

"OFF" position (direction of arrow) and fix it again by me-
ans of a hexagon screw - see illustration!
Please note: The permissible towing speed is equivalent

to the driving speed!
The distance for towing is unlimited!

Revised: 08.2004 1305 / 1505 / 1605 / 1705 Mobile
7.9 Examples of tooth contact for Gleason-type gear teeth
Ideal tooth-contact pattern i.e. pinion distance is correct
Figure 1/3/5
Coast side (concave)
Figure 1
Figure 2/4/6
Drive side (convex)
Figure 2

1305 / 1505 / 1605 / 1705 Mobile Revised: 08.2004
Pinion distance must be increased Pinion distance must be decreased

Revised: 08.2004 1305 / 1505 / 1605 / 1705 Mobile
7.10List of tools for assembling and disassembling

DISASSEMBLING ASSEMBLING Name/application of special tools (S)
Mounting car complete with turning device
for axles and gearboxes.

Universal application.
In connection with:
Illustration 76 Receptacle
Axle drive
Tension ring
Illustration 10 Illustration 209 M12 adjusting screw # (1 set = 2 screws)
for assembling and dismantling the drive box.
Illustration 16 Adjusting spanner

Illustration 40
Illustration 302 for removing the sealing washer from the housing bore.
Illustration 304 For removing the planetary wheel from the planetary pin.
For removing the shaft sealing ring from the gearbox.
– Drive output –
Two screws are required.
Illustration 21 Illustration 187 Mounting device #
for initial tension of the disk spring set
Illustration 38 Inner extractor
for removing the pinion cage.

In connection with:
counter support
Illustration 41 Double-armed extractor
for removing the inner ring of the tapered bearing of the planet
pin.
Illustration 46 Mounting levers (1 set = 2 units)

Illustration 62
for pressing off shaft sealing rings and housing parts.

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for removing the needle bearing from the housing bore hole.
– Pinion drive –
in connection with:
counter support
Illustration 67 Inner extractor #
for removing the shuttle valves.

In connection with:
extractor hammer #
Illustration 71 Illustration 101 M 12 # pulling-off screw (1 set = 2 units)

Illustration 246
for removing and mounting the full gearbox and the differential
cage.
Illustration 80 “Super” gripping device #
for removing the inner ring of the tapered bearing from the
differential cage housing.
In connection with:
pressure piece #
forcing insert #
Illustration 86 “Super” gripping device #
for removing the inner ring of the tapered bearing of the driving
pinion.
In connection with:
basic appliance #
for pulling out the outer ring of the tapered bearing from the hou-
sing bore.
– Differential cage –

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Re. illustration on Barrel gauge #

page 25
for measuring the axle drive housing. In connection with:
stop ring #
stop ring #
measuring shaft
adaptor (1 set - 2 units)
Illustration 94 Holding device *
for inserting the tapered roller bearing outer ring into the hou-
sing bore
– differential cage –
for inserting the tapered roller bearing outer ring into the
housing bore.
Illustration 99 Holding device * #
for inserting the shaft sealing ring into the housing bore
– differential cage –
for the axial fixation of the driving pinion

Illustration 106 Press-on sleeve
for inserting the tapered roller bearing outer ring into the
gearbox housing
Illustration 110 Mounting fork

Illustration 116
for engaging the drive flange when screwing and unscrewing
the flange screws.

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for checking the rolling moment.

In connection with:
holding device * #

Illustration 323
Illustration 328 for inserting the shaft sealing ring into the gearbox housing
– drive output –

Illustration 327
Illustration 330 for pressing the safety plate onto the screw heads of the drive
flange screws.
Illustration 133 Magnetic measuring support
for determining the tooth profile clearance.

In connection with:
a dial gauge
Illustration 138 Press-on sleeve
for pressing the ball-bearing with the bearing cap onto the
helical gear.
for pressing the needle bush onto the helical gear.
for inserting the shaft sealing ring into the guide bushing
Illustration 175 Slip bushing
to facilitate mounting of the seal onto the drive shaft.

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Illustration 188 Hydraulic connection #

Illustration 216
In connection with
Illustration 189 HP pump

Illustration 217
with a manometer, high-pressure pipe and brake connection
for checking the impermeability of the hydraulic brake
operation.
Illustration 198 Checking gauge #
for measuring the “A” reduction dimensions on the brakes.

The disc spring set is pre-stressed.
Illustration 197 Tensioning bar

Illustration 203
for pre-tensioning the discs.
for the axial initial tension of the motor shaft.

In connection with:
counter support
for mounting the Turcon ring onto the piston
for mounting the sealing elements onto the control piston.

In connection with:
calibrating bushing
Illustration 237 Adjustment screw M 8 # (1 set = 2 units)
to facilitate mounting the pump cap.

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Illustration 306 Ring screw range
for various lifting tasks.
Illustration 309 Illustration 316 Vice-grip pliers
for deflecting the circlip into and out of the cap.
Illustration 320 Hot air fan 220 V

Hot air fan 110 V
for heating up housing and bearing parts.

Illustration 321 M 12 # adjusting screw (1 set = 2 units)
to facilitate mounting the cap onto the gearbox housing.
Handle
for diverse holding devices *.
# Very special tools!

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7.112 HL 100 switch protection

Model B: aluminium diecast switching
for extracting the needle bearing from the housing.

In connection with:
counter-sets #
Illustration 311 Drive mandrel #
for inserting the needle bearing into the housing drill hole.
Installation dimension of 0.2 + 0.5 mm results on stopping.
Illustration 312 Slip bushing #

Illustration 312a
to facilitate positioning the sealing in the ring groove of the
piston.
In connection with:
calibrating bushing
Illustration 322 M 8 # adjusting screw (1 set = 2 units)

Illustration 325
to facilitate mounting and removing housings parts, sealing
and distance plates.
Inner forcing pliers set #
for deflecting inner-tension circlips in accordance with

DIN 472.
Comprises I1 to I4 straight tongs.
Outer forcing tong set #
for deflecting outer-tension circlips in accordance with

DIN 471.
Comprises A1 to A4 straight tongs.
# Very important special tools for partial maintenance

(repairing parts subject to wear and tear).

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7.12Shift protection device:
1 Housing 22 Needle bush

2 Sealing 23 Set of rotors
3 Pressure spring 24 Gauze filter
4 Screw plug 25 Ball
6 Screw plug 27 Circlip
7 Sealing ring 28 Hexagon screw
8 Piston 29 Sealing
9 Pressure control valve 30 Cap
10 O-ring 31 O-ring
11 O-ring 32 Pan head screw
12 Check valve 33 Hexagon screw
13 O-ring 34 Pan head screw
14 O-ring 35 Disc
15 Check valve 36 Pump shaft
16 O-ring 37 Pump shaft
17 O-ring 38 Pump cap
18 O-ring 39 Ball bearing
19 Check valve 40 Circlip
20 O-ring 41 Connection piece
21 O-ring 42 O-ring

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8 Dismantling
8.1 Removing the clutch
Fasten the gearbox to the mounting car
Loosen the stopper (arrow) and drain off the oil.
(S) Mounting car equipped with turning device

(S) receptacle
Remove both of the cables - see arrows!

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Remove the fixing screw - see arrow!
Deflect the snap ring (arrow)
Loosen all of the pan head screws to the same extent,

install two adjusting screws and separate the drive housing
from the gearbox housing.
Please note: the gearbox housing springs have been pre-

stressed!
(S) (M12) adjusting screw
Remove both of the disc springs.

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Close the feeder (arrow) and press the pistons out of the
housing drill holes by means of compressed air.
Remove the screw plug and the ventilator (arrow).
Remove the sealing ring and the bearing ring from the ring
groove of the housing (arrow).
Deflect the snap ring.

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Pull the sealing disc out of the housing drill hole by means
of an offset screw driver.
(S) Adjustment
Remove the O-Ring (arrow).
Remove the set of discs and the end plate.
Deflect the circlip (arrow).

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Remove the clutch unit.
Align and fix the sun wheel by means of a mounting device,

deflect the circlip and release the set of disc springs.
(S) Mounting device
Remove the disc and the sun wheel after they have been
cleared.
Remove the ring gear from the motor shaft.

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Deflect the circlip and remove the plug washer.
Remove the set of discs.
Remove the metal sheet.
Lever the inner disc supports off the piston.

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Lever the piston off the motor shaft.
Remove the set of disc springs.
Remove the sealing ring and the O-Ring.

Remove the disc (arrow).
Please note: Sealing elements must definitely be

renewed!
Deflect the circlip.

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Remove the circlip from the ring groove of the guide bush
(Ø 85 mm).
Remove the guide bush from the motor shaft.
Deflect the snap ring and remove the rotary shaft lip seal
(arrow).
Deflect the circlip and press the bearings from the shaft.

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Remove the throttle valve.
8.2 Removing and dismantling the

planetary drive
Deflect the circlip (arrow).
Turn the housing 90°.
Separate the pinion cage from the helical gear by means of

an inner extraction device and remove it.
(S) Inner extraction device

(S) counter support

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Remove the planet wheel from the planet pin by means of

an offset screwdriver.
Remove individual parts that are released.
(S) Adjustment
Remove the bearing inner ring.
(S) Double-armed extractor
Deflect the circlip and remove the ball bearing.
8.3 Switching off and removing and

dismantling the spur wheel
Loosen the hexagon screw (control lever fixing) and
remove the sliding sleeve with the slide rings.

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Loosen the screw plug.
Knock out the dowel pin (arrow).
Lever the control lever out of the housing drill hole and
remove the exposed gearshift fork.
(S) Mounting lever
Remove the suction line.

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Loosen the pan head screws (4 screws) and take the

switch protection device off the housing.
Pull the rotary set off the shaft and remove the driving ball
(arrow).
Lever the pump cap out of the housing bore.

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Remove the pump shaft.
Detach the helical gear (illustration 54) and take it out

of the housing (illustration 55).

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Deflect the circlip and remove the adjusting disc.
Remove the shifting claw and the distance ring.
Please note: Depending on the model, with or without a

spacer, see spare parts list!
Pull the needle bearing out of the housing bore by means

of an inner pull-out device.

(S) counter support
Press the helical gear out of the cap piece of the bearing.

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Deflect the circlip and press the ball bearings out of the cap
piece of the bearing.
Lever the ball bearing from the collar of the helical gear.
(S) Mounting lever

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8.4 Dismantling the shift protection device

Model A: cast-iron switching
Please note: Should damage be ascertained in the region

of the lubricant pump (rotary or valve casing), the entire
shift protection device is to be replaced.
Remove the shift piston.
Dismantle the shift piston.
Please note: The threaded pin (arrow) has been secured

with Loctite - warm up prior to screwing out!
Remove the piston valve.
Remove the shuttle valves.

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Remove the shuttle valves.
Please note: Special tools (S) must be used to remove the

bushings, see illustration.
(S) inner extraction device

(S) extractor hammer
Remove the panel.
Please note: The panel is secured with Loctite!
8.5 Dismantling the drive output, axle

drive housing and differential
Model A: The gearbox is mounted on the axle.
Please note: Dismantling the drive output of model B

– separate gearbox installation – is described from
page 104 on.
Release the hexagon screws, remove and take off the drive
flange.
Lever out the shaft sealing ring.

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Loosen the hexagon screws and separate the axle drive

from the gearbox housing by means of pulling-off screws.
Please note: Use two adjusting screws. Pay attention to

the released bearing inner ring and the adjusting disc.
Pull the drive output wheel off the driving pinion.
Remove the protective sheeting.
Push the bearing outer ring out of the housing drill hole.

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Lever the shaft sealing ring out of the housing bore.
Lift up the axle drive housing with the mounting device.
Drive out both of the dowel pins.
(S) receptacle - axle drive

(S) straining ring
Release the initial tension of the differential bearing by

means of loosening the adjusting nut.
Loosen the hexagon screws and remove both of the bea-

ring supports and the adjusting nuts.
Please note: Mark the bearing supports and the

installation position on the axle drive housing.

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Lift the full differential unit out of the axle drive housing.
Remove both of the bearing inner rings.
(S) "Super" gripping device

(S) carrying piece
(S) pressure unit
Loosen the pan head screws.
Separate the differential cage parts and remove the expo-

sed individual parts.

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Press the ring gear off the differential cage.
Remove the driving pinion.
Remove the O-ring and the bushing.
Pull the tapered roller bearing off the driving pinion.
(S) "Super" gripping device

(S) basic device

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Pull the bearing outer ring out of the housing bore by

means of an inner pull-out device.

(S) counter support
Remove the adjusting disc.

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9 ASSEMBLY
9.1 Axle drive housing, drive output and
differential
Model A - the gearbox is mounted on the axle.
Please note: Mounting the drive output of Model B - sepa-

rate gearbox installation - is described from page 107 on.
Attention: If the ring gear or the driving pinion is damaged,

both parts must be renewed at the same time. On installing
a completely new ring gear set, please ensure that the ring
gear and the driving pinion have the same pairing numbers.
The drawing must be referred to when replacing a full set of

ring gears or the axle drive housing.
9.1.1 Thickness of the adjusting disc in order to

achieve perfect tooth bearings
Please note: The following measuring procedures must be
Draft for the determination of
carried out with absolute precision. Incorrect measuring the adjusting disc
will result in faulty contact pattern and will make it necessa-
ry to remove and remount the driving pinion and the diffe-
rential (partly) after the contact pattern has been inspected.
Install shims (3) and temporarily fix both of the bearing sup-
ports with hexagon screws. Mount the barrel gauge (1) and
insert the gauge shaft (2) - see the drawing.
For housing
1 (S) barrel gauge
(S) stop ring
(S) stop ring
2 (S) measuring shaft
3 (S) shim
Determine the gap (dimension b) between the measuring

piston and the measuring shaft with a feeler gauge.
Dimension b for example ........................ 0,85 mm
Calculation example "A":

Dimension a (= measuring piston) .......... 134,00 mm
Dimension b .......................................... + 0,85 mm
Dimension c (1/2 Ø measuring shaft) ... + 15,00 mm
equals dimension X 149,85 mm

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Determine the bearing height.

Bearing height for example ..................... 36,50 mm
Read the pinion dimension.

Pinion dimension for example (112 -0.15 ) 111,85 mm
Calculation example "B":

Bearing .................................................. 36,50 mm
Pinion dimension ................................... +111,85 mm
Equals dimension Xi 148,35 mm
Calculation example "C":

Dimension X .......................................... 149,85 mm
Dimension Xi .......................................... - 148,35 mm
Difference = thickness of the s = 1,50 mm
adjusting disc
Remove the shims and the measuring shaft again.
9.1.2 Installing the driving pinion

Put the adjusting disc (acc. to the sample calculation
(s = 1.50 mm) into the housing bore.

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Undercool the bearing outer ring and insert it until it rests.
(S) Holding device

(S) Handle
Insert the second bearing outer ring into the housing drill
hole until it rests.
(S) Holding device

(S) Handle
Install the connection piece - see arrow!
Please note: Install a new sealing edge ring.

Use Loctite (no. 586)
Install the entire oil pipe and fasten it with hexagon screws.
Please note: Secure the hexagon screws with Loctite

(no. 586).
Tightening torque (M8/8.8) ... MA = 23 Nm

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Position the protection sheet until it rests.
Please note: Observe the installation position,

see illustration.
Position the shaft sealing ring until it rests.

Install the O-ring - see arrow!
Please note: Observe the installation position of the shaft

sealing ring (open end to the top) - see illustration.
Coat the exterior diameter of the shaft sealing ring with a
mixture of spirits and water (1:1) and lubricate the sealing
lip.
(S) Holding device

(S) Handle
Insert the drive output wheel.
Please note: Observe the installation position - see illustra-

tion.
Install two adjusting screws, line up the housing and secure

it with hexagon screws.
Please note: Observe the installation position - see illustra-

tion.

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Heat up the tapered roller bearings and line up until they

rest.
Line up the bushing and insert the O-ring in the nut groove
(arrow).
Please note: Grease the O-ring.
Insert the driving pinion.
Temporarily align and fix the driving pinion with a pulling-off

device.
(S) Double-armed extractor

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Please note: Prior to mounting the adjusting disc and the

bearing inner ring, place the drive output wheel over the
O-ring or until it rests on the spacer - see illustration.
(S) Pressed-on sleeve
9.1.2.1 Set the rolling moment of the driving

pinion bearing = 2.5 … 3.5 Nm
Adjusting disc for example s = 2.60 mm alignment.
Please note: The adjusting disc s = 2.60 mm is an experi-

mental value! It is, however, absolutely essential to check
the rolling moment at a later stage.
Heat up the bearing inner ring and line up until it rests.
Align the drive output flange.

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Attach the drive output flange with the disc and hexagon
screws.
Please note: While the hexagon screws are being tighte-

ned, the driving pinion must be turned right through several
times in both directions.
(S) Mounting fork
Check the rolling moment of the driving pinion bearing.
Please note: In the event of a deviation of the required

rolling resistance of 2.5 … 3.5 Nm, adjustment must be
carried out with a respective adjusting disc
(illustration 107).
Then remove the drive output flange again.
(S) double-armed extractor

(S) holding device
(S) handle
Mount the shaft sealing ring.
Please note: On using the stipulated holding device (S) a

precise installation depth (2 + 1 mm) will result! Coat the
outer diameter of the shaft sealing ring with sprits (1:1) and
lubricate the sealing lip.
(S) Holding device
Place hexagon screws into the drive output flange and align
them radially (illustration 113) to enable the dust protection
cover sheet (illustration 114) to be installed at a later stage.

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Press the sheet to the collar of the drive output drive until it
rests.
Align the drive output flange and install the O-Ring - see the
arrow!
Please note: Grease the O-Ring prior to installation.
Permanently attach the drive output flange with the disc

and hexagon screws.
(S) Mounting fork
Fix the hexagon screws with the protection sheet (arrow).
(S) Holding device

(S) Handle

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9.1.3 Completing and installing the differential
Please note: Lubricate all of the individual differential parts

with oil prior to installation.
Drive the dowel pins (2 pins per drill hole) into the pocket
borings (4) of the differential halves.
Please note: Mount the openings of the dowel pins in the

circumferential direction respectively and staggered at
180°.
Press the ring gear over the dowel pins until it comes to
rest.
Mount the stop disc.

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Insert the axle conical gear wheel.
Mount the complete differential spider and put on the

2. axle conical gear wheel.
Please note: Pay attention to a radial installation position

of the stop discs - noses point upwards - see arrow!
Stick the stop disc into the differential cage half II with
grease.
Put on the differential cage half.
Please note: ensure a radial installation position
Attach the differential by means of a press.
Insert the segments and tighten the pan head screws.
Torque moment (M15x1, 5/12.9) ... MA = 145 Nm

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Press both of the inner bearing rings of the differential

bearing until they rest.
Put on the outer bearing rings and place the differential in

the axle drive housing.
Please note: Observe the installation position of the ring

gear - see illustration 127!
Illustration 127 shows the installation position of the ring

gear (differentials) in a rear axle arrangement.
The direction of the arrow indicates "drive forwards"!
Screw both of the adjusting nuts into the bores of the

bearing.

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Drive the straight pin into the bore of the two bearing sup-
ports until it rests.
Please note: Use Loctite (no. 242)!
Attach both of the bearing supports and fix with hexagon

screws.
Please note: Pay attention to the installation position of the

two bearing supports - see marks (arrows).

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9.1.3.1 Adjusting the tooth profile clearance and the initial bearing tension
Tooth profile clearance - see the data etched into the ring
gear.
Initial tension of the bearing 1 … 4 Nm
Place the dial gauge at a right angle onto the outer diame-
ter of the tooth profile/ring gear.
Adjust the adjusting nut on the ring gear side until the requi-
red tooth profile clearance has been achieved.
Screw the second adjusting nut (opposite the ring gear
side) until the differential bearing has no clearance.
Then tighten the adjusting nut by two grooves more in order
to achieve the required bearing tension of the differential
bearing.
Check the tooth profile clearance once again and adjust if

necessary.
Please note: On carrying out this task race the differentials

several times.
Check the installation dimensions = 216 ± 0.05 mm and

adjust if required (repeat the tasks on illustrations 130
and 131).
Place the dial gauge on the end face/ ring gear, turn the ring
gear at least one turning and set the axial wobble.
Permissible wobble max. 0.08 mm.
(S) magnetic measuring stand

(S) dial gauge
Coat some of the tooth profiles on the ring gear with spot-
ting paint.
Roll the ring gear in both directions over the driving pinion.
Remove the contact pattern and compare it to the "Sample
contact pattern" sheet on pages 29…30.
Please note: A substantial contact pattern deviation indi-

cates that an error was made on determining the adjusting
disc (item 9.1.1). It is essential that this error be rectified.

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Fix both of the adjusting nuts by means of straight pins.
9.2 Installing the helical gear and the

shut-off device
Install the ball bearing in the cap piece of the bearing and
fix it with a circlip.
Press the ball bearing into the collar of the helical gear until
it comes to rest and fix it with a circlip.
Press the cap (ball bearing) with the circlip facing upwards
until it rests.
(S) Pressed-on sleeve

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Mount the spacer and the shifting claw.
Please note: Depending on the model, with or without a

spacer, see the respective spare-parts list.
Fasten the shifting claw with a shim and a circlip.
Please note: observe the max. permissible

axial clearance = 0.1 mm.
Press the needle bearing until it rests.
Please note: Observe the installation position - name

points upwards.
(S) Holding device

(S) Handle
Insert the pre-assembled helical gear into the housing bore.

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Fasten the cap piece of the bearing with a circlip,

see arrow.
The illustration opposite shows the individual parts of the

claw clutch.
Deflect the circlip (1) and install the O-ring.
Insert the gearshift fork and the sliding sleeve.

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Insert the selector shaft until it comes to rest.
Align the selector shaft radially and fasten by driving in the

dowel pin until it is flush.
Install the screw plug.
Tightening torque (M22x1.5) ... MA = 60 Nm
Please note: Install a new O-ring
9.3 Completing and installing the pinion

cage
Pre-assemble the planet wheel.
Please note: insert the cylindrical rollers with grease.

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Press the pre-assembled planet wheels until they come to

rest.
Install the flanged wheel and the circlip.
Install the ball bearing until it rests and fix it with a circlip.
Heat up the ball bearing and insert the pinion cage until it
rests.

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Fix the pinion cage with a circlip (arrow).
9.3.1 Adjusting the switch-off device
Line up the gear lever and temporarily fasten it with a hexa-

gon screw (arrow) in the "off" position.
Use an accessory screw (M8) to bring the selector shaft to

rest with a clockwise turn and clamp the gear lever by
means of a pan head screw and a plain washer.
Tightening torque M10/8.8) ... MA = 46 Nm
Then bring the gear lever into the "on" position (arrow) and
fasten it with a hexagon screw.

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9.4 Pre-assembling and installing the coupling (on-the-road gear)

Press the ball bearing until it rests and fix it with a circlip.
Deflect the plain compression rings (arrows) and interlock

them.
Please note: Using the holding device stipulated will result

in the exact installation depth. Coat the outer diameter of
the rotary shaft seal with spirits. Lubricate the sealing lip.
(S) Holding device

(S) Handle
Fasten the rotary shaft seal with a snap ring.

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Lubricate both of the plain compression rings, align them in

the centre and press the motor shaft into the guide bush un-
til it comes to rest.
Fasten the bush with a circlip.
Deflect the circlip (arrow) and put on the supporting ring

with the end face facing upwards.
Please note: Installation of a new circlip only permissible.
Determine the "B" setting dimension,

see illustration 166 - 172:
Setting B
for 10 pairs of discs = 10,6 + 0,2 mm
Setting B
for 11 pairs of discs = 7,8 + 0,2 mm

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Insert the piston.
Line up the disc supports (illustration 168) and use impact

to bring them to rest (illustration 169).
Install the metal sheet.

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Alternately align the set of discs, commencing with an inner

disc.
Please note: For the number of inner and outer discs, refer
to the corresponding spare-parts list. Install the set of discs
without any lubrication firstly.
Determine dimension B, from the fore-part of the inner disc

support to the outer disc.
Dimension b for example ...10.70 mm
Please note: Any adjustments required are to be carried

out with the respective outer discs (S = 1.0, 1.2, 1.4 or
1.8 mm).
Determine setting dimension "D" (illustration 173

and 174):
Please note: Use the adjusting disc

(see arrow, illustration 174) to determine the axial
clearance of the disc support, ball bearing and sun wheel.
Maximal permissible axial clearance = 0.1 mm
Install the ball bearing and the sun wheel.
Align the adjusting disc (s = 3.0 … 3.9 mm, see arrow)

secure it with a circlip and check the axial clearance.
Then deflect the circlip again and remove the individual
parts, removing the piston last.

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Deflect the sealing ring with the sealing lip facing towards
the pressure zone (upwards) into the ring groove (arrow).
Please note: Use a slip bushing (S). Lubricate the sealing

ring.
(S) Slip bushing
Install the O-ring - see the arrow!
Please note: Grease the O-ring.
Layer the disk springs in accordance with the illustration

opposite.
Align the piston.

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Install the sealing ring (arrow) with the sealing lip facing to-
wards the pressure zone and insert the inner disc supports
until they rest.
Please note: Grease the sealing ring.
Put on the metal sheet.
Alternately align the set of discs, commencing with an inner

disc.
Please note: For the number of inner and outer discs, refer
to the corresponding spare-parts list. Oil the discs prior to
installation.
Install the ball bearing into the centering disc and fasten
with a circlip.

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Put the centring disc into the bore of the ring gear and
fasten with a criclip.
Align the outer discs radially and align the ring gear until all
of the discs have been picked up.
Align the sun wheel.

see illustration.
Install the adjusting disc determined (illustration 173

and 174).

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Apply initial tension to the disc spring set with a mounting

device (S) and align the circlip.
Please note: Only the installation of a new circlip is

permissible.
(S) Mounting device
9.4.1 Checking the imperviousness and

functioning of the coupling (Illustration 188…190)
Install the hydraulic connection (S)
(S) Hydraulic connection
De-aerate the piston zone by means of repeated filling.
Establish a test pressure of p = 35 bar and close the

connection to the HP pump by means of a stop valve.
Pressure may not drop for a test period of 3 minutes.
(S) HP pump

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Remove the pressure connection and install a throttle

valve.
Please note: Install new O-rings - see the arrow!
Install the pre-assembled coupling.
Deflect a circlip (190x4).
9.5 Installing the brakes (off-the-road

gear)
Install the end plate.

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Determine the setting dimension "A" = 1.4 + 0.2 mm

(Illustration 195 … Sample calculation E):
Alternately align the set of discs, commencing with an outer

disc.
Please note: For the number of outer and inner discs, refer
to the corresponding spare-parts list. Oil the discs.
Position the piston until it rests.
Install both of the disk springs and align in the centre.
Please note: Observe the installation position, see illustra-

tion.
Align the checking gauge (S) and fix it evenly with 4 pan
head screws.
(S) Checking gauge

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Determine dimension I, from the end face of the checking

gauge to the end face/piston.
Dimension I for example ......................... 32,60 mm
CALCULATION EXAMPLE "D":

Dimension I .......................................... 32,60 mm
Checking gauge production dimension .. – 20,00 mm
Difference = dimension X 12,60 mm
Please note: The production dimension is stamped into the

checking gauge and is always 20.00 mm.
Measure dimension Y, from the contact surface of the ge-

arbox housing to the flange mount surface.
Dimension Y for example........................ 11,10 mm
CALCULATION EXAMPLE "E":

Dimension X ........................................... 12,60 mm
Dimension Y ........................................... – 11,10 mm
Difference = setting dimension A = 1,50 mm
Please note: Any adjustments required are to be

carried out with the respective outer discs (S = 3.0, 3.2, and
3.5 mm). Then remove the checking gauge and remove the
piston again.

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Place the O-ring in the ring groove of the housing,

see arrow.
Please note: Stretch the O-ring slightly prior to installation

in order to ensure that it rests exactly in the turned groove.
The drawing opposite shows the installation position of the

disc, the piston and its sealing elements.
1 Drive housing
2 Gearbox housing
3 Sealing (support and lip seal)
4 Sealing (support and lip seal)
5 Circlip
6 O-ring
7 Disc
8 Sealing (lip seal and bearing ring)
9 Sealing (lip seal and bearing ring)
10 Piston
11 Disc spring
12 O-ring
Place the bearing ring and the lip seal in the ring groove
(arrow) and oil.
Position the disc until it rests.

see illustration 200.
Fasten the disc with a snap ring.

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Place the bearing ring and the lip seal in the ring groove of
the housing (arrow) and oil. Align the piston
(illustration 203) and bring it to rest evenly with a checking
gauge (illustration 204) and pan head screws.
Then remove the checking gauge again.
(S) Checking gauge
Install both of the disc springs and align in the centre.

see illustration 200.
9.6 Mounting the drive housing
Insert the O-ring (arrow 1) into the counterbore.
Insert both of the O-rings into the ring grooves of the guide
bush, see arrows.
Please note: Grease the O-rings.

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Place the O-ring into the ring groove of the drive housing
and grease.
Align the guide bush radially.
Align the drive housing.
Please note: Ensure a radial installation position.
Pull the drive housing until it rests evenly by means of pan

head screws.
Tightening torque (M12/8.8) … MA = 79 Nm

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Using an inner extraction device, pull the motor shaft and

the guide bush out of the housing bore until the snap ring
can be deflected.

(S) counter support
Fasten the guide bush radially with a screw plug,

see arrow.
Please note: install a new CU-ring.
Place the sealing comprising an O-ring and a turcon ring

into the ring groove of the piston and lubricate.
Please note: Heat up the turcon ring in an oil quenching

bath prior to installation.
Use a slip bushing.
Observe the installation position, see illustration.
(S) Slip bushing
Place the pre-assembled piston and spring into the housing

bore and fasten with a screw plug.
Please note: provide the screw plug with a new O-ring.

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Install the breather (arrow 1) and the screw plug (arrow 2).
Please note: provide the screw plug with a new O-ring.
Install both of the screw plugs (1)

and the detach stopper (2).
9.7 Checking that the brakes do not leak

and that they function (off-road gear), see
illustrations 216 and 217
Install the hydraulic connection (S)
(S) Hydraulic connection
De-aerate the piston area by means of repeated knocks.

Establish a test pressure of p = 35 bar and close the con-
nection to the HP pump with a stop valve.
The pressure may not fall during a 3-minute test phase.
(S) HP pump

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Remove the hydraulic connection (S) and install a throttle

valve.
Please note: Install new O-rings (arrow)!
9.8 Pre-assembling and installing the shift

protection
Model A: Cast iron shift
Please note:
The following describes the installation of replaceable indi-
vidual parts.
The set of rotors and the valve housing cannot be indivi-
dually replaced. Should damage be ascertained in the regi-
on of the lubricant pump (rotary or valve casing), the entire
shift protection device is to be replaced.
On doing so, only parts (rotors and valve casing) with the
same colour marking may be paired.
Oil the discs prior to installation.
Install the detach stopper and the König stopper,

see illustrations 219 and 220.

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Install the shuttle valves in accordance with the diagram

opposite.
Please note: Observe the installation position of the

pistons (see illustration).
Provide the screw plug with new O-rings.
Tightening torque (M18x1,5) ... MA = 50 Nm
Install the valves.
Please note: Install new O-rings, see arrow!
Install the piston valve and the screw plug.

1 Gearbox housing
2 Spring
3 Disc s = 1.2 mm (experimental value)
4 Piston valve
5 Screw plug
6 Screw plug
Please note: The lubrication pressure is determined with

the disc s = 1.2 mm. If the test drive results in a deviation
from the lubrication pressure stipulated of 2.8 + 0.3 bar,
a suitable disc s = 1.5 or 1.8 mm must be used for adjusting
purposes.
Provide the screw plug with new O-rings.

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Pre-assemble the operating piston and install it (illu-

stration 224 … 2281:
Install the seal (comprising an O-ring and a plastic ring) by

means of a slip bushing (s) onto the respective top and bot-
tom ring groove of the piston.
Then calibrate both of the seals with a bush (s)

(illustration 225).
(S) slip bushing

(S) calibration bush
Install the individual parts:
Please note: Install the threaded stop with Loctite

(type no. 586)
1 Operating piston
2 Spring
3 Ball
4 O-Ring
5 Bushing
6 Spring
7 Ball
8 Threaded stop

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Install the individual parts.
Please note: Install a new O-ring, see arrow!
Close the borings - see the arrows.
De-aerate the piston area and check the operating pistons

for leaks.
Test pressure 35 bar.
Please note: Pressure may not drop for a test period of

5 minutes.
Install the screwed sockets in accordance with the diagram

opposite.
Please note: Install new O-rings!
Install the panel (arrow 1) and the O-ring (arrow 2).
Please note: Install the panel with Loctite (type no. 270).

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9.8.1 Installing the lubrication oil pump
Oil the set of rotorsand insert in the housing bore.
Please note: Only parts (valve housing and rotor set) with
the same colour marking may be paired!
Fill the gaps between the inner and outer rotor (arrow) with
acid-free grease.
Please note: This improves the suction for initial operation.
Place the shaft seal in the bore of the pump cap (arrow 1).
Grease the O-ring and insert it in the ring groove (arrow 2).
Pre-assemble the pump shaft.

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Insert the pump shaft.
Please note: Ensure a radial installation position - bore for

the tappet balls facing upwards!
Fasten the pump shaft with a circlip - see arrow.
Use two adjusting screws to insert the pump cap into the
housing bore until it rests.
Please note: Ensure a radial installation position
(S) adjusting screw (M8)
Place the tappet balls into the drive shaft - see arrow.

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Align the shift protection device.
Please note: Observe the contact ratio between the tappet

balls and the groove of the inner rotor.
Fasten the shift protection with pan head screws.
9.9 Installing the screw plugs and the oil

lines
Install the screw plugs - see the arrows!
Please note: install new O-rings.
Tightening torque (M10x1) ..................... MA = 25 Nm

Tightening torque (M14x1,5) .................. MA = 35 Nm
Tightening torque (M18x1,5) .................. MA = 50 Nm
Please note: The position of the screw plugs

varies depending on the model - see the respective spare
parts list.
Mount the suction pipe.

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Install the connection stopper (arrow 1) and the screw plug

(arrow 2).
Tightening torque M10x1 ...................... MA = 25 Nm

Tightening torque M14x1,5 .................... MA = 35 Nm
Please note: install new O-rings.

The position of the connection piece and the screw plug will
differ, depending on the model.
Install the pressure lines.
Install the screw plugs - see the arrows!
Tightening torque (M26x1,5) … MA = 80 Nm
Please note: Please make a note of pages 26/27 prior to

commencing with gear operation.

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9.10Dismantling the drive output

Model B - separate gear installation
Release the hexagon screws, remove and take off the po-
wer output flange.
Lever the shaft sealing ring out of the housing bore.
(S) Adjusting screw
Release the hexagon screws, remove and take off the

power output flange.
Remove the shaft sealing ring.
(S) Adjusting key

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Remove the hexagon screws.
Remove the drive output wheel with the cap from the gear-
box housing with a lever tool.
(S) Eye bolt range
Press the drive output out of the cap piece or the ball
bearing.
Remove the oil barrier.

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(S) Vice-grip pliers
Press the ball bearing out of the bearing bore.
Remove the protective sheeting.
Press the ball bearing out of the bearing bore.

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9.11Mounting the drive output

Model B - separate gear installation
If necessary, install a suction pipe - see page 637,

illustrations 96 and 97.
Undercool the ball bearing and insert it until it comes to

rest.
Position the protection sheet until it rests.

Please note: ensure a radial installation position.
Undercool the ball bearing and insert it in the bore of the

cap piece until it rests.
Fasten the ball bearing with a circlip.
(S) Circlip pliers

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Install the oil barrier.
Please note: ensure a radial installation position!
Press the cap piece of the bearing over the short side of
the drive output wheel.
Please note: In order to avoid damaging the ball bearing,

place the pressure bushing (arrow) onto the inner ring of
the ball bearing.
Insert an O-ring into the ring groove and grease.

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Heat up the ball bearing (illustration 320), insert two adju-

sting screws and install the cap piece of the bearing until it
comes to rest (illustration 321).
(S) Hot air fan 220 V

(S) Hot air fan 110 V
(S) Adjusting screws (M12)
Fasten the cap with hexagon screws.
Tightening torque (M12/8.8) … MA = 79 Nm
Please note: Using the holding device stipulated (S) will re-
sult in the exact installation depth. If the outer diameter is
rubber-coated the sealing surface must be coated in spirits.
Otherwise a sealant (Curil T) is to be used.
Fill up the gap between the sealing lip and the dust lip with
grease.
(S) Holding device

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Insert hexagon screws into the bores of the drive output

flange and press the dust protection sheet (arrow)on until it
rests.
Preassemble the drive output flange opposite as required.
Grease the O-ring and insert it in the gap between the drive
output flange and the drive output wheel.
Place the disc on and fasten the drive output flange with
hexagon screws.
Fix the hexagon screws with the protection sheet.
(S) Holding device

(S) Handle

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Please note: Using the holding device stipulated (S) will re-
sult in the exact installation position. If the outer diameter is
rubber-coated the sealing surface must be coated in spirits.
Otherwise a sealant (Curil T) is to be used. Fill up the gap
between the sealing lip and the dust lip with grease.
(S) Holding device
Grease the O-ring (arrow) and insert it in the gap between

the drive output flange and the drive output wheel.
Place the disc on and fasten the drive output flange with
hexagon screws.
Then tighten the hexagon screws with the protection sheet
(arrow).
Please note: Please make a note of pages 26/27 prior to

commencing with operation of the unit.
(S) Holding device

(S) Handle

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9.12Gear switch protection

Model B: aluminium diecast gear
9.12.1 Dismantling, see also picture chart on

pages 38 and 120!
Remove the oil pipe and the tubes from the cap.
Remove the pan head screws (4 screws, see arrows) and

remove the shift protection device from the gearbox
housing.
Remove all of the hexagon screws and remove the cap and
the sealing from the housing.
Remove the hexagon screws and remove the pump cap

from the housing.

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Pull the inner rotor (arrow) off the pump shaft.
Remove the ball (see arrow for position) and pull the control
casing with the outer rotor off the pump shaft.
Please note: Be careful with balls and compression

springs which are released.
Remove the pump shaft - see illustration opposite.
Pull the needle bush out of the housing borehole.

(S) counter support

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Remove the check valves and the pistons.
Please note: Mark the installation position of the individual

check valves.

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9.12.2 Assembly, see also picture chart on pages 38 and 120
Coat the contact surface of the panel with Loctite (type

no. 242) and insert the panel until it comes to rest.
Then remove any residual Loctite from the panel with

compressed air.
Insert the needle bush.
Please note: Using the drive mandrel (S) stipulated will

result in the required installation depth of 0.2 +0,5 mm.
Mount the needle bush with the reinforced cover facing the
insertion tool.
(S) Drive mandrel
Install the seal (comprising a plastic ring and an

O-Ring) (illustrations 312 and 312a).
Insert an O-ring (arrow) into the ring groove of the piston.

Guide the plastic ring over the piston with the slip bushing
(S) and bring it into position on the O-ring.
(S) Slip bushing
Calibrate the plastic ring by means of the bushing (S).

(S) Sizing bushing

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Install the individual parts in accordance with the diagram

opposite.
Please note: Pay attention to the installation position of the

various check valves. Oil the individual parts in accordance
with the lubricant list TE-ML 07.
Re illustration 313:
1 Check valve (complete) MA = 10 Nm
ZF no. 4143242010
2 Pressure spring
3 Piston (complete)
4 Screw plug MA = 50 Nm
(install a new O-ring)
5 Sealing ring
6 Screw plug MA = 20 Nm
ZF no. 4143 242 009
ZF no. 4143 242,008
Please note: Provide all of the check valves and the pres-
sure control valve with new O-rings.
Secure the check valves and the limiting valves (pos. 1,7,8
and 9) with two centre blows each (illustration 313a).
Pre-assemble the pump cap in accordance with the illustra-

tion opposite.
Insert the pressure springs (1) and the balls (2) with grease
in the bores (arrows) of the pump cap.

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Oil pump (illustration 316 … 319)
Please note: The set of rotors (comprising the control hou-

sing, outer rotor and inner rotor) may only be replaced as
one complete part.
Align the control housing with the outer rotor.
Insert the ball with grease in the counter bore of the pump
shaft (arrow) and align the inner rotor.
Please note: The driving of the inner rotor is carried out

with the ball.
Pay attention to a precise installation position.
Insert the pre-assembled pump cap into the housing bore

(illustration 318) and fasten with hexagon screws
(illustration 319).
Tightening torque (M6/8.8) ... MA = 9,5 Nm

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Place the O-ring into the ring groove (arrow) and lubricate.
Install both adapters and the screwed sockets.
Please note: Install new O-rings!

Tightening torque (adaptor) MA = 25 Nm
Tightening torque (screwed sockets) MA = 35 Nm
Install two adjusting screws.

Line up the seal and the cap.
(S) adjusting screws (M8)
Fasten the cap with hexagon screws (use plain washers).
Tightening torque . . . . . . . . . . . . . . MA = 20 Nm

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Install the pump shaft until the gearing has been taken up.
Insert two adjusting screws and bring the switch protection

device to rest on the gearbox housing.
(S) adjusting screws (M8)
Fasten the switch protection device to the gearbox housing

with pan head screws (use plain washers).
Tightening torque . . . . . . . . . . . . . . . MA = 23 Nm
Install the oil pipe and hoses (arrow) in accordance with the
illustration opposite.
ATTENTION: Please observe the instructions for operation

and maintenance (pages 26/27) prior to putting the unit into
operation.

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Revised: 08.2004 1305 / 1505 / 1605 / 1705 Mobile
Chapter 15
Electrical System
Contents
1 Electrical System .......................................................................................................... 3
Page 1 of 4
1305 / 1505 / 1605 / 1705 Mobile Revised: 08.2004
Electrical System
Revised: 08.2004 1305 / 1505 / 1605 / 1705 Mobile
1 Electrical System
The electrical system is described in the TEREX ATLAS training documents XX05, EDP No. 6050429
electrical system, excavator.
Electrical System
1305 / 1505 / 1605 / 1705 Mobile Revised: 08.2004
Electrical System
Revised: 08.2004 1305 / 1505 / 1605 / 1705 Mobile
Chapter 16
Axles
Contents
1 WY 217 planetary steering axle ......................................................................................2

2 WY 218 planetary rigid axle ..........................................................................................40
Page 1 of 68
1305 / 1505 / 1605 / 1705 Mobile Revised: 08.2004
1WY 217 planetary steering axle

Contents
1.1 General information and maintenance ................................................................................... 4
1.1.1 Introduction ............................................................................................................................. 4
1.1.2 Ordering spare parts .............................................................................................................. 4
1.1.3 Liability and guarantee for structural components relevant to safety ..................................... 5
1.1.4 Working conditions and tools ................................................................................................. 5
1.1.5 Maintenance work .................................................................................................................. 6
1.1.5.1 Lubrication chart ..................................................................................................................... 6
1.1.5.2 Maintenance rates .................................................................................................................. 7
1.1.5.2.1 Initial filling ............................................................................................................................... 8
1.1.5.2.2 Lubricating ............................................................................................................................... 8
1.1.5.2.3 Oil change ............................................................................................................................... 9
1.1.5.2.4 Checking the oil level ............................................................................................................ 10
1.1.5.2.5 Check .................................................................................................................................... 10
1.2 Repair instructions ................................................................................................................ 11
1.2.1 Replacing the entire differential ............................................................................................ 11
1.2.2 Repairs to the differential ..................................................................................................... 12
1.2.2.1 Replacing the ring gear / pinion ............................................................................................ 12
1.2.2.1.1 Determining the thickness of the levelling disc (45) .............................................................. 15
1.2.2.1.3 Setting the pinion bearing or completing installation ............................................................. 17
1.2.2.1.4 Setting the tooth clearance and the ring gear bearing .......................................................... 17
1.2.2.1.5 Checking the contact pattern ................................................................................................. 18
1.2.2.2 Replacing the differential cage (compensating gears) ......................................................... 19
1.2.3 Planetary gears .................................................................................................................... 22
1.2.3.1 Fully replacing the equalisation cage ................................................................................... 22
1.2.3.2 Replacing the sun wheel ...................................................................................................... 23
1.2.3.2.1 Checking and adjusting the hydraulic gear cluster setting .................................................... 23
1.2.3.3 Replacing planetary pins and wheels ................................................................................... 25
1.2.3.4 Replacing the toothed ring ................................................................................................... 25
1.2.4 Wheel bearing ...................................................................................................................... 26
1.2.4.1 Changing the wheel bearings ............................................................................................... 26
1.2.4.2 Adjusting the wheel bearing ................................................................................................. 28
1.2.5 Brakes .................................................................................................................................. 29
1.2.5.1 Checking disc wear and tear ................................................................................................ 29
1.2.5.2 Replacing piston packing ..................................................................................................... 30
1.2.5.3 Replacing the brake discs and the pressure springs ............................................................ 32
1.2.6 Replacing the double-jointed cardan shaft ........................................................................... 34
1.2.6.1 Replacing the shaft seals ..................................................................................................... 34
1.2.7 Steering swivel bearing ........................................................................................................ 36
1.2.7.1 Removing the axle pivot pins ............................................................................................... 36
1.2.7.2 Replacing bearing bushes .................................................................................................... 36
1.2.7.3 Installing axle pivot pins ....................................................................................................... 37
1.2.7.4 Determining the thickness of the bearing discs .................................................................... 37
1.2.8 Replacing the steering cylinder ............................................................................................ 38
1.2.9 Setting the track ................................................................................................................... 39
Axles
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1.1 General information and maintenance

1.1.1 Introduction
Serial production of the WY 217 commenced in November 2001. This model is fitted with a permanent dif-
ferential device. The two external planetary gears are driven by double-jointed cardan shafts. The axle is
controllable and has been constructed for pendulum suspension. The main drive is carried out with a Ø120
cardan flange. The installation includes two hydraulically-operated multiple-disc brakes as service brakes.
1.1.2 Ordering spare parts

It is advisable to purchase spare parts for this NAF axle direct from an authorised WEYHAUSEN agent who
is likely to have many of the parts on stock. Even if parts are not available immediately we recommend that
they be ordered through the dealer and not from the factory. The agent will generally be able to describe
the part required in more detail and indicate the exact part number, hence helping to avoid errors and in-
correct deliveries.
When ordering spare parts it is essential to provide the full, exact type specification with the works number
and the year of construction. The nameplate is located on the differential housing near the oil check screw
- see illustration 1. Use original NAF spare parts only. If spare parts produced by other manufacturers are
used there will no longer be any guarantee; the function may be impaired and the useful life span of the
equipment may be shortened.
Illustration 1
1 Breather service brake "E" marking

2 Nameplate
4 Planetary drive breather
5 M 14 x 1.5 disc service brake connection "P" marking
6 M 16 x 1.5 steering cylinder connection Steering pressure max. 160 bar
7 M 14 x 1.5 disc service brake connection "P" marking
31 Hydraulic-type lubricating nipple AM 8 x 1
40 Diff. oil-filling and oil-check screw
Axles
1305 / 1505 / 1605 / 1705 Mobile Revised: 08.2004
1.1.3 Liability and guarantee for structural components relevant to safety

We highly recommend that for structural components relevant to safety (e.g. shift cylinders, steering cylin-
ders, brake cylinders, spring-loaded cylinders, etc.) the whole structural component be replaced.
There is no longer any entitlement to claim on the basis of a guarantee or liability once the structural com-
ponent relevant to safety has been dismantled and opened, i.e. NAF does not assume any product liability
for the drive unit. This also applies if the entire drive unit is still under guarantee.
1.1.4 Working conditions and tools

A clean, well-lit place of work is essential in order to be able to carry out repairs properly. There should also
be sufficient space available to be able to lay out and arrange the various parts and structural components.
A full set of quality tools of all basic tools required is also essential. In addition a few special tools are also
required. These tools usually prove to be invaluable when certain repairs need to be carried out frequently.
A great deal of time (and trouble) can be spared. These special tools are described or indicated in more
detail in the respective sections (e.g. with the tool number).
Furthermore, certain specialised knowledge and even training is essential for carrying out certain repairs.
Axles
Revised: 08.2004 1305 / 1505 / 1605 / 1705 Mobile
1.1.5 Maintenance work
1.1.5.1 Lubrication chart
Lubrication chart for the WY 217

Lubrication point No. Quantity Lubricants
Differential 40/42 9.0 litres SAE 90 (hypoid oil)
Planetary gears 50/51/52 4.0 litres each SAE 90 / SAE 80 / LS
Steering swivel bearing 30 as required Premium EP grease
Track rod 31 as required Premium EP grease
Description of the lubrication point numbers:

No. 30 ⇒Lubrication nipple on the axle pivot pin
No. 31 ⇒Lubrication nipple on the track rod
No. 40 ⇒Oil filler screw for the differential
No. 42 ⇒Oil drain screw for the differential
No. 50 ⇒Oil filler screw for the planetary gears
No. 51 ⇒Oil drain screw for the planetary gears
No. 52 ⇒Oilpan drain plug for the planetary gears and the inspection hole
(see also illustrations 1 and 2)
Example of SAE 90 premium EP gear oil in the specification: API-GL 5 / MIL-L-2105 B LS

DEA (Deagear LS SAE 85 W-90), (Dearon BHS SAE 90)
Mil (Mobilube SHC-LS 75 W-90)
Esso (Gear oil LSA 85 W-90)
Schell (Gear oil 90LS)
Fuchs (Renogear LS 90), (Renogear HLS 90)
Example of premium EP multi-purpose grease, lithium-based, water-resistant (DIN 51825)

Klüber (Microlube GL 261) (Klüberplex BE 31-502)
Tripol (Tribol 3020 / 1000 -1)
Please observe the details on the lubrication chart for filling quantities
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1.1.5.2 Maintenance rates

NAF axles have been developed and constructed on the basis of yearlong experience and knowledge con-
cerning machine stress. However, perfect functioning and constant operation is only ensured if the axles
are taken care of, treated well and regularly serviced. This includes observing maintenance rates, using
the proper lubricants in accordance with the lubrication chart and monitoring a few maintenance items. No
special tools are required for maintenance work.
Maintenance rate chart for the WY 217

Maintenance point (no.) Hours of operation
0/ After 1 day 50-500 Every Every 2000 or
Putting into 500 once a year
operation
Differential (40/42) 1 - 3 4 3
Planetary gears (50/51/52) 1 - 3 4 3
Steering swivel bearing (30) 2 - - 2 -
Sliding bar joint (31) 2 - - 2 -
Wheel nuts 5 5 5 5 -
All of the visible screws and nuts - - 5 - 5
1 = Initial filling (see Chapter 1.5.2.1)

2 = Lubricating (see Chapter 1.5.2.2)
3 = Oil change (see Chapter 1.5.2.3)
4 = Oil level check (see Chapter 1.5.2.4)
5 = Check (see Chapter 1.5.2.5)
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1.1.5.2.1 Initial filling

• Differential
Remove the oil filler screws (no. 40) and fill up with oil in accordance with the lubrication chart until the
oil level reaches the bottom of the thread. Check after 5 minutes and fill in more oil if necessary. The
tightening torque of the filler screw (no. 40) is 95 + 20 Nm. (illustration 1)
• Planetary gears
Turn both of the wheel hubs so that the screw plugs (no. 50) are horizontal (illustration 4). Remove the
screw plugs (no. 50 / 51) and fill oil into the top opening (no. 51) in accordance with the lubrication chart
until the oil level reaches the bottom of the thread bore (no. 50). Check after 5 minutes and fill in more
oil if necessary. The tightening torque of the screw plugs (no. 50 / 51) is 50 +10 Nm.
1.1.5.2.2 Lubricating
• Steering swivel bearing
Lubricate the 4 bearing points (no. 30) with grease in accordance with the lubrication chart until the
grease overflows. Wipe off excess grease (illustration 2).
• Sliding bar joints
Press in grease at the four lubrication points (no. 31) in accordance with the lubrication chart until the
grease overflows. Wipe off excess grease (illustration 2).
Illustration 2
42 Diff. oil-drainage screw
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1.1.5.2.3 Oil change
Please note: clean the area around the screw plugs prior to changing oil
• Differential
Carry out the oil change with warm oil. Remove the oil filling screw (no. 40) and then open the oil drain
screw (no. 42). Completely drain off the oil. Only fill in new oil in accordance with the lubrication chart
once the oil has been drained off the planetary gears. The tightening torque for the oil filling screw and
the oil drain screw is 95 +20 Nm (illustrations 1 and 2).
• Planetary gears
Carry out the oil change with warm oil at the same time as for the differential. To do so, turn the wheel
hubs until both of the screw plugs (no. 50/52*) are right at the bottom (illustration 3). Remove the screw
plugs (no. 50/51/52) and completely drain off the oil. Then turn the wheel hubs back by 90° until the
screw plugs (no. 50) are horizontal and insert the screw plug (no. 52) (illustration 4). Fill oil into the top
opening (no. 51) in accordance with the lubrication chart until the oil level reaches the bottom of the
horizontal thread bore (no. 50). Check the oil level after 5 minutes and fill in more oil if necessary.
The tightening torque of the screw plugs (no. 50/51/52) is 50 +10 Nm.
(*) on the back of the wheel hub.
Illustration 3 Illustration 4
50 Position of the screw plug for draining off oil 50 Position of the screw plug for filling in and for
checking the oil
52 Disc wear check with the oil drain screw plug
(on the back of the wheel hub)
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1.1.5.2.4 Checking the oil level
Please note: clean the area around the screw plugs prior to checking the oil level
• Differential
Remove the oil filling screws (no. 40) and if necessary, fill in new oil in accordance with the lubrication
chart. The tightening torque of the oil filler screw (no. 40) is 95 +20 Nm (illustration 1).
• Planetary gears
Turn the wheel hubs so that the two screw plugs (no. 50) are horizontal (illustration 4). Remove the
screw plugs (no. 50). The oil level should be at the bottom of the thread. If necessary fill in more oil in
accordance with the lubrication chart. The tightening torque of the screw plugs (no. 50) is 50 +10 Nm.
1.1.5.2.5 Check
• All of the screws and nuts
Screws and nuts may loosen as a result of stress and vibration of the vehicle. Tightening them in good
time will avoid leaks and substantial damage. The wheel nuts and the cardan flange screws in particu-
lar must be checked. The tightening torque for the wheel nuts is 450 - max. 550 Nm.
Please note: the glued nut for fastening the cardan flange (pinion nut) may not be tightened.
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1.2 Repair instructions

1.2.1 Replacing the entire differential
(see illustration 5 on page 13)
Please note: in the event of substantial damage to the differential it would be better to replace the entire
differential instead of carrying out repairs.
• To do so, it is advisable to remove the whole axle from the chassis.
• Dismantle the steering cylinder (see Chapter 2.7)
• Drain off the differential oil.
• Screw out the hexagon screws (no. 24) on both sides of the differential.
(see illustration 5 on page 13) and take off - or pull out - the axle support (no. 1) with the cardan shafts.
• Replace the differential
Please note: original NAF replacement and repair differentials have been properly set in the factory. The
bearing and contact pattern settings of differentials which have not been processed by NAF must be chek-
ked prior to installation.
• Remove the rust-protection coating on fitting surfaces.
• Renew the O-rings (no. 28).
• Install the spline shaft profile of the double-jointed cardan shaft in the spacing wheels (no. 22) by
means of turning the cardan flange (no. 39) slightly (see illustration 5 on page 13).
• Then push the axle support up to the flange position, observe the straight pins (no. 9).
• Insert hexagon screws (no. 24). The tightening torque is 400 +30 Nm.
• Re-install the steering cylinder, tighten new Allen screws and check the gap between the flange and
the differential housing with a thickness gauge (0.20 +0,65 mm).
• Install the axle into the vehicle (connect the brakes, steering cylinder and cardan shaft).
• Fill oil into the differential.
• Do a test drive and drive the steering cylinder up to the limit stop several times to the left and the right
when stationary and check all of the links and connections once again.
• Attention: do not forget to bleed the brakes.
• Check the track and adjust if necessary (toe-in = 0).
• After testing and adjusting if required, screw the hexagon nut onto the eye bolt with the safety plate.
• Do a test drive and check the brakes several times.
• Tighten the axle fastening screws after test driving.
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1.2.2 Repairs to the differential
1.2.2.1 Replacing the ring gear / pinion

Please note:
• The ring gear and the pinion (no. 13) can only be replaced as a set. They cannot be replaced indivi-
dually since their toothed wheels overlap. The respective parts which belong together are indicated by
means of the same numbers on the ring gear and the pinion - engraved with an electric writing device.
• In the case of such a repair it is advisable to replace all of the bearings as well.
• Remove the differential (Chapter 2.1).
• Remove the flange (no. 5) once the Allen screws (no. 4) have been loosened.
• Remove the differential cage (no. 11/11) with the ring gear (no. 13).
• Check both of the tapered roller bearings (no. 10 and no. 16) and renew if necessary.
• Remove the pinion nut (no. 41), supporting the cardan flange with a hold-up device while doing so.
In order to facilitate installation, heat up the nut to approx. 100°C
(the releasing torque may be up to 800 Nm)
• Remove the cardan flange (no. 39) and pull out the pinion (no. 13) towards the inside.
• Remove the rotary shaft lip seals (no. 36) and (no. 37).
• Check the tapered roller bearings (no. 10/16) for the differential cage bearing and (no. 35/42) for the
pinion bearing and renew if necessary.
• Press the ring gear (no. 13) out of the differential cage (no. 11/11) after loosening the hexagon
screw (no. 7).
• Push a new ring gear onto the differential cage (no. 11) and on doing so also install the two cylinder
pins (no. 12). Tighten new hexagon screws (no. 7) (due to coating on the thread) obliquely with a dyna-
mometric key. The tightening torque is 185 Nm.
• Determine the thickness of the spacer (no. 45) - see Chapter 2.2.1.1.
• Press in the levelling disc (no. 45) selected and the bearing outer rings (from no. 42, no. 35, no. 10 and
no. 16) into the differential housing (no. 23) or flange (no. 5, no. 10) in the case of replacement .
• Insert the bearing inner rings (from no. 10 and 16) with the roll body onto the differential
cage (no. 11/11).
• The installation temperature for the bearing inner ring (no. 42) is max. 80°.
• Insert the bearing inner ring (from no. 42) with the roll body onto the pinion (no. 13).
The installation temperature for the bearing inner ring (no. 42) is max. 80°.
• Press the pinion (no. 13) from the inside and hold up.
• Determine the thickness of the levelling disc (no. 44) - see Chapter 2.2.1.2.
• Firstly align the levelling disc(s) (no. 44) onto the pinion (no. 13) and then the spacer bush (no. 43).
• Press the bearing inner ring (from no. 35) with the roll body onto the pinion (no. 13).
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• Put on the cardan flange (no. 35) and tighten the pinion nut (no. 41) without Loctite at 800 Nm.
• Check the bearing pre-tension of the pinion bearing with a torque gauge and change the levelling disc
if necessary (pre-stress: 0.5 - 6.0 Nm for new pinion bearings) (pre-stress: 0 -5.0 Nm for used pinion
bearings).
This data applies without shaft seals and a ring gear being installed. Make a note of the pinion bearing
pre-tension measured.
• Loosen the pinion nut (no. 41) again and clean the thread of the pinion and the nut to remove dirt, oil
and preservatives.
• Install the shaft seals (no. 36 and no. 37) with a press-fit mandrel and fill the gap between the two shaft
seals (no. 36 and no. 37) with grease until it is half filled.
• Install a new O-ring (no. 38).
• Coat the thread of the pinion (no. 13) and the nut (no. 41) with Loctite 639 right around and along the
whole length of the thread.
• Screw the nut (no. 41) onto the pinion (no. 13) and tighten at 800 Nm. The final position must have
been reached within 3 to 5 minutes in order for the Loctite to remain fully effective.
• Insert the differential cage (no. 11) with the ring gear (no. 13), place a new O-ring (no. 6) onto the
flange (no. 3) and fasten with Allen screws (no. 4). Also fasten the two flanges (no. 5 and no. 14) with
four M18 x 2 x 40 auxiliary screws each.
• Check or adjust the torsional flank clearance between the ring gear and the pinion (clearance of 0.15 -
0.25) (see chapter 2.2.2).
• Remove the M18 x 2 x 40 auxiliary screws and install the differential (see Chapter 2.1).
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Illustration 5
1. Hexagon screw 2. Safety plate
2a. Safety plate 3. Nut
4. Allen screw 5. Flange
6. O-ring 7. Hexagon screw
8. Disc 9. Straight pin
10. Tapered roller bearing 11. Differential housing
12. Straight pin 13. Ring gear / pinion
14. Flange 15. Hexagon screw
16. Tapered roller bearing 17. Nut
18. Pressure disc 19. Equalising wheel
20. Cross bolt 21. Stop disc
22. Spacing wheel 23. Differential cage
24. Hexagon screw 25. Detent edged ring
26. Screw plug 27. Sealing ring
28. O-ring 29. Hydraulic-type lubricating nipple
35. Tapered roller bearing 36. Shaft seal
37. Shaft seal 38. O-ring
39. Cardan flange 40. Axle support
41. Nut 42. Tapered roller bearing
43. Distance bush 44. Levelling disc
45. Levelling disc 46. Double-jointed cardan shaft
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1.2.2.1.1 Determining the thickness of the levelling disc (45)
Please note: selecting the levelling disc (no. 45) determines the contact pattern setting.
Illustration 6
1 Differential centre
2 Installation clearance
• Calculate the thickness of the levelling disc (no. 45)

Se = L2 - Le - Lr -L1
A disc thickness of between 2.4 and 3.65 mm must result.
The nearest disc thickness is to be taken. The max. permissible deviation of the disc thickness
from the dimension calculated is 0.1 mm.
"L2" = dimension between the bearing seat (no. 42) and the centre of the differential. (147 +0,1)
"Le"" = target setting (engraved on the front of the pinion, approx. 68.83 mm).
"Lr" = measure the addendum of the pinion and make a note of the measurement.
(approx. 45.17 +/- 0.03)
"L1" = measure the actual height of the new bearing (no. 42).
The dimension "L1" is approx. 30.162
(slide gauge with a jaw length of at least 120 mm).
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• Press new bearing outer rings (from no. 42 (with levelling discs(s) (no. 45) and (no. 35) in the differen-
tial housing (no. 23) until they rest.
• Insert the bearing inner ring (from no. 42) with the roll body onto the pinion (no. 13). The installation
temperature for the bearing inner ring (no. 42) is max. 80°.
• Select two to three levelling discs (no. 44) and the distance bush (no. 43). Compile with a total dimen-
sion in the range of 26.82 to 28.26 mm.
Please note:
Firstly check or use the combination selected in the factory.
Levelling disc thickness: 0.96 to 1.44 (with stages of 0.04)
Distance bush (no. 43): 24.9 +/-0.02 mm
• Insert the pinion (no. 13) from the inside into the housing (no. 23) and support.
• Firstly place the levelling disc(s) selected (no. 44) onto the pinion (no. 13) and then put on the spacer
bush (no. 43) (see illustration 5 on page 13).
• Press the bearing inner ring (from no. 42) with the roll body onto the pinion (no. 13). The installation
• Rub abrasion-resistant and scuff-limiting paste onto the side of the nut (no. 41) facing the plant (e.g.
Wolfracote SSP by Klüber)
• Put on the cardan flange (no. 39) and screw the pinion nut (no. 41) onto the pinion (no. 13) and tighten
at 800 Nm.
• Check the pinion bearing pre-stress with the torque gauge and if necessary change the levelling disc
(no. 44). The pinion bearing must not have any axial clearance; it should be possible to turn it at 0.5 to
6.0 Nm. For bearings already used the setting is 0 to 5.0 Nm (pinion bearing pre-stress for new bea-
rings: 0.5 - 6.0 Nm).
Make a note of the bearing pre-stress set for setting the ring gear bearing later (see Chapter 2.2.1.4).
• When the bearing pre-stress is correct, secure the pinion nut (no. 41) with Loctite (see Chapter 2.2.1.3)
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1.2.2.1.3 Setting the pinion bearing or completing installation
• Clean any dirt, oil and preservatives off the pinion (no. 13) and the pinion nut (no. 41).
• Rub abrasion-resistant and scuff-limiting paste onto the side of the nut (no. 50) facing the plant
(e.g. Wolfracote SSP by Klüber).
• Screw the nut (no. 50) onto the pinion (no. 13) and tighten at 800 Nm, while backing it onto the cardan
flange (no. 51). Use a few blows onto the outside of the housing in the area of the pinion bearing to
align the roller bearings. The final position must have been reached within 3 to 5 minutes in order for
the Loctite to remain fully effective.
• Check the bearing pre-stress of the pinion bearing with a torque key and if necessary adjust the set-
ting. The pinion bearing may not have any axial clearance; it should be possible to turn it at 0.5 to 6.0
Nm. For used bearings the setting is 0 to 5.0 Nm.
• Make a note of the bearing pre-stress set for setting the ring gear bearing later.
1.2.2.1.4 Setting the tooth clearance and the ring gear bearing
• Loosen the screws (no. 1) and remove both of the safety plates (no. 2).
• Screw in the nut (no. 17) approximately one thread turn and screw out the nut (no. 3) approx. 2 thread-
turns.
• Fully insert the differential cage (no. 11).
• Fasten the flange (no. 10) and the new O-ring (no. 6) with Allen screws (no. 4). Also fasten the flange
(no. 10) with four M 18 x 30 auxiliary screws.
• Turn both of the nuts (no. 17) and (no. 3) until a tooth flank clearance of 0.15 to 0.25 has been reached.
• Once the right tooth flank clearance has been reached, secure the nut (no. 3) with the safety sheet (no.
2) and a hexagon screw (no. 1).
• Set the bearing pre-stress of the ring gear bearing (no. 10) and (no. 16). To do so, turn the nut (no. 17)
until the required bearing pre-stress of 1.0 - 3.0 Nm has been reached.
• This figure is determined on the pinion nut (no. 41) with a torque gauge, namely by means of adding a
torque of 0.2 to 0.7 to the pinion bearing pre-stress (figure noted in Chapter 2.2.1.3).
• Once the bearing pre-stress has been reached, secure the nut (no. 17) with the safety sheet (no. 2)
and a hexagon screw (no. 1).
• Make a note of the bearing friction torque.
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1.2.2.1.5 Checking the contact pattern
• Loosen the auxiliary screws and the Allen screws (no. 4) on the flange (no. 5) and remove the flange.
• Take out the differential cage (no. 11) and paint the tooth profiles of 2 tooth spaces (= 4 tooth profiles)
on the ring gear (no. 13) with thin yellow paint and install the differential cage (no. 11) and the flange
(no. 5) with auxiliary screws again.
• Race the pinion so that the contact pattern is marked by means of the oil paint.
• Dismantle the flange (no. 5), remove the differential cage (no. 11) with the ring gear and inspect the
contact pattern. If the levelling disc thickness is right, a contact pattern in accordance with illustration 9
must be achieved, otherwise select a new levelling disc (no. 45) (see chapter 2.2.1.1).
If the contact pattern complies with illustration 7 or 8, the pinion must be adjusted with the help of changing
the disc thickness of the levelling disc (45) in order to achieve a contact pattern in accordance with illustra-
tion 9. By turning the nuts (3) and (17) the ring gear will need to be adjusted in accordance with illustration
7 or 8 too.
.
Please note: always pay attention to the correct
pre-stress of the bearings (10) and (16) during the
setting procedures. Also pay attention to correct tooth
clearance on turning the nuts (3) and (17). Repeated-
ly wash off old oil paint from previous attempts at set-
ting.
Illustration 9
Once the tooth profile clearance and the bearing pre-stress have been set, secure both of the nuts (no. 3)
and (no. 17) with safety sheets (no. 2) and new hexagon screws (no. 1).
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1.2.2.2 Replacing the differential cage (compensating gears)

Please note:
• The two halves of the differential cage (no. 11 and no. 11) can only be replaced together; observe the
position markings and the other markings.
• Remove the differential (see Chapter 2.1).
• Remove the differential cage (no. 11/no. 11) with the ring gear (no. 13).
• Press the ring gear (no. 13) out of the differential cage (no. 11) after loosening the hexagon
screws (no. 7).
• Remove the hexagon screws (no. 15) and open the differential cage.
• Remove the cross bolt (no. 20) with the equalising wheel (no. 19) and the pressure disc (no. 18) as a
unit. Check the components and renew if necessary.
• Remove the differential pinions (no. 22) with the stop discs (no. 21). Check the components and renew
if necessary.
• Make the differential cage setting by means of selecting "s" on the stop discs (no. 21).
Selection of thickness "s" of the stop discs (no. 21) between 1.5 and 2.5 mm
To do so, screw the two differential cage halves together with the selected components as a test with
4 uncoated auxiliary m 10 x 90 screws. Race the differential gear with the help of a profiled shaft butt
end. There must be no perceivable resistance or shaking. The axial clearance on the differential pinion
(no. 22) must be less than 0.2 mm. If the setting is false, change the stop disc accordingly and repeat
the test procedure.
• When the setting is correct, remove the four uncoated auxiliary screws and screw permanently toge-
ther with 12 new coated hexagon screws (no. 15). The tightening torque for the hexagon
screws (no. 15) is 67 +5 Nm.
• Press on both of the tapered roller bearings (no. 10 and no. 16) and also replace the bearing cups in
the flanges (no. 5 and no. 14) when renewing.
• Insert the differential gear and check the torsional flank clearance between the ring gear and the pinion
(clearance 0.15 - 0.25) (see Chapter 2.2.1.4 and 2.21.5).
• Install the differential (see Chapter 2.1).
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Illustration 10
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1. Axle ball 2. Hexagon screw

3. Disc 4. Equalising cage
5. Shearing bush 6. Stop disc
7. Planet pin 8. Needle ring
9. Gear ring 10. Planet wheel
11. Gear ring carrier 12. Disc
13. Equalising cage 14. Seeger circlip ring
15. Sun wheel 16. Screw plug
17. Groove nut 18. Levelling discs
19. Set of levelling discs 20. Pin
21. Tapered roller bearing 22. Wheel hub
23. Disc 24. Tapered roller bearing
25. Outer disc 26. -
27. Axle pivot 28. Inner disc
29. O-ring 30. Shaft seal
31. Wheel hub 32. Hexagon screw
33. Countersunk screw 34. O-ring
35. O-ring 36. O-ring
37. Snap ring 38. Allen screw
39. Piston 40. Cylinder
41. Double-jointed cardan shaft 42. Piston packing
43. Piston packing 44. Cylinder
45. Close-tolerance groove pin 46. Ring
47. Pressure spring 48. Snap ring
49. Tolerance ring 50. Screw plug
51. Sealing ring 52. Screw plug
53. Straight pin 54. Hexagon screw
55. Hexagon screw 56. Breather valve
57. Disc 58. Inner ring
59. Bush 60. Axle support
61. Hydraulic-type lubricating nipple 62. Adapter sleeve
63. O-ring 64. Set of levelling discs
65. Wheel pin 66. Centring ring
67. Limes-type ring 68. Eye screw
69. Sealing ring 70. Collar stud
71. HV disc 72. Sg. ring
73. Sliding bar 74. Disc
75. Guard plate 76. Set of levelling discs
77. Collar stud 78. Sliding bar rod
79. Bush 80. Steering cylinder
81. Hexagon nut 82. Disc
83. Hydraulic-type lubricating nipple 84. Hexagon screw
85. Axle pivot pin 86. Axel pivot pin
87. Bush 88. Bearing disc
89. Bearing disc 90. Heavy-type dowel pin
91. Cap 92. Bush
93. - 94. Shaft seal
95. Shaft seal 96. Shaft seal
97. Shaft seal
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1.2.3 Planetary gears
1.2.3.1 Fully replacing the equalisation cage

(see illustration 10)
• Lift up the vehicle and secure

• Remove the wheel
• Drain off oil (Chapter 1.5.2.2)
• Loosen the countersunk screws (no. 33)
• Remove the equalising cage (no. 13) completely
• Replace the O-ring (no. 35) and place it onto the wheel hub (no. 22)
• Place the recess of the new equalising cage (no. 13) over the marking on the bearing of the wheel hub
(no. 22) and install as a unit.
To do so, the gearing of the sun wheel and the three planet wheels are to be brought into the interwea-
ving position. Then push the equalising cage on with a slight turn until the planet wheels engage into
the toothed ring (no. 9).
Then push the equalising cage on completely.
• Insert the countersunk screws (no. 33) - tightening torque 70 Nm.
• Fill up oil (Chapter 1.5.2.3 - planetary gears)
• Mount the wheel.
• Lower the vehicle.
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1.2.3.2 Replacing the sun wheel
• Remove the equalising cage (no. 13) (see Chapter 2.3.1).

• Remove the Seeger circlip ring (no. 14).
• Pull the sun wheel (no. 15) off the double-jointed cardan shaft.
• Push on a new sun wheel (no. 15).
• Insert the Seeger circlip ring (no. 14) again.
• Equalising cage (no. 13) (see Chapter 2.3.1)
1.2.3.2.1 Checking and adjusting the hydraulic gear cluster setting
Please note: hydraulic cluster = screw plug (no. 16)

(see illustration 10 and 11)
• Measure the distance (14) between the wheel hub flange area (no. 22) and the front of the double-join-
ted cardan shaft (no. 41) and the distance (15) between the flange area of the equalising cage (no. 13)
and the stop face of the hydraulic cluster (no. 16) with a reducing scale.
Axial clearance: l5 - l4 must be at least 0.5 mm (max. permissible 2.0 mm)
• If the axial clearance measured is beyond these figures, the hydraulic cluster (no. 16) must be adjusted
accordingly with a new set of discs (no. 19).
• In order to do so the hydraulic cluster (no. 16) must be screwed right out. To facilitate installation, heat
up to approx. 80 °.
• Then install the equalising cage (no. 13) onto the wheel hub (no. 22) in accordance with Chapter 2.3.1.
Using light knocks with a hammer, bring the double-jointed cardan shaft through the thread bore
M 30 x 1.5 with a mandrel of approx. Ø 20 mm.
• Choice of set of discs "S" (no. 19)
"S" min = 22 "A" measured
"S" max = 23 - "A" measured
"A" = distance from the spot facing on the equalising cage to the front of the double-jointed cardan
shaft.
• Remove any dirt, oil or preservatives from the thread M 30 x 1.5 in the equalising cage (no. 13).
• Screw the hydraulic cluster (no. 16) with the set of discs selected "S" (no. 19) into the equalising cage
and tighten at between 200 and 240 Nm.
• Fill up with oil (Chapter 1.5.2.3 - planetary gears).
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Illustration 11
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1.2.3.3 Replacing planetary pins and wheels

• Remove the equalising cage (no. 13) - see Chapter 2.3.1.

• Put down the equalising cage (no. 13) with the opening facing to the top.
• Loosen three hexagon screws (no. 2).
• Fasten the WZ 190 sharpening wheel onto the three planetary nuts and at the same time as the inner
part of the equalising cage (no. 4), strip evenly.
• Remove the stop discs (no. 6), and pull down the planetary wheels (no. 10) and the needle
rings (no. 8).
• Press the planetary nut (no. 7) out of the inner part of the equalising cage (no. 4) with an auxiliary pin of
approx. Ø 23 mm.
• Insert new planetary pins (no. 7) into the outer part of the equalising cage (no. 13).
• Insert the stop discs (no. 6) into the equalising cage (no. 13) with the nose pointing towards the enga-
ging diameter.
• Put two needle rings (no. 8) each and the new planet wheel (no. 10) onto the planetary pins (no. 7).
• Insert the shearing bushes (no. 5) or check to ensure that they are complete.
• Align the stop discs (no. 6) with the gib pointing towards the engaging diameter on the inner part of the
equalising cage (no. 4).
• Press on the equalising cage (no. 4) and screw it on with new, coated screws (no. 2) and discs. The
tightening torque is 115 Nm.
• Check the clearance of the planet wheels (no. 10) and the axial clearance (min. 0.3 mm).
• Install the entire equalising cage (no. 13) (see Chapter 2.3.1).
1.2.3.4 Replacing the toothed ring


• Take out the snap ring (no. 37).
• Insert a new toothed ring (no. 9).
• Insert the snap ring (no. 37) again.
Please note: it should now be possible to move the toothed ring radially by +/- 0.4 mm on the toothed
wheel support (no. 9).
• Install the equalising cage (no. 13). See chapter 2.3.1
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1.2.4 Wheel bearing

Two holding devices (WZ 041) are required for repairs on the wheel bearing with the axle installed. Alter-
natively, half of the axle (axle support from the differential on) must be completely dismantled (for the
mounting structure later)
(see too illustration 10)
1.2.4.1 Changing the wheel bearings
• Completely remove the equalising cage (no. 13) (Chapter 2.3.1)

• Dismantle the sun wheel (no. 15) (Chapter 2.3.2)
• Loosen 10 hexagon screws (no. 32) and fasten a holding device WZ 041 in each of the two removal
threads (M12) of the wheel hub (no. 31) with the help of an auxiliary screw M 12 x 20.
• Screw off the groove nut (no. 17).
To do so, heat up the groove nut M 70x1.5 (no. 17), for example, with a soldering device, and remove
with a special WZ 036 socket spanner
• Remove the levelling disc (no. 18) and the toothed ring support (no. 11) with the toothed ring (no. 9)
• Use a suitable pulling-off device to simultaneously remove the wheel hub (no. 22) and the outer wheel
bearing from the axle joint.
• Remove the disc (no. 23) and the entire cylindrical piston cylinder of the disc brakes.
• First remove the inner discs (no. 26 / 25) and then the outer discs (no. 28).
• Remove the WZ 041 holding devices and carefully lift up the wheel hub (no. 31).
• Remove the bearing inner ring of the inner wheel bearing (no. 24), with the roll body, off the axle
pivot (no. 27)
• Check the O-ring face on the axle pivot (no. 27) and the wheel hub (no. 31) and if required, replace
both parts
• Press the bearing outer rings of the wheel bearings (no. 21 and no. 24) out of the wheel hub.
• Insert new bearing outer rings into the wheel hub (no. 31)
• Pull the new bearing inner ring of the bearing (no. 24) with the roll body onto the axle pivot (no. 27) and
press firmly against the collar of the axle pivot. The installation temperature for the bearing inner ring
(no. 21) is max. 80°.
• Check the shaft seal (no. 30) and the V-ring and if necessary, replace both parts
• Insert a new shaft seal (no. 30) with a mounting ring (WZ 588) and push a new V-ring onto the axle
pivot (no. 27).
• Carefully put the wheel hub (no. 31) on and keep it in position with a WZ 041 holding device.
• Insert five straight pins (no. 20).
• Firstly push on the inner disc (no. 26) with the recess in the axle pivot (no. 27) and covering in the inner
disc (no. 26), and make a mark on one of the large oil outlet holes on the wheel hub (no. 22) with a felt-
tip pen.
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• Remove the inner disc (no. 26) again and insert the set of discs, beginning with the inner disc (no. 28),
alternately with the outer discs (no. 25). On assembling observe the marking made and place the oil
outlet holes over one another; insert an inner disc (no. 26) last.
• Visibly mark the recess on the axle pivot (no. 27) for the installation of the ring piston cylinder.
• Check both O-rings (no. 34) and no. (36) and replace if necessary, coating them with Wolfracote SSP
Klüber paste.
• Visibly mark the position of the Allen screw heads (no. 38) on the ring piston cylinder
• Draw the piston (no. 39) in the cylinder (no. 40) until it stops, place it over the marked recess of the axle
pivot (no. 27) and install. Install carefully in order to avoid damaging the O-rings. After installation,
check the scheduled bearing of the piston (no. 39) on the set of discs (the heads of the Allen screws
(no. 38) must be in the recesses of the axle pivot (no. 27)).
• Insert a new O-ring (no. 29) and mount the outer part of the wheel hub (no. 22) with the marking on the
marking of the inner part of the wheel hub (no. 31). A visible mark (for example, with a felt-tip pen) in
addition to the present marking (borings in both of the wheel hub parts) is recommended to assist with
mounting.
• Remove any dirt, oil, adhesives or preservatives from the thread M 70x1.5 of the axle pivot (no. 27) and
the groove nut.
• Insert the disc (no. 23) with the chamfer towards the ring piston cylinder side.
• Place the wheel hub (no. 22) on centrally and completely mount the heated-up bearing inner ring
(no. 21) onto the axle pivot (no. 27) and with a mounting bush, press firmly onto the collar of the axle
pivot. The installation temperature for the bearing inner ring (no. 21) is max. 80°.
• Push on the toothed ring support (no. 11) with the toothed ring (no. 9).
• Tighten the wheel bearing setting (Chapter 2.4.2) and the groove nut (no. 17) with a WZ 036 groove nut
key.
• Insert the sun wheel (no. 15).
• Insert the Seeger circlip ring (no. 14).
• Mount the equalising cage (no. 13) - see Chapter 2.3.1.
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1.2.4.2 Adjusting the wheel bearing
• "X1" ⇒Dimension on the axle pivot, measure and note down (theor. = 21 +/-0.2).
• Coat the front surface of the toothed ring support with Wolfracote SSP Klüber paste.
• Tighten the groove nut (no. 17) until the bearing pre-tensioning of 45 Nm has been reached (with the
sealing ring). Align the roll body and the wheel bearing; to do so, turn the wheel hub 1-2 x or hit a few
blows onto the wheel hub and the toothed ring support with a soft hammer.
• "X2" ⇒Dimension between the axle pivot and the front of the toothed ring support
(theor. = 19 +0.4/-1.0)
• "d" ⇒Calculate levelling disc (no. 18)
Disc thickness: "d"= "X1" - "X2"
"dmax"= "X1" - "X2"
"dmin"= ("X1" - "X2") - 0.12 (see illustration 10)
• Loosen and remove nut (no. 17) again.
• Remove any oil, dirt, preservatives or adhesive from the thread M70 x 1.5 of the axle pivot (no. 4) and
the nut (no. 17).
• Insert a levelling disc of the right thickness "d"
• Coat the front of the toothed ring support once more with Wolfracote SSP Klüber paste
(do not coat nut no. 17).
• Coat thread M70 x 1.5 of the axle pivot (no. 27) and nut (no. 17) around the whole circumference and
on the whole length with Loctite 242.
• Tighten nut (no. 17) at 1600 Nm. On using the torque amplifier (Sk 3.91-1007) at a gear transmission of
5:1, the tightening torque is 320 Nm.
• The bearing pre-tension set must be between 45 and 55 Nm.
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1.2.5 Brakes
1.2.5.1 Checking disc wear and tear

• Turn the wheel hub so that the opening of the oil draining plug (no. 52) comes to stop in the upper half
(above the oil level).
• Bring the disc set into the braked position and carry out a check in this position.
• Remove the oil draining plug (no. 52).
• Use a calliper gauge to measure from the end face for the sealing ring of the screw plug (no. 52) to the
test gib of the 3. outer disc
(target dimension for new discs 45.7 ±0.5 mm).
(engaging dimension for worn-out discs 43 -0.5 mm)
Disc wear check: Check on braked quality
Illustration 12
New discs = 45,7 mm
Worn discs = 43,0 mm
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1.2.5.2 Replacing piston packing
Two holding devices (WZ 041) are required for repairs on the piston packing with the axle installed. Alter-

To do so, heat up the groove nut M 70 x 1.5 (no. 17), for example, with a soldering device, and remove
bearing (no. 21) from the axle pivot (no. 4).
• Remove the disc (no. 23) and the entire cylindrical piston cylinder of the disc brakes. For dismantling
purposes, two removal threads (M 8) have been installed in the piston (no. 39), in which the extractor
can be fastened after removing the cylinder (no. 40).
• Secure the inner discs (no. 26 / 28) and the outer discs (no. 25) to prevent them from falling out.
• Pull the piston (no. 39) out of the cylinder (no. 40).
• Pull the piston packing (no. 42) and (no. 43) out of its seat with suitable tools (scribing iron or a suitably
robust plastic tool). Do not damage the sealing surface of the piston (no. 39) on dismantling.
• Insert new piston packing (no. 42) and (no. 43) and oil slightly
• Make a visible marking (with a felt-tip pen) for the groove in the cylinder (no. 44) and for the close-tole-
rance groove pin (no. 45) in the cylinder (no. 40).
• Place the markings on the piston (no. 39) and the cylinder on top of one another and bring them toge-
ther carefully until they rest firmly. On mounting, take care with the sealing lip of the outer piston
packing (no. 42) so that it is not turned up and damaged when being pushed on. The close-tolerance
groove pin (no. 45) must be inserted into the groove of the cylinder (no. 46).
Klüber paste.
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(no. 38) must be in the recesses of the axle leg (no. 27)).
mounting.
• Remove any dirt, oil, adhesives or preservatives from the thread M 70 x 1.5 of the axle pivot (no. 27)
and the groove nut.
• Place the wheel hub (no. 22) on centrally and completely mount the heated-up bearing inner
ring (no. 21) onto the axle pivot (no. 27) and with a mounting bush, press firmly onto the collar of the
axle pivot. The installation temperature for the bearing inner ring (no. 21) is max. 80°.
• Tighten the wheel bearing setting (Chapter 2.4.2) and the groove nut (no. 17) with a WZ 036 special
socket wrench.
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1.2.5.3 Replacing the brake discs and the pressure springs
Two holding devices (WZ 041) are required for repairs on the brake discs with the axle installed. Alterna-
tively, half of the axle (axle support from the differential on) must be completely dismantled (for the moun-
ting structure later). In addition a pressing device with a lifting power of at least 0.5 t is required.

with a special WZ 036 socket wrench.
can be fastened after extracting the cylinder (no. 40).
• Firstly push on the new inner disc (no. 26) with the recess in the axle pivot (no. 27) and covering in the
inner disc (no. 26), and make a mark on one of the large oil outlet holes on the wheel hub (no. 22) with
a felt-tip pen.
• Remove the inner disc (no. 26) again and insert the set of discs, beginning with an inner disc (no. 28),
alternately with the outer discs (no. 25). On assembling observe the marking made and place the oil
outlet holes over one another. Only insert the third outer disc with the test gib opposite the
thread M20 x 1.5 (no. 52). Insert an inner disc (no. 26) last.
• Loosen the Allen screws (no. 38) remove disc (no. 12) and take out 8 pressure springs (no. 47).
• Insert new pressure springs (no. 47) and tighten the disc (no. 12) with Allen screws (no. 38). The tigh-
tening torque is 4.1 Nm.
• Press the piston (no. 39) in the cylinder (no. 40) and make a visible marking (with a felt-tip pen) onto
the piston (no. 39) for the groove in the cylinder (no. 44) and onto the cylinder (no. 40) for the close-
tolerance groove pin (no. 45).
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• Restoring the adjusting device:
Allow the ring piston cylinder in the pressing device to rest on the piston (no. 39) with a ring support
with an internal diameter of 22 mm and an external diameter of 300 mm and press on the
cylinder (no. 40) which will restore the ring (no. 46) to its former position.
• Check both O-rings (no. 34) and no. (36), and replace if necessary, coating them with Wolfracote SSP
Klüber paste.
check the scheduled bearing of the piston (no. 39) on the set of discs (the heads of the Allen
screws (no. 38) must be in the recesses of the axle pivot (no. 27)).
mounting.
and the groove nut.
axle. The installation temperature for the bearing inner ring (no. 21) is max. 80°.
socket wrench.
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1.2.6 Replacing the double-jointed cardan shaft
• Completely remove the equalising cage (see Chapter 2.3.1)

• Drain off the oil out of the differential and the planetary gears (see Chapter 1.5.2.2)
• Remove the sun wheel (see Chapter 2.3.2)
• Remove the Seeger circlip ring (no. 72), and the Seeger supporting disc (no. 71) and pull the collar
stud (no. 70) out of the axle balls (no. 1) and the connecting rod (no. 73).
• Loosen the M 16 hexagon screws (no. 84) and remove.
• Take out the axle pivot pin at the top (no. 85) and the bottom (no. 86). To do so screw
two M10x50 DIN 933 removal screws into the respective removal threads (remove the plastic plug
before).
• Remove the axle ball (no. 1) together with the mounted axle pivot.
• Pull the double-jointed cardan shaft (no. 41) out of the axle support (no. 60) (illustration 10)
Please note: should the cardan shaft be broken on the inner profile shaft in the differential, the stump,
once the other side has been dismantled, can be pushed out with a round rod of approx. Ø20 x 800
mm through a hole in the cross bolt.
• Check on the condition of the cardan shaft guide bearings / bush and the Simmer circlip rings in the
axle support and axle pivot and replace if necessary.
Please note:
the bushings are slotted. Driving a small screw driver between the axle support and the axle pivot and
the bushing near the slit will deform the bushing so that it can be pulled out with flat-nosed pliers.
• Lightly scrape the new bushings after they have been pressed in and the bearing surface around the
gap at the joint. Insert new shaft seals and fill the gaps with grease. Pay attention to the position of the
sealing lips for the respective structural components.
• Push a new cardan shaft (no. 41) into the axle support (no. 60) and install into the profile of the diffe-
rential. On doing so, ensure that the sealing lip of the outer shaft seal (no. 95) is not turned up.
• Push on the axle ball (no. 1) together with the mounted axle pivot. On doing so, ensure that the sealing
lip of the outer shaft seal (no. 97) is not turned up.
• Mount the axle pivot pins. See steering swivel bearing (Chapter 2.7)
• Push on the sun wheel (no. 15) (Chapter 2.3.2)
• Insert the Seeger circlip ring (no. 14)
• Install the equalising cage (Chapter 2.3.1)
1.2.6.1 Replacing the shaft seals

• The procedure here is as described in Chapter 2.6
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Detail "X" Detail "Y"
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1.2.7 Steering swivel bearing
1.2.7.1 Removing the axle pivot pins

• Remove the steering cylinder, depending on the side (see Chapter 2.8)
• Loosen the M 16 hexagon screws (no. 84) and remove.
• Take out the axle pivot pin at the top (no. 85) and the bottom (no. 86). To do so screw two
M10 x 50 DIN 933 removal screws into the respective removal threads (remove the plastic plug
before).
• Remove the bearing discs (no. 93) and (no. 88) and the cap (no. 91).
• Remove the axle ball with the cardan shaft
1.2.7.2 Replacing bearing bushes
Please note:
the bushings (no. 92) are slotted.
• Driving a small screw driver between the axle support and the bushing near the slit will deform the
bushing so that it can be pulled out with flat-nosed pliers.
• Press new bushings in with a press.
• Slightly scrape the running surface near the gap at the joint.
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1.2.7.3 Installing axle pivot pins

• Check all of the axle discs and if necessary replace them.

• Fasten the bearing disc (no. 89) with the two dowel pins (no. 90) onto the axle support.
• Pull bearing disc (no. 88) over bearing disc (no. 89) and stick with grease.
• Place the cap (no. 91) over bearing disc (no. 88) and stick with grease.
• Push on the axle ball with the cardan shaft (no. 41). Push the cardan shaft into the axle support and
install into the profile of the differential. On doing so, ensure that the sealing lip of the outer shaft
seal (no. 95) is not turned up.
• Insert the axle pivot pin (no. 86) at the bottom and use a jack to push up the axle pivot pin with the axle
ball and to hold it in position.
• Insert the axle pivot pin (no. 85) at the top with a newly-determined bearing disc (no. 93). The oil
groove of the bearing disc points towards the contact area of the axle pivot pin (see Chapter 2.7.4).
• Insert new hexagon screws (no. 84). Tightening torque 290 +15 Nm
1.2.7.4 Determining the thickness of the bearing discs
• Push the axle ball right up (see Chapter 2.7.3).

• Insert the axle pivot pin (no. 86) at the bottom and use a jack to push up the axle pivot pin with the axle
ball and to hold it in position.
• Determine the thickness of the bearing discs (see illustration 14)
Dimension C:C = A - B + 0.2
• Dimension A: With a reducing scale, measure from the top of the axle ball to the eye end face of the
axle support.
• Dimension B: use a reducing scale to measure the flange height on the axle pivot pin.
Illustration 14
3 Bearing pin
10 Bearing disc
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1.2.8 Replacing the steering cylinder

• Loosen both of the steering cylinder connections.

• Bend the discs (no. 82) open on both sides and loosen the hexagon nut (no. 81).
• Remove the Seeger circlip ring (no. 75) on both sides, remove the Seeger supporting disc (no. 74) and
pull the collar stud (no. 77) out of the sliding bar (no. 73), or hammer out with a suitable pin punch (for
example, brass pin). Attention! The pins are hardened.
• Loosen the four Allen screws (no. 99) and pull the steering cylinder (no. 80) out of the differential hou-
sing (no. 23) towards the flange side (no. 100).
• Screw out the eye bolts (no. 76) on both sides of the steering cylinder. Make a note of the number of
turns when removing for installing later.
• Insert the steering cylinder (no. 80) and on mounting place the position of the connections horizontally.
• Use new, coated Allen screws (no. 99). (Tightening torque 300 Nm)
Important: a gap of at least 0.20 mm and at the most 0.9 mm must be measurable with the feeler
gauge between the flange (no. 100) and the housing (no. 23) (see illustration 15).
• Insert new discs (no. 82) and screw in eye bolts (no. 76) on both sides of the steering cylinder. Observe
the number of turns noted when screwing in.
Important: the measurements must be the same on both sides. (approx. 52 mm, see illustration 15)
• Insert the collar stud (no. 77) again.
• Check the track and if necessary adjust on both sides by means of evenly turning the eye
bolts (no. 76). When correctly adjusted, secure both of the collar studs (no. 77) with a Seeger suppor-
ting disc (no. 74) and a Seeger ring (no. 75).
• Tighten both of the hexagon screws (no. 81) and secure by means of folding over the disc (no. 82)
(tightening torque 600 Nm +50Nm).
• Re-connect the steering cylinder connections and drive the steering cylinder twice on both sides to the
stop position and check the seat.
Illustration 15
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1.2.9 Setting the track

• Bend the discs (no. 82) open on both sides and loosen the hexagon nut (no. 81).
• Remove the Seeger ring (no. 75) on both sides, remove the Seeger supporting disc (no. 74) and pull
the collar stud (no. 77) out of the sliding bar (no. 73), or hammer out with a suitable pin punch (for
example, brass pin). Attention! The pins are hardened.
• Check the track and adjust on both sides by means of evenly turning the eye bolts (no. 76). When cor-
rectly adjusted, secure both of the collar studs (no. 77) with a Seeger supporting disc (no. 74) and a
Seeger ring (no. 75).
• Tighten both of the hexagon nuts (no. 81) and secure by means of folding over the disc (no. 82) (tighte-
ning torque 600 Nm +50Nm)
Subject to change
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Tools list for WY 217 axles
Name: WZ number:
Press-fit mandrel WZ 201

for shaft seals 1160.209 / 1160.110 on the cardan flange
(with a spacer for the inner shaft seal)
(no spacer for the outer shaft seal)
Holding device + M 12 x 20 WZ 041

for lifting up the wheel hub for WY 217
Sharpening wheel WZ 190
for the inner part of the equalising cage
Press punch WZ 588
for shaft seal 7308.082 in the wheel hub
Groove nut key WZ 036

+ torque converter bearing
for groove nut 7329.085 in the wheel hub
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2WY 218 planetary rigid axle

Contents
2.1 General information and maintenance ................................................................................. 42
2.1.1 Introduction ........................................................................................................................... 42
2.1.2 Ordering spare parts ............................................................................................................ 42
2.1.3 Liability and guarantee for structural components relevant to safety ................................... 43
2.1.4 Working conditions and tools ............................................................................................... 43
2.1.5 Maintenance work ................................................................................................................ 44
2.1.5.1 Lubrication chart ................................................................................................................... 44
2.1.5.2 Maintenance rates ................................................................................................................ 45
2.1.5.2.1 Initial filling ............................................................................................................................. 46
2.1.5.2.2 Oil change ............................................................................................................................. 46
2.1.5.2.3 Checking the oil level ............................................................................................................ 47
2.1.5.2.4 Check .................................................................................................................................... 47
2.2 Repair instructions ................................................................................................................ 48
2.2.1 Replacing the entire differential ............................................................................................ 48
2.2.2 Repairs to the differential ..................................................................................................... 49
2.2.2.1 Replacing the ring gear / pinion ............................................................................................ 49
2.2.2.1.2 Setting the pinion bearing or completing installation ............................................................. 53
2.2.2.1.3 Setting the tooth clearance and the ring gear bearing .......................................................... 53
2.2.2.1.4 Checking the contact pattern ................................................................................................. 54
2.2.2.2 Replacing the differential cage (compensating gears) ......................................................... 55
2.2.3 Planetary gears .................................................................................................................... 56
2.2.3.1 Fully replacing the equalisation cage ................................................................................... 58
2.2.3.2 Replacing the sun wheel ...................................................................................................... 58
2.2.3.3 Replacing planetary pins and wheels ................................................................................... 59
2.2.3.4 Replacing the toothed ring ................................................................................................... 59
2.2.4 Wheel bearing ...................................................................................................................... 60
2.2.4.1 Changing the wheel bearings ............................................................................................... 60
2.2.4.2 Adjusting the wheel bearing ................................................................................................. 62
2.2.5 Replacing a half-shaft ........................................................................................................... 63
2.2.6 Brakes .................................................................................................................................. 64
2.2.6.1 Checking disc wear and tear ................................................................................................ 64
2.2.6.2 Replacing piston packing ..................................................................................................... 65
2.2.6.3 Replacing the brake discs and the pressure springs ............................................................ 67
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2.1 General information and maintenance

2.1.1 Introduction
Serial production of the WY 218 commenced in November 2001. This model is fitted with a permanent dif-
ferential device. The two external planetary gears are driven by half-shafts and sun wheel shafts. The axle
is rigid and has been constructed as a direct frame attachment with fittings for pushing bars. The main drive
is carried out by a Æ120 cardan flange, with two hydraulically-operated disc brakes as service brakes.
2.1.2 Ordering spare parts

It is advisable to purchase spare parts for this NAF axle direct from an authorised WEYHAUSEN agent who
is likely to have many of the parts on stock. Even if parts are not available immediately we recommend that
they be ordered through the dealer and not from the factory. The agent will generally be able to describe
the part required in more detail and indicate the exact part number, hence helping to avoid errors and in-
correct deliveries.
When ordering spare parts it is essential to provide the full, exact type specification with the works number
and the year of construction. The nameplate is located on the differential housing near the oil check screw
- see illustration 1. Use original NAF spare parts only. If spare parts produced by other manufacturers are
used there will no longer be any guarantee; the function may be impaired and the useful life span of the
equipment may be shortened.
Illustration 1

40 Oil-filling and oil-check screw
2 Nameplate
4 M 14 x 1.5 disc service brake connection "P" marking Mineral oil
5 M 14 x 1.5 disc service brake connection "P" marking Mineral oil
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2.1.3 Liability and guarantee for structural components relevant to safety

We highly recommend that for structural components relevant to safety (e.g. shift cylinders, steering cylin-
ders, brake cylinders, spring-loaded cylinders, etc.) the whole structural component be replaced.
There is no longer any entitlement to claim on the basis of a guarantee or liability once the structural com-
ponent relevant to safety has been dismantled and opened, i.e. NAF does not assume any product liability
for the drive unit. This also applies if the entire drive unit is still under guarantee.
2.1.4 Working conditions and tools

A clean, well-lit place of work is essential in order to be able to carry out repairs properly. There should also
be sufficient space available to be able to lay out and arrange the various parts and structural components.
A full set of quality tools of all basic tools required is also essential. In addition a few special tools are also
required. These tools usually prove to be invaluable when certain repairs need to be carried out frequently.
A great deal of time (and trouble) can be spared. These special tools are described or indicated in more
detail in the respective sections (e.g. with the tool number).
Furthermore, certain specialised knowledge and even training is essential for carrying out certain repairs.
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2.1.5 Maintenance work
2.1.5.1 Lubrication chart
Lubrication chart for the WY 218

Lubrication point No. Quantity Lubricants
Differential 40/41 14,0 litres SAE 90 (hypoid oil) / GL 5 / LS
Planetary gears 50/51/52 4,0 litres each SAE 90 (hypoid oil) / GL 5 / LS
Description of the lubrication point numbers:

No. 40 ⇒Oil filler screw for the differential
No. 41 ⇒Oil drain screw for the differential
No. 50 ⇒Oil filler screw for the planetary gears
No. 51 ⇒Oil drain screw for the planetary gears
No. 52 ⇒Oilpan drain plug for the planetary gears and the inspection hole for disc wear and tear
(see also illustrations 1 and 2)
Example of SAE 90 premium EP gear oil in the specification: API-GL 5 / MIL-L-2105 B / LS

Fuchs (Renogear LS 90), (Renogear HLS 90)
DEA (Deagear LS SAE 85 W-90), (Dearon BHS SAE 90)
Mobil (Mobilube SHC-LS)
Esso (Gear oil LSA 85 W-90)
Schell (Gear oil 90LS)
BP (Energear LS 90
ELF (Tranself BM-LS 90)
Aral (Degol 3216)
Please observe the details on the lubrication chart for filling quantities
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2.1.5.2 Maintenance rates

NAF axles have been developed and constructed on the basis of yearlong experience and knowledge con-
cerning machine stress. However, perfect functioning and constant operation is only ensured if the axles
are taken care of, treated well and regularly serviced. This includes observing maintenance rates, using
the proper lubricants in accordance with the lubrication chart and monitoring a few maintenance items. No
special tools are required for maintenance work.
Maintenance rate chart for the WY 218

Maintenance point (no.) Hours of operation
0/ After 1 day 50-500 Every Every 2000 or
Putting into 500 once a year
operation
Differential (40/42) 1 - 2 3 2
Planetary gears 1 - 2 3 2
(50/51/52)
Wheel nuts 4 4 4 4 -
All of the visible screws and - - 4 - 4
nuts
Disc wear check - - - - 4
1 = Initial filling (see Chapter 1.5.2.1)

2 = Oil change (see Chapter 1.5.2.2)
3 = Oil level check (see Chapter 1.5.2.3)
4 = Check (see Chapter 1.5.2.4)
Illustration 2
1 Breather
42 Oil drainage screw on the back
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2.1.5.2.1 Initial filling

• Differential
Remove the oil filler screws (no. 40) and fill up with oil in accordance with the lubrication chart until the
oil level reaches the bottom of the thread. Check after 5 minutes and fill in more oil if necessary. The
tightening torque of the filler screw (no. 40) is 80 +10 Nm. (illustration 1)
• Planetary gears
Turn both of the wheel hubs so that the screw plugs (no. 50) are horizontal (illustration 4). Remove the
screw plugs (no. 50 / 51) and fill oil into the top opening (no. 51) in accordance with the lubrication chart
until the oil level reaches the bottom of the thread bore (no. 50). Check after 5 minutes and fill in more
oil if necessary. The tightening torque of the screw plugs (no. 50 / 51) is 45 +5 Nm. (illustration 3)
2.1.5.2.2 Oil change

Please note: clean the area around the screw plugs prior to changing oil
• Differential
Carry out the oil change with warm oil. Remove the oil filling screw (no. 40) and then open the oil drain
screw (no. 42). Completely drain off the oil. Only fill in new oil in accordance with the lubrication chart
once the oil has been drained off the planetary gears. The tightening torque for the oil filling screw and
the oil drain screw is 80 +10 Nm (illustrations 1 and 2).
• Planetary gears
Carry out the oil change with warm oil at the same time as for the differential. To do so, turn the wheel
hubs until both of the screw plugs (no. 50/52*) are right at the bottom (illustration 3). Remove the screw
plugs (no. 50/51/52) and completely drain off the oil. Then turn the wheel hubs back by 90° until the
screw plugs (no. 50) are horizontal and insert the screw plug (no. 52) (illustration 4). Fill oil into the top
opening (no. 51) in accordance with the lubrication chart until the oil level reaches the bottom of the
horizontal thread bore (no. 50). Check the oil level after 5 minutes and fill in more oil if necessary.
The tightening torque of the screw plugs (no. 50/51/52) is 45 +5 Nm.
(*) on the back of the wheel hub.
50 Position of the screw plug for draining off oil 50 Position of the screw plug for filling in and for
checking the oil
52 Disc wear check with the oil drain screw plug
(on the back of the wheel hub)
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2.1.5.2.3 Checking the oil level

Please note: clean the area around the screw plugs prior to checking the oil level
• Differential
Remove the oil filling screws (no. 40) and if necessary, fill in new oil in accordance with the lubrication
chart. The tightening torque of the oil filler screw (no. 40) is 80 +10 Nm (illustration 1).
• Planetary gears
Turn the wheel hubs so that the two screw plugs (no. 50) are horizontal (illustration 4). Remove the
screw plugs (no. 50). The oil level should be at the bottom of the thread. If necessary fill in more oil in
accordance with the lubrication chart. The tightening torque of the screw plugs (no. 50) is 45 +5 Nm.
2.1.5.2.4 Check
• All of the screws and nuts
Screws and nuts may loosen as a result of stress and vibration of the vehicle. Tightening them in good
time will avoid leaks and substantial damage. The wheel nuts and the cardan flange screws in particu-
lar must be checked. The tightening torque for the wheel nuts is 450 - max. 550 Nm.
Please note: the glued nut for fastening the cardan flange (pinion nut) may not be tightened.
• Disc wear check
(see illustration 12 / page 28).
test gib of the 4. outer disc.
(target dimension for new discs 39.4 +/-0.6 mm)
(intervention dimension for worn-out discs 36.8 -0.5 mm)
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2.2 Repair instructions

2.2.1 Replacing the entire differential
Please note: in the event of substantial damage to the differential it would be better to replace the entire
differential instead of carrying out repairs.
• To do so, it is advisable to remove the whole axle from the chassis.
• Drain off the differential oil.
• Screw out the hexagon screws (no. 24) on both sides of the differential,
and take off - or pull out - the axle support (no. 40) with the half-shaft (46). (see illustration 5)
• Replace the differential
Please note: original NAF replacement and repair differentials have been properly set in the factory. The
bearing and contact pattern settings of differentials which have not been processed by NAF must be
checked prior to installation.
• Remove the rust-protection coating on fitting surfaces.
• Renew the O-rings (no. 28).
• Install the spline shaft profile of the half-shaft in the spacing wheels (no. 22) by means of turning the
cardan flange (no. 39) slightly (see illustration 5).
• Then push the axle support up to the flange position, observe the adapter sleeve (no. 9).
• Screw in hexagon screws (no. 24). The tightening torque is 290 +10 Nm.
• Install the axle into the vehicle (connect the brakes, steering cylinder and cardan shaft).
• Fill oil into the differential and the planetary gears.
• Attention: do not forget to bleed the brakes.
• Do a test drive and check the brakes several times.
• Tighten the axle fastening screws after test driving.
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2.2.2 Repairs to the differential
2.2.2.1 Replacing the ring gear / pinion

Please note:
The ring gear and the pinion (no. 13) can only be replaced as a set. They cannot be replaced individually
since their toothed wheels overlap. The respective parts which belong together are indicated by means of
the same numbers on the ring gear and the pinion - engraved with an electric writing device.
In the case of such a repair it is advisable to replace all of the bearings as well.
• Remove the differential (Chapter 2.1).
• Remove the differential cage (no. 11/11) with the ring gear (no. 13).
• Remove the pinion nut (no. 41), supporting the cardan flange with a hold-up device while doing so.
In order to facilitate installation, heat up the nut to approx. 100°C
(the releasing torque may be up to 800 Nm)
• Remove the cardan flange (no. 39) and pull out the pinion (no. 13) towards the inside.
• Remove the rotary shaft lip seals (no. 36) and (no. 37).
• Check the tapered roller bearings (no. 10/16) for the differential cage bearing and (no. 35/42) for the
pinion bearing and renew if necessary.
• Press the ring gear (no. 13) out of the differential cage (no. 11/11) after loosening the hexagon
screw (no. 7).
• Push a new ring gear onto the differential cage (no. 11) and on doing so also install the two cylinder
pins (no. 12). Tighten new hexagon screws (no. 7) (due to coating on the thread) obliquely with a dyna-
mometric key. The tightening torque is 185 Nm.
• Press in the bearing outer rings (from no. 42, no. 35, no. 10 and no. 16) into the differential housing (no.
23) or flange (no. 5) in the case of replacement.
• Insert the bearing inner rings (from no. 10 and 16) with the roll body onto the differential
cage (no. 11/11).
• Insert the bearing inner ring (from no. 42) with the roll body onto the pinion (no. 13).
• Press the pinion (no. 13) from the inside and hold up.
• Determine the thickness of the levelling disc (no. 44) - see Chapter 2.2.1.2.
• Firstly thread the spacer bush (no. 43) and then the spacer disc(s) (no. 44) selected onto the pinion
(no. 13).
• Press the bearing inner ring (from no. 35) with the roll body onto the pinion (no. 13).
• Put on the cardan flange (no. 39) and tighten the pinion nut (no. 41) without Loctite at 800 Nm.
• Check the bearing pre-tension of the pinion bearing with a torque gauge and change the levelling disc
if necessary
(pre-stress: 0.5 - 6.0 Nm for new pinion bearings).
(pre-stress: 0 -5.0 Nm for used pinion bearings).
This data applies without shaft seals and a ring gear being installed.
Make a note of the pinion bearing pre-tension measured.
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• Loosen the pinion nut (no. 41) again and clean the thread of the pinion and the nut to remove dirt, oil
and preservatives.
• Install the shaft seals (no. 36 and no. 37) with a press-fit mandrel and fill the gap between the two shaft
seals (no. 36 and no. 37) with grease until it is half filled.
• Install a new O-ring (no. 38).
• Screw the nut (no. 41) onto the pinion (no. 13) and tighten at 800 Nm. The final position must have
been reached within 3 to 5 minutes in order for the Loctite to remain fully effective.
• Insert the differential cage (no. 11) with the ring gear (no. 13), place a new O-ring (no. 6) onto the
flange (no. 5) and fasten with Allen screws (no. 4). Also fasten the two flanges (no. 5) with four
M16 x 40 auxiliary screws each.
• Check or adjust the torsional flank clearance between the ring gear and the pinion (clearance of 0.15 -
0.25) (see chapter 2.2.1.3).
• Remove the M16 x 40 auxiliary screws and install the differential (see Chapter 2.1).
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Illustration 5
1. Hexagon screw 2. Safety plate
3. Nut 4. Allen screw
5. Flange 6. O-ring
7. Hexagon screw 8. Disc
9. Adapter sleeve 10. Tapered roller bearing
11. Differential housing 12. Straight pin
13. Ring gear / pinion 14. Flange
15. Hexagon screw 16. Tapered roller bearing
17. Nut 18. Pressure disc
19. Equalising wheel 20. Cross bolt
21. Stop disc 22. Spacing wheel
23. Differential cage 24. Hexagon screw
25. Detent edged ring 26. Screw plug
27. Sealing ring 28. O-ring
29. Hydraulic-type lubricating nipple 35. Tapered roller bearing
36. Shaft seal 37. Shaft seal
38. O-ring 39. Cardan flange
40. Axle support 41. Nut
42. Tapered roller bearing 43. Distance bush
44. Levelling disc 45. Levelling disc
46. Half-shaft
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• Press new bearing outer rings (from no. 42 (with levelling discs(s) (no. 45) and (no. 35) in the differen-
tial housing (no. 23) until they rest.
• Insert the bearing inner ring (from no. 42) with the roll body onto the pinion (no. 13). The installation
• Insert the pinion (no. 13) from the inside into the housing (no. 23) and support.
• Select two to three levelling discs (no. 44) and the distance bush (no. 43). Compile with a total dimen-
sion in the range of 26.84 to 28.26 mm.
Please note:
Firstly check or use the combination selected in the factory.
Levelling disc thickness: 0.96 to 1.44 (with stages of 0.04)
Distance bush (no. 43): 25.0 +/-0.02 mm
• Firstly place the levelling disc(s) selected (no. 44) onto the pinion (no. 13) and then put on the spacer
bush (no. 43) (see illustration 5).
• Press the bearing inner ring (from no. 42) with the roll body onto the pinion (no. 13). The installation
(e.g. Wolfracote SSP by Klüber)
• Put on the cardan flange (no. 39) and screw the pinion nut (no. 41) onto the pinion (no. 13) and tighten
at 800 Nm.
• Check the pinion bearing pre-stress with the torque gauge and if necessary change the levelling disc
(no. 44). The pinion bearing must not have any axial clearance; it should be possible to turn it at 0.5 to
6.0 Nm. For bearings already used the setting is 0 to 5.0 Nm (pinion bearing pre-stress for new bea-
rings: 0.5 - 6.0 Nm).
Make a note of the bearing pre-stress set for setting the ring gear bearing later (see Chapter 2.2.1.4).
• When the bearing pre-stress is correct, secure the pinion nut (no. 41) with Loctite (see Chapter 2.2.1.2)
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2.2.2.1.2 Setting the pinion bearing or completing installation
• Clean any dirt, oil and preservatives off the pinion (no. 13) and the pinion nut (no. 41).
(e.g. Wolfracote SSP by Klüber).
• Screw the nut (no. 41) onto the pinion (no. 13) and tighten at 800 Nm, while backing it onto the cardan
flange (no. 39). Use a few blows onto the outside of the housing in the area of the pinion bearing to
align the roller bearings. The final position must have been reached within 3 to 5 minutes in order for
the Loctite to remain fully effective.
• Check the bearing pre-stress of the pinion bearing with a torque key and if necessary adjust the set-
ting. The pinion bearing may not have any axial clearance; it should be possible to turn it at 0.5 to 6.0
Nm. For used bearings the setting is 0 to 5.0 Nm.
• Make a note of the bearing pre-stress set for setting the ring gear bearing later.
2.2.2.1.3 Setting the tooth clearance and the ring gear bearing
• Loosen the screw (no. 1) and remove the safety plate (no. 2).
• Screw out the nut (no. 3) approx. 2 threadturns.
• Fully insert the differential cage (no. 11).
• Fasten the flange (no. 5) and the new O-ring (no. 6) with Allen screws (no. 4). Also fasten the flange
(no. 5) with four M 16 x 40 auxiliary screws.
• Set the bearing pre-stress of the ring gear bearing (no. 10) and (no. 16). To do so, turn the nut (no. 3)
until the required bearing pre-stress of 1.0 - 3.0 Nm has been reached. The tooth profile clearance
must still be in the range of 0.15 to 0.25 mm.
• The figure is determined on the pinion nut (no. 41) with a torque gauge, namely by means of adding a
torque of 0.5 to 1.5 to the pinion bearing pre-stress (figure noted in Chapter 2.2.1.2).
• In order to adjust the tooth profile clearance, the adjusting disc (no. 14) behind the bearing cup of the
tapered roller bearing (no. 16) is to be replaced accordingly (experimental value = 1.9 mm)
• Once the tooth profile clearance and the bearing pre-stress has been reached, secure the nut (no. 3)
with the safety sheet (no. 2) and a hexagon screw (no. 1).
• Make a note of the bearing friction torque.
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2.2.2.1.4 Checking the contact pattern
• Loosen the auxiliary screws and the Allen screws (no. 4) on the flange (no. 5) and remove the flange.
• Take out the differential cage (no. 11) and paint the tooth profiles of 2 tooth spaces (= 4 tooth profiles)
on the ring gear (no. 13) with thin yellow paint and install the differential cage (no. 11) and the flange
(no. 5) with auxiliary screws again.
• Race the pinion so that the contact pattern is marked by means of the oil paint.
• Dismantle the flange (no. 5), remove the differential cage (no. 11) with the ring gear and inspect the
contact pattern. If the levelling disc thickness is right, a contact pattern in accordance with illustration 9
must be achieved, otherwise select a new levelling disc (no. 14) (see chapter 2.2.1.3).
If the contact pattern complies with illustration 7 or 8, the pinion must be adjusted with the help of changing
the disc thickness of the levelling disc (45) in order to achieve a contact pattern in accordance with illustra-
tion 9.
Please note: always pay attention to the correct

pre-stress of the bearings (10) and (16) during the
setting procedures. Also pay attention to correct tooth
clearance on turning the nuts (3). Repeatedly wash
off old oil paint from previous attempts at setting.
Illustration 9
Once the tooth profile clearance and the bearing pre-stress have been set, secure both of the nuts (no. 3)
with safety sheets (no. 2) and new hexagon screws (no. 1).
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2.2.2.2 Replacing the differential cage (compensating gears)

Please note:
The two halves of the differential cage (no. 11 and no. 11) can only be replaced together; observe the
position markings and the other markings.
• Remove the differential (see Chapter 2.1).
• Remove the differential cage (no. 11/no. 11) with the ring gear (no. 13).
• Press the ring gear (no. 13) out of the differential cage (no. 11) after loosening the hexagon
screws (no. 7).
• Remove the hexagon screws (no. 15) and open the differential cage.
• Remove the cross bolt (no. 20) with the equalising wheel (no. 19) and the pressure disc (no. 18) as a
unit. Check the components and renew if necessary.
• Remove the differential pinions (no. 22) with the stop discs (no. 21). Check the components and renew
if necessary.
• Make the differential cage setting by means of selecting "s" on the stop discs (no. 21).
Selection of thickness "s" of the stop discs (no. 21) between 1.5 and 2.5 mm
To do so, screw the two differential cage halves together with the selected components as a test
with 4 uncoated auxiliary m 10 x 90 screws. Race the differential gear with the help of a profiled shaft
butt end. There must be no perceivable resistance or shaking. The axial clearance on the differential
pinion (no. 22) must be less than 0.2 mm. If the setting is false, change the stop disc accordingly and
repeat the test procedure.
• When the setting is correct, remove the four uncoated auxiliary screws and screw permanently toge-
ther with 12 new coated hexagon screws (no. 15). The tightening torque for the hexagon
screws (no. 15) is 67 +5 Nm.
• Press on both of the tapered roller bearings (no. 10 and no. 16) and also replace the bearing cups in
the flanges (no. 5 and no. 14) when renewing.
• Insert the differential gear and check the torsional flank clearance between the ring gear and the pinion
(clearance 0.15 - 0.25) (see Chapter 2.2.1.4 and 2.21.5).
• Install the differential (see Chapter 2.1).
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2.2.3 Planetary gears
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Illustration 10
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1. Axle support 2. Hexagon screw 3. Disc

4. Snap ring 5. Snap ring 6. Stop disc
7. Planet pin 8. Needle ring 9. Gear ring
10. Planet wheel 11. Gear ring carrier 12. Disc
13. Equalising cage 14. Seeger circlip ring 15. Sun wheel
16. Screw plug 17. Groove nut 18. Levelling disc
19. Set of levelling discs 20. Straight pin 21. Tapered roller bearing
22. Wheel hub outer part 23. Disc 24. Tapered roller bearing
25. Outer disc 26. Inner disc 27. Axle pivot
28. Inner ring 29. O-ring 30. Shaft seal
31. Wheel hub 32. Hexagon screw 33. Countersunk screw
34. O-ring 35. O-ring 36. O-ring
37. Snap ring 38. Allen screw 39. Piston
40. Cylinder 41. Half-shaft 42. Piston packing
43. Piston packing 44. Cylinder 45. Close-tolerance groove pin
46. Ring 47. Pressure spring 48. Seeger circlip ring
49. Tolerance ring 50. Screw plug 51. -
52. Screw plug 53. Straight pin 54. Hexagon screw
55. O-ring 56. Breather 57. Disc
58. - 59. Sealing ring 60. Seeger circlip ring
61. O-ring 62. Bush 63. -
64. Wheel pin 65. Centring ring 66. Limes-type ring
Tightening torque 500-50 Nm with a
torque key
67. Flat collar nut 68. Pin insertion depth 8.7-0,5 69. Bearing setting: Pre-stress: 45 - 55
Nm with a sealing ring(disc brake in a
horizontal position)
70. Bearing marking for installation 71. Clearance 1.2 - 4.9
2.2.3.1 Fully replacing the equalisation cage
• Place the recess of the new equalising cage (no. 13) over the marking on the bearing of the wheel hub
To do so, the gearing of the sun wheel and the three planet wheels are to be brought into the interwea-
the toothed ring (no. 9). Then push the equalising cage on completely.
2.2.3.2 Replacing the sun wheel
• Remove the equalising cage (no. 13) (see Chapter 2.3.1).
• Remove the Seeger circlip ring (no. 14).
• Pull the sun wheel (no. 15) off the double-jointed cardan shaft.
• Push on a new sun wheel (no. 15).
• Insert the Seeger circlip ring (no. 14) again.
• Equalising cage (no. 13) (see Chapter 2.3.1)
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2.2.3.3 Replacing planetary pins and wheels


• Put down the equalising cage (no. 13) with the opening facing to the top.
• Loosen three hexagon screws (no. 2).
• Remove both of the snap rings (no. 4 and 5) and the disc (no. 3).
• Remove the planetary pins (no. 7) with an M 12 extractor hammer.
• Remove the planet wheel (no. 10) with the needle ring (no. 8) and the stop discs (no. 6) as a unit
towards the centre of the equalising cage.
• Insert the new unit (planet wheel + needle ring + stop discs) and press in the planetary pins (no. 7) to a
depth of 8.7 mm.
Please note: The engaging gibs of the stop discs must point towards the middle of the equalising cage
(no. 13) on being installed.
• Install the disc (no. 3) and the two snap rings (no. 4 and 5) once again.
• Tighten the three newly-coated hexagon screws (no. 2) at 70 Nm.
• Check the clearance of the planet wheels (no. 10) and the axial clearance (min. 0.3 mm).
• Install the entire equalising cage (no. 13) (see Chapter 2.3.1).
2.2.3.4 Replacing the toothed ring


• Take out the snap ring (no. 37).
• Insert a new toothed ring (no. 9).
• Insert the snap ring (no. 37) again.
Please note: it should now be possible to move the toothed ring radially by +/- 0.4 mm on the toothed
wheel support (no. 9).
• Install the equalising cage (no. 13). See chapter 2.3.1)
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2.2.4 Wheel bearing

If during a repair the seal (slide ring seal) has to be opened, it is necessary to fit a new seal assembly, also
when it is not worn yet. Two holding devices (WZ 042) are required for repairs on the wheel bearing with
the axle installed. Alternatively, half of the axle (axle support from the differential on) must be completely
dismantled (for the mounting structure later)
2.2.4.1 Changing the wheel bearings

To do so, heat up the groove nut M 70x1.5 (no. 17), for example, with a soldering device, and remove
bearing from the axle joint.
• Remove the disc (no. 23) and the entire cylindrical piston cylinder of the disc brakes.
• Remove the WZ 042 holding devices and carefully lift up the wheel hub (no. 31).
• Remove the bearing inner ring of the inner wheel bearing (no. 24), with the roll body, off the axle
pivot (no. 27)
• Check the O-ring face on the axle pivot (no. 27) and the wheel hub (no. 31) and if required, replace
both parts
• Press the bearing outer rings of the wheel bearings (no. 21 and no. 24) out of the wheel hub.
• Insert new bearing outer rings into the wheel hub (no. 31)
• Pull the new bearing inner ring of the bearing (no. 24) with the roll body onto the axle pivot (no. 27) and
press firmly against the collar of the axle pivot. The installation temperature for the bearing inner ring
(no. 21) is max. 80°.
• Check the shaft seal (no. 30) and the V-ring and if necessary, replace both parts
• Insert a new shaft seal (no. 30) with a mounting ring (WZ 588) and push a new V-ring onto the axle
pivot (no. 27).
• Carefully put the wheel hub (no. 31) on and keep it in position with a WZ 041 holding device.
• Push on the inner disc (no. 26) with the recess covering the recess in the axle pivot (no. 27), and make
a mark on one of the large oil outlet holes on the wheel hub (no. 22) with a felt-tip pen.
• Insert the set of discs, beginning with an inner disc (no. 26) alternately with outer discs (no. 25), and on
doing so, insert the first two outer discs turned by a pitch (72°) (i.e. the test gib of the first two outer
discs may not be opposite the thread boring (no. 52). On mounting, please observe the marking made
and place the oil flow holes on top of one another; insert the third outer disc (no. 25) with the test gib
opposite the thread boring (no. 52) and then insert an inner disc (no. 26) last.
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Klüber paste.
(no. 38) must be in the recesses of the axle pivot (no. 27)).
mounting.
• Remove any dirt, oil, adhesives or preservatives from the thread M 70x1.5 of the axle pivot (no. 27) and
the groove nut.
• Place the wheel hub (no. 22) on centrally and completely mount the heated-up bearing inner ring
(no. 21) onto the axle pivot (no. 27) and with a mounting bush, press firmly onto the collar of the axle
pivot. The installation temperature for the bearing inner ring (no. 21) is max. 80°.
• Tighten the wheel bearing setting (Chapter 2.4.2) and the groove nut (no. 17) with a WZ 504 groove nut
key.
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2.2.4.2 Adjusting the wheel bearing
• "X1" ⇒Dimension on the axle pivot, measure and note down (theor. = 21 +/-0.2).
• Coat the front surface of the toothed ring support with Wolfracote SSP Klüber paste.
• Tighten the groove nut (no. 17) until the bearing pre-tensioning of 45 Nm has been reached (with the
sealing ring). Align the roll body and the wheel bearing; to do so, turn the wheel hub 1-2 x or hit a few
blows onto the wheel hub and the toothed ring support with a soft hammer.
• "X2" ⇒Dimension between the axle pivot and the front of the toothed ring support
(theor. = 19 +0.4/-1.0)
• "d" ⇒Calculate levelling disc (no. 18)
Disc thickness: "d"= "X1" - "X2"
"dmax"= "X1" - "X2"
"dmin"= ("X1" - "X2") - 0.12 (see illustration 10)
• Loosen and remove nut (no. 17) again.
• Remove any oil, dirt, preservatives or adhesive from the thread M70 x 1.5 of the axle pivot (no. 4) and
the nut (no. 17).
• Insert a levelling disc of the right thickness "d"
• Coat the front of the toothed ring support once more with Wolfracote SSP Klüber paste
(do not coat nut no. 17).
• Coat thread M70 x 1.5 of the axle pivot (no. 27) and nut (no. 17) around the whole circumference and
on the whole length with Loctite 242.
• Tighten nut (no. 17) at 1600 Nm. On using the torque amplifier (Sk 3.91-1007) at a gear transmission of
5:1, the tightening torque is 320 Nm.
• The bearing pre-tension set must be between 45 and 55 Nm.
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2.2.5 Replacing a half-shaft

Please note! In order to avoid new settings in the planetary drive, the entire axle should be removed from
the vehicle chassis, or the half of the axle on which the half-shaft is to be replaced should be removed from
the differential and the vehicle frame.
• Pull the half-shaft (no. 41) together with the sun wheel from the steering stub axle.
• Place the sun wheel (no. 15) onto the new half-shaft and secure with a Seeger circlip ring (no. 14).
• Thread the new half-shaft (no. 41) through the steering stub axle (no. 27).
• Turning on the half-shaft slightly back and forth will facilitate threading in the hub profile of the differen-
tial pinion.
• Place the recess of the new equalising cage (no. 13) over the bearing marking on the wheel hub
• To do so, the gearing of the sun wheel and the three planet wheels are to be brought into the interwea-
the toothed ring (no. 9).
• Then push the equalising cage on completely.
• Fill up oil in the differential and in the planetary gears (Chapter 1.5.2.3)
Axles
Revised: 08.2004 1305 / 1505 / 1605 / 1705 Mobile
2.2.6 Brakes
2.2.6.1 Checking disc wear and tear

test gib of the 3. outer disc
(target dimension for new discs 45.7 ± 0.5 mm).
(engaging dimension for worn-out discs 43.0 - 0.5 mm)
Disc wear check: check on braked quality
Illustration 12
New discs = 45.7 mm

Worn discs = 43.0 mm
Axles
1305 / 1505 / 1605 / 1705 Mobile Revised: 08.2004
2.2.6.2 Replacing piston packing
Two holding devices (WZ 042) are required for repairs on the piston packing with the axle installed. Alter-

can be fastened after removing the cylinder (no. 40).
• Secure the inner discs (no. 26 / 28) and the outer discs (no. 25) to prevent them from falling out.
• Pull the piston (no. 39) out of the cylinder (no. 40).
• Pull the piston packing (no. 42) and (no. 43) out of its seat with suitable tools (scribing iron or a suitably
robust plastic tool). Do not damage the sealing surface of the piston (no. 39) on dismantling.
• Insert new piston packing (no. 42) and (no. 43) and oil slightly
• Make a visible marking (with a felt-tip pen) for the groove in the cylinder (no. 44) and for the close-tole-
rance groove pin (no. 45) in the cylinder (no. 40).
Klüber paste.
(no. 38) must be in the recesses of the axle leg (no. 27)).
mounting.
Axles
Revised: 08.2004 1305 / 1505 / 1605 / 1705 Mobile
and the groove nut.
axle pivot. The installation temperature for the bearing inner ring (no. 21) is max. 80°.
socket wrench.
Axles
1305 / 1505 / 1605 / 1705 Mobile Revised: 08.2004
2.2.6.3 Replacing the brake discs and the pressure springs
Two holding devices (WZ 042) are required for repairs on the brake discs with the axle installed. Alterna-
tively, half of the axle (axle support from the differential on) must be completely dismantled (for the moun-
ting structure later). In addition a pressing device with a lifting power of at least 0.5 t is required.

with a special WZ 465 socket wrench.
can be fastened after extracting the cylinder (no. 40).
• Insert five pins (no. 20) or check to see that they are complete.
• Push on an inner disc (no. 26) with the recess covering the recess in the axle pivot (no. 27), and make
a mark on one of the large oil outlet holes on the wheel hub (no. 22) with a felt-tip pen.
• Insert the set of discs, beginning with the inner disc (no. 26) alternately with outer discs (no. 25), and
on doing so insert the first three outer discs turned by a pitch (72°) (i.e. the test gib of the first two outer
discs may not be opposite the thread boring (no. 52). On mounting, please observe the marking made
and place the oil flow holes on top of one another; insert only the fourth outer disc (no. 25) with the test
gib opposite the thread boring (no. 52) and then insert an inner disc (no. 26) last.
Please note: the set of discs comprises 4 inner discs (no. 26) and 3 outer discs (no. 25).
• Loosen the Allen screws (no. 38) remove disc (no. 12) and take out 8 pressure springs (no. 47).
• Insert new pressure springs (no. 47) and tighten the disc (no. 12) with Allen screws (no. 38). The tigh-
tening torque is 4.1 Nm.
• Press the piston (no. 39) in the cylinder (no. 40) and make a visible marking (with a felt-tip pen) onto
the piston (no. 39) for the groove in the cylinder (no. 44) and onto the cylinder (no. 40) for the close-
tolerance groove pin (no. 45).
Axles
Revised: 08.2004 1305 / 1505 / 1605 / 1705 Mobile
• Restoring the adjusting device:
Allow the ring piston cylinder in the pressing device to rest on the piston (no. 39) with a ring support
with an internal diameter of 22 mm and an external diameter of 300 mm and press on the
cylinder (no. 40) which will restore the ring (no. 46) to its former position.
• Check both O-rings (no. 34) and no. (36), and replace if necessary, coating them with Wolfracote SSP
Klüber paste.
check the scheduled bearing of the piston (no. 39) on the set of discs (the heads of the Allen
screws (no. 38) must be in the recesses of the axle pivot (no. 27)).
mounting.
and the groove nut.
axle. The installation temperature for the bearing inner ring (no. 21) is max. 80°.
socket wrench.
Subject to change
Axles
1305 / 1505 / 1605 / 1705 Mobile Revised: 08.2004
Tools list for WY 218 axles
Name: WZ number:
Press-fit mandrel WZ 227

for shaft seals 1160.209 / 1160.110 on the cardan flange
(with a spacer for the inner shaft seal)
(no spacer for the outer shaft seal)
Holding device + M 12 x 20 WZ 042

for lifting up the wheel hub for WY 218
Sharpening wheel WZ 190
for the inner part of the equalising cage
Press punch WZ 588
for shaft seal 7308.082 in the wheel hub
Groove nut key WZ 465

for groove nut 7329.085 in the wheel hub
Axles
Revised: 08.2004 1305 / 1505 / 1605 / 1705 Mobile
Chapter 17
Hydraulic circuit diagrams
Contents
1 Control block, detailed view .......................................................................................... 2

2 1305 M hydraulic circuit diagram .................................................................................. 3
Page 1 de 8
1305 / 1505 / 1605 / 1705 Mobile Revised: 08.2004
1 Control block, detailed view
VERSTELLZYLINDER =
adjusting cylinder
ZYLINDER 140/90 =
cylinder 140/90
Kundenseitig = provided by
customer
DREHWERK = slewing gear
DUESE = nozzle
Greiferschaltung = grab control
Stiel = handle
ZYLINDER 125/80 =
cylinder 125/80
LOEFFEL = bucket
ZYLINDER 105/70 =
cylinder 105/70
Anfahrtsbypass bis 14 bar =

starting bypass until 14 bar
Ausleger = boom
2 x ZYLINDER 105/70 =
2 x cylinder 105/70
Anfahrtsbypass bis 14 bar =

starting bypass until 14 bar
EINSPEISEKOLBEN =
feed piston
Kundenseitig = provided by
customer
Vorwaerts FAHREN =
drive forwards
Rueckwaerts FAHREN =
drive backwards
ABSTUETZUNG =
stabilizers
2 x ZYLINDER 90/60 =
2 x cylinder 90/60
Revised: 08.2004 1305 / 1505 / 1605 / 1705 Mobile
2 1305 M hydraulic circuit diagram
1305 / 1505 / 1605 / 1705 Mobile Revised: 08.2004
Revised: 08.2004 1305 / 1505 / 1605 / 1705 Mobile
1305 / 1505 / 1605 / 1705 Mobile Revised: 08.2004
Revised: 08.2004 1305 / 1505 / 1605 / 1705 Mobile
1305 / 1505 / 1605 / 1705 Mobile Revised: 08.2004
Revised: 08.2004 1305 / 1505 / 1605 / 1705 Mobile
Chapter 18
Maintenance
Contents
1 Safety instructions for maintenance.............................................................................. 2

2 Renewing hydraulic fluid filter element ......................................................................... 6
3 Renewing fuel filter ....................................................................................................... 9
4 Changing engine oil, renewing engine oil filter ........................................................... 10
5 Maintenance schedule ................................................................................................ 13
Page 1 de 14
1305 / 1505 / 1605 / 1705 Mobile Revised: 08.2004
1 Safety instructions for maintenance

• Carefully read the operation and maintenance instructions.
• Only qualified personnel may carry out maintenance.
• Always read the maintenance instructions before you carry out any maintenance.
• Read the Deutz operating instructions before performing any maintenance on the engine.
• Do not perform any maintenance not described in the maintenance instructions.
• To avoid unnecessary down time in operation, ATLAS-TEREX recommends seals be renewed on all
maintenance work described.
• Use only genuine ATLAS-TEREX spare parts.
• When boarding and leaving the excavator, use only the steps and handrails provided.
• Never climb on to the boom/jib. Use a ladder or work platform, if necessary.
• To ensure a safe stand, keep steps, handrails and stand areas free of dirt, oil, grease, and ice and
snow.
• Wear non-slip footwear.
• Do not use the excavator again until maintenance has been effectively completed.
Maintenance
Revised: 08.2004 1305 / 1505 / 1605 / 1705 Mobile
• If maintenance is done at a job site (e.g. on a construction site), cordon off the job site.
• Do maintenance only if the stability of the excavator is ensured.
• Lower the boom/jib and dozer blade to the ground, or support them.
• Never work under the excavator, if it is being held up only by the hydraulic system!
• When the excavator is raised, support it with suitable material (e.g. stands).
• The engine must be stopped before any maintenance is carried out.
• Absolute cleanliness is essential!

Dirt may cause considerable damage to the excavator.
• Risk of scalding!
Beware of hot oil and hot coolant.
• Battery acid harms the skin and eyes!

Wear acid-proof gloves and protective glasses.
• Oil, lubricating grease, fuel, coolant and cleaning agents harm the skin!
Use skin lotions and/or protective equipment.
• Release the pressure from the hydraulic fluid tank before working on the hydraulic system.
• Switch off the electrical system with the battery isolator before working on the electrical system.
Checks of the electrical system might damage it!
• Use only a digital multimeter or a voltage tester.
• Do not use a test lamp.
Maintenance
1305 / 1505 / 1605 / 1705 Mobile Revised: 08.2004
1
3
Welding work on the excavator might damage the electrical system!
• The battery must be connected up and the electrical system switched on with the battery isolator.
• A good earth connection for the welding equipment must be made close to the welding point.
• Remove plug from auxiliary heater control unit (optional extra).
• Remove cover of the electronics box located behind the seat and disconnect the six plugs (1).
• Open maintenance hood (2).
• Release the clamps that secure the plugs (3) on the sockets and disconnect the plugs from the
EMR-unit as shown. The clamps are located at the lower part of the plugs.
Maintenance
Revised: 08.2004 1305 / 1505 / 1605 / 1705 Mobile
M+P-05A-1867
• Note the risk of fire and explosion:

do not smoke, do not use a naked flame, keep a fire extinguisher ready to hand.
M+P–05A–039
• Comply with environmental protection laws.
• Collect engine oil, hydraulic fluid, fuel and coolant separately and dispose of them as specified in the
regulations.
• Wipe up fuel, lubricants and coolant which have run out or been spilled, or use appropriate binding
agents on them.
Maintenance
1305 / 1505 / 1605 / 1705 Mobile Revised: 08.2004
2 Renewing hydraulic fluid filter element

For the first time after 50 hours of operation, then every 500 hours of operation.
DANGER!
Risk of accident from escaping hydraulic fluid!

Before any work is performed on the hydraulic system, the preload pressure in the hydraulic
fluid tank must be released; see operating instructions.
1
2
3
4
5
M+P-05C-0030
• Trap the fluid from the hydraulic oil filter and the hydraulic oil in a suitable vessel.
• Unscrew hex.-head bolts (1) and take off cover (2).
• Remove O-ring (3) from cover (2).
• Remove spring (4) from hydraulic fluid filter (5).
• Take out hydraulic fluid filter (5) and allow the hydraulic fluid to drain out of the filter.
Maintenance
Revised: 08.2004 1305 / 1505 / 1605 / 1705 Mobile
9
6
8 10
• Unscrew spring assembly with hex. nut (10) from magnetic rod (6) and pull out magnetic rod (6) from
filter casing (9).
• Take off O-ring (7).
• Pull out filter element (8) from filter casing (9) and dispose of properly.
• Clean magnetic rod (6) and filter casing (9).
• Insert new filter element (8) into filter casing (9) and place a new O-ring (7) in position, if necessary.
• Place filter casing (9) in position and screw hex. nut and spring assembly (10) tight.
Maintenance
1305 / 1505 / 1605 / 1705 Mobile Revised: 08.2004
1
2
3
4
5
M+P-05C-0030
• Insert hydraulic fluid filter (5) into the hydraulic fluid tank and place spring (4) on it.
• Fit a new O-ring (3) into cover (2).
• Place cover (2) in position and tighten crosswise the hex.-head bolts (1) uniformly.
• Dispose of any hydraulic fluid which has run out, as specified in the regulations.
• Pressurize the hydraulic fluid tank again.
• Operate the excavator equipment several times, see operating instructions.
• Check the hydraulic fluid level, top up if necessary, see operating instructions.
Maintenance
Revised: 08.2004 1305 / 1505 / 1605 / 1705 Mobile
3 Renewing fuel filter
• Place a suitable vessel underneath.
• Open hood (5).
• Unscrew cap (1) of fuel filter and take off with seal ring (2).
• The casing (4) drains itself.
• Carefully pull filter cartridge (3) out of the casing (4) and dispose of it as specified in the regulations.
• Clean casing (4), inlying guidance and cap (1).
DANGER!
Only genuine ATLAS-TEREX spare parts are to be used.
• Carefully insert new filter cartridge (3) into the casing (4) via the guidance.
• Renew seal ring (2), if necessary and brush with fuel.
• Screw cap (1) with seal ring (2) tight (25 Nm) and close hood (4).
Maintenance
1305 / 1505 / 1605 / 1705 Mobile Revised: 08.2004
4 Changing engine oil, renewing engine oil filter

Allow the engine to warm up to operating temperature of approx. 80 °C.
DANGER!
Risk of accident from rotating parts!

Change engine oil and renew engine oil filter only with the engine stopped.
• Stop the engine.
• Remove engine compartment bottom panel (1).
• Unscrew protective cap (3).
• Trap the oil in a suitable vessel.
DANGER!
Risk of scalding from hot oil!

The oil drain valve opens automatically when the oil drain hose is screwed tight.
• Hold the free end of oil drain hose (2) in the oil trap vessel and screw the other end with the grommet to
the oil drain valve.
• After the oil has drained out completely, take off oil drain hose (2) and screw protective cap (3) back on.
• Dispose of used oil as specified in the regulations.
• Trap the oil in a suitable vessel.
Maintenance
Revised: 08.2004 1305 / 1505 / 1605 / 1705 Mobile
10
DANGER!
Risk of scalding!
Engine oil is hot.
• Open hood (4).
• Unscrew cap (5) of engine oil filter and take off with seal ring (6).
• The casing (10) drains itself.
• Carefully pull filter cartridge (7) out of the casing (10) and dispose of it as specified in the regulations.
• Clean casing (10) with inlying guidance and cap (5).
• Carefully insert new filter cartridge (7) into the casing (10) via the guidance.
• Renew seal ring (6), if necessary and oil slightly.
• Screw cap (5) with seal ring (6) tight (25 Nm).
Maintenance
1305 / 1505 / 1605 / 1705 Mobile Revised: 08.2004
• Unscrew filler neck cap (8) and add oil through the filler neck up to the MAX mark on dipstick (9).
• For filling capacities and lubricants, see operating and maintenance instructions.
• Run the engine, then stop it and check the oil filter for leaks.
• Check the oil level again, and add more oil if necessary.
• Close hood (4).
• Install engine compartment bottom panel.
Maintenance
Revised: 08.2004 1305 / 1505 / 1605 / 1705 Mobile
5 Maintenance schedule
Daily Every Every Every Every Every Every
10 Oh 50 Oh 100 Oh 500 Oh 1000 Oh 2000 Oh 3000 Oh
Lubricate Lubrication points
Slewing ring
Engine Engine oil (1. )
Engine oil filter (1. )
Coolant
Mesh strainer fuel filter
Fuel filter (1. )
Air cleaner
V-belts (1. )
* Radiator
Hydr. system Hydraulic fluid
Hydraulic fluid filter element (1. )
* Hydraulic fluid cooler
Transmission Manual gearbox (1. ) (1. )
Axles Differentials (1. ) (1. )
Planetary gear hubs (1. ) (1. )
Travel gear Wheel nuts (1. )
Elec. system Batteries
Heating and air Medium level
conditioning V-belt (1. )
system
* Recirc.- fresh air filter
* Condenser
* Reduce this period in very dusty conditions (1. ) First time only Have this maintenance
Lubrication points, every 10 Oh Check work performed by
Lubrication points, every 50 Oh Clean ATLAS Service after 50
Lubrication points, every 100 Oh Renew hours of operation and
Lubricate gear teeth with special grease, Drain water then every 500 hours of
(Order No. 3620153), every 100 Oh operation.
Oh Operating hours
Lubrication points, every 500 Oh
Maintenance
1305 / 1505 / 1605 / 1705 Mobile Revised: 08.2004
Maintenance
Revised: 08.2004 1305 / 1505 / 1605 / 1705 Mobile
Chapter 19
Miscellaneous
Contents
1 Repair Instruction for Welded Assemblies .................................................................... 2

1.1 Introduction ................................................................................................................... 2
1.1.1 Service consultation...................................................................................................... 2
1.1.2 Area of application ........................................................................................................ 2
1.1.3 General problems ......................................................................................................... 2
1.2 Damage evaluation ....................................................................................................... 3
1.2.1 General ......................................................................................................................... 3
1.2.2 Course of crack............................................................................................................. 3
1.3 Consulting the Service organization ............................................................................. 4
1.3.1 General ......................................................................................................................... 4
1.3.2 Doubler of metal sheet.................................................................................................. 4
1.3.3 Drawings / Examples .................................................................................................... 4
1.4 Preparing the repair ...................................................................................................... 5
1.4.1 Cleaning........................................................................................................................ 5
1.4.2 Drilling ........................................................................................................................... 5
1.4.3 Grinding ........................................................................................................................ 5
1.4.4 Preheating the welding area ......................................................................................... 5
1.5 Qualification of the welding personnel .......................................................................... 6
1.5.1 General ......................................................................................................................... 6
1.6 Selecting the filler metal................................................................................................ 7
1.6.1 General ......................................................................................................................... 7
1.6.2 Welding wire selection .................................................................................................. 7
1.7 Repair sequence........................................................................................................... 8
1.8 Follow-up work .............................................................................................................. 9
Page 1 de 10
1305 / 1505 / 1605 / 1705 Mobile Revised: 08.2004
1 Repair Instruction for Welded Assemblies

1.1 Introduction
1.1.1 Service consultation
This regulation was created for ATLAS excavators and ATLAS cranes. In case welding is needed for repair,
it is always important to obtain assistance from the Service organization. The repair should be discussed
with the Service organization to clarify details and to eliminate difficulties in advance.
1.1.2 Area of application

This Repair Instruction offers replies to the most common and most basic questions arising when welding
work has to be done in cases of damage. It can be used for damage on all components on either cranes
or excavators; please note that you should consult the Service organization in certain cases.
1.1.3 General problems

You should be generally aware of the fact that an ever-increasing number of components in the crane, even
in the excavator field, are manufactured from high-strength fine-grained structural steels. These materials
should be treated specifically to prevent the material from losing its beneficial properties. Moreover, the
components are charged by oscillations, and the material is loaded with the limit to reduce weight.
Any repair welding work should always be carried out, as far as possible, in a preferred welding position
(trough location). This might require the dismounting of the component to be welded, unless the weld is of
a minor importance.
The machines will arrive from service and will therefore be splashed with oil, dirty and also primed and
painted.
On the next pages you will find a description how to cope with these difficulties.
Important note:
Only repairs which are completed with extreme care will be permanently lasting!
Miscellaneous
Revised: 08.2004 1305 / 1505 / 1605 / 1705 Mobile
1.2 Damage evaluation

1.2.1 General
If you find a crack in a component, start action immediately. For damage evaluation, it is better to first clean
the surroundings of the damaged place with the help of a high-pressure cleaner. Then remove any paint
or other coatings from the area of the crack. Also take off any parts which might be obstructive to inspection
(pipes, hoselines, control boxes, electric cables etc.).
1.2.2 Course of crack

The course of the crack is vital for all repairs to be carried out accordlingly. To determine the crack head
and tail end with maximum precision, use appropriate means (dye penetration test, magnaflux test or
such). Prior to consulting the Service organization, determine the following criteria:
a) Crane / excavator serial no.

b) Accurate crack position
c) Length of crack
d) Crack in a weld or through the basic material
Miscellaneous
1305 / 1505 / 1605 / 1705 Mobile Revised: 08.2004
1.3 Consulting the Service organization

1.3.1 General
Discuss all items which are necessary for repair. The Service organization will determine if repair is
possible.
If the crack area is close to the seat of a bearing and negative impact on the associated fit must be expected
from warping due to welding, repair may generally be out of question.
If this is not the case, the repair should be either completed according to this Repair Instruction for Welded
Modules, or the Service organization will suggest special procedures fixed for the concerned type of da-
mage.
1.3.2 Doubler of metal sheet

If a doubler of metal sheet is necessary from the point of view of the Service organization, you have to fix
dimensions and material.
Material: similar to basic material

Sheet metal thickness: approximately 2/3 x basic material thickness
Shape: soft transitions to eliminate stiffness leaps
1.3.3 Drawings / Examples

chamfer as from 10 mm
Miscellaneous
Revised: 08.2004 1305 / 1505 / 1605 / 1705 Mobile
1.4 Preparing the repair

1.4.1 Cleaning
Thoroughly remove any traces of grease, oil, paint, moistness and other pollutions and coatings, since
these would strongly affect the weld quality.
1.4.2 Drilling
Always bore out the crack head and tail end. Bore hole diameters have to be adapted to sheet metal
thickness:
with t = 3 mm sheet metal thickness - bore hole 5 mm
with t > 10 mm sheet metal thickness - bore hole 10 mm
1.4.3 Grinding
Grind the crack internally in the shape of a V over its whole length. Opening angle should be between
50 and 60 degrees.
Drawing
You can also produce the groove by means of a gouging blowpipe or groove electrodes. Here gain, groove
flanks should be clean and smooth, ground with the help of an angle grinder, if necessary.
If you wish to carry out the repair in the open, protect the welding area from atmospheric exposure (wind,
rain, snow).
1.4.4 Preheating the welding area

Preheating is required if:
a) workpiece temperature is lower than 5 °C when the welding process is started.

b) the design of the component for repair is very rigid.
c) components of fine-grained structural steel of a wall thickness exceeding 10 mm are used or repaired
respectively. Preheating temperature abt. 150 - 200 °C
d) components from S355 J2G3 of a wall thickness exceeding 20 mm. Preheating
temperature abt. 120 °C
Miscellaneous
1305 / 1505 / 1605 / 1705 Mobile Revised: 08.2004
1.5 Qualification of the welding personnel

1.5.1 General
Only welders with proof of qualification are authorized to carry out repair welding work!
Welding qualification acc. to DIN EN 287 Part 1
The choice of the welder should be based on the basic material, welding method, welding position and
other criteria. Have an experienced welder carry out the repair to ensure that the welding work is solid and
of a high quality.
Qualified welders
111 – welding process: manual arc welding
135 – welding process: Active gas metal-arc welding (MAG)
P – sheet metal
BW – butt welding
FW – fillet weld
WO1 – material group: plain carbon steel
WO3 – material group: fine-grained structural steels, upper yield point Óch > 355N/mm2
wm – with filler metal
t – sheet metal thickness
PF – welding position: rising
ss – single-fillet welding
nb – welding without weld pool securing
Miscellaneous
Revised: 08.2004 1305 / 1505 / 1605 / 1705 Mobile
1.6 Selecting the filler metal

1.6.1 General
The filler metal depends on the basic material. As most components nowadays consist of high-strength
fine-grained structural steels, you also have to use corresponding welding rods or stick electrodes. The
manufacturer's instructions have to be observed imperatively:
• such as current type and polarity

• Back-drying
• Current intensity
• Welding position
1.6.2 Welding wire selection
Basic material Welding wire Welder acc.

(DIN EN 287/19)
name name name name
new former new former
S235 J2G3 ST37-3 G4 Si 1 SG 3
135 PBW W01
S355 J2G3 ST52-3 G4 Si 1 SG 3 w m t10 PF ss nb
StE 460 - G4 Si 1 SG 3
StE 550 - NiMo - 135 PFW W03
w m t1 0 PF ss nb
StE 690 - NiMo -
1.6.3 Stick electrode selection
Basic material Stick electrodes DIN EN 499 Welder acc.

(DIN EN 287/19)
name name
new former
S235 J2G3 ST37-3 E35 4 B 42 H5 111 PBW W01
Bt10 PF ss nb
S355 J2G3 ST52-3 E42 2 RB 32 H10
StE 460 - E42 2 RB 32 H10
StE 550 - E50 4 B 42 H5 111 PFW W03
Bt10 PF ss nb
StE 690 - E69 6 Mn NiCrMo B 42
H5 prEN 757
Stick electrodes should be preheated prior to being processed.
Preheating temperature: 220 - 250 °C
Miscellaneous
1305 / 1505 / 1605 / 1705 Mobile Revised: 08.2004
1.7 Repair sequence

When all preparatory work is finished, start with the repair welding work. The following criteria have been
observed:
a) material quality and sheet metal thickness

b) component and/or preheating temperature
c) welders with appropriate qualificiations
d) filler metal selection according to present basic material
e) processing instructions supplied by the filler metal manufacturer
f) notes and rules of the Service organization
When treating fine-grained structural steels, which are most commonly used, it is important to weld with
low drawing energy, ie you should weld thin and narrow welds. Wide welds will allow a large application of
heat and thus reduce the mechanical strength properties of the basic material.
If the crack is going as far as to the material outside edge, you have to ensure with an ignition plate that
approach errors are not situated within the weld but in the ignition plate which you remove afterwards. This
plate should beground and must not be knocked off in order to prevent the material from tearing.
Welding should be done:
• from the outside towards the inside

• shear welds prior to tension welds prior to compression welds
• always in the most beneficial welding position (descending welds are prohibited)
• with extreme care
ignition plates + exit plates (drawing)
1 = ignition plate
2 = welding direction
3 = exit plate
Miscellaneous
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1.8 Follow-up work

Remove the ignition plate without damaging the basic material. Then grind the weld end to remove
notches.
Welding work with removal of notches are especially important for transition areas from the weld to the
basic material.
If the Service organization has recommended the attachment of a reinforcement metal sheet, weld this one
on, making sure that a minimum amount of air remains between the metal sheets during tacking.
If no crack is visible any more, clean the repaired area and apply some appropriate antirust agent.
Miscellaneous
1305 / 1505 / 1605 / 1705 Mobile Revised: 08.2004
Miscellaneous

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Workshop Manual

ATLAS 1305 / 1505 / 1605 /1705

Generally, service technicians work under their

In order to prevent personal and material dama-

Only qualified and trained specialists are autho-

For machine care and maintenance work, refer

The contents of this Manual is in the property of

2 Display and controls

6 Pilot Control Equipment

8 Main rotation connection

9 Slewing gear gears and motor

10 Pressure setting tables / setting regulations

13 Air conditioner system

14 Power shift transmission

17 Hydraulic circuit diagrams

Size Unit 1305 M 1505 M 1605/1705 M

A3.2, C3.0, A5.2, C6.0, A6.2, C6.0,

A3.2, C3.3M, A5.2, C6.3M, A6.2, C6.3M,

Size Unit 1305 M 1505 M 1605/1705 M

Load Sensing (S)

Size Unit 1305 M 1505 M 1605/1705 M

Hydr. VG circuit retarder

Hydraulic saturation drive

1 General view of cab ...................................................................................................... 2

1 General view of cab

1 Slider, side window 10 Windshield

2 Seat with consoles

1 Air outlets for legroom

3 Left switch panel

1 Control lever for:

4 Right switch panel

1 Control lever for:

5 "DELUXE" Control and display

1 Parking brake pushbutton 12 Work-area lights pushbutton

Display Working parameters

1305M - 6066073 - 05B003-03

Warning symbols The warning symbols can be hidden by pressing

51 Low coolant level Low fuel level

In addition the following information symbols can be shown on the display.

60 Parking brake activated while selecting travel direction

6 "STANDARD" Controls and display

The F1 to F3 operating modes have been set as follows:

Operating mode Motor speed Delta-P

1 Parking brake pushbutton

Standard indication display

• Motor speed (rpm)

• Coolant temperature (°C)

• Motor oil pressure (bar)

• Fuel level (%)

The indicator lamp i will light up.

Setting the time and the date

• Press the +/- buttons simultaneously.

• Set the current hour by pressing the +/- buttons.

• Set the minutes, day, month and year as described above.

The warning light (1) will light up.

Any other error messages will be indicated and can be confirmed.

7 Control panel heating and air conditioning

1 Display air distribution

1.2 Overview of system

EMR (1) Ladeluftdrucksensor = Loading air

(5) Energieversorgung = Power supply

For the vehicle:

For the engine:

The functions of the EMR relate to rotary-speed-regulation, volume-limitation (injection), monitoring,