en
Service Manual (20
Wheel Loader (10 points)
L524 / L534 / L538(10
en
Service Manual (20
Wheel Loader (10 points)
L524 / L534 / L538 (10
Address LIEBHERR-WERK BISCHOFSHOFEN GMBH Dr. Hans Liebherr – Straße 4 A – 5500 BISCHOFSHOFEN
Product ID Manufacturer: Product group: Type: Production number: Serial number:
LIEBHERR-WERK BISCHOFSHOFEN GMBH Wheel loader L524 L534 L538 438 434 432 from 0101 from 0101 from 0101
Document ID Order number: Author: Document version: Manual number: Owner:
8450818 LBH / T-DOK department 02
General information
1
Product description
2
Maintenance
3
Diesel engine
4
Cooling system
5
Travel hydraulics
6
Working hydraulics
7
Steering system
8
Brake system
9
Electrical system
10
Transfer gear
11
Axles and cardan shaft
12
Machine frame and ballast weight
13
Central lubrication system
14
Coverings and access
15
Cab, heating and air-conditioning
16
Lift arms and quick-change device
17
Equipment and accessories
18
Repairs and troubleshooting
19
Options
20
1 General Information 1.0 Chapter contents 1
General Information ............................................................ 1.0-1 1.1
Safety regulations ...........................................................................1.1-1 1.1.1
Introduction...........................................................................1.1-1
1.1.2
Overview of the safety regulations .......................................1.1-2
1.2
L524 - 438 / from 0101 L534 - 434 / from 0101 L538 - 432 / from 0101
Special tools for maintenance and repair work...............................1.2-1 1.2.1
Special tools in general ........................................................1.2-1
1.2.2
Special tools for Liebherr diesel engines..............................1.2-1
1.2.3
Special tools for hydraulic cylinders .....................................1.2-3
1.2.4
Special tools for electronics..................................................1.2-3
1.2.5
Special tools for axles...........................................................1.2-4
1.2.6
Central lubrication system ....................................................1.2-4
1.2.7
Special tools for the air conditioning system ........................1.2-4
MJFCIFSS
1.0-1 of 2
Service Manual
General Information Safety regulations
1.1 Safety regulations Working on the machine poses safety risks to the operator, driver or maintenance engineers. You can prevent risks and accidents by regularly reading and observing the various safety instructions. This is especially important for personnel who only occasionally work on the machine, for example, carrying out rigging or maintenance work. The safety regulations listed below, if conscientiously followed, will ensure your own safety and that of others, and will prevent the machine from being damaged. Whenever tasks which could cause danger to personnel or damage to the machine are described, the necessary safety precautions are explained in this manual. These are indicated by the headings Danger, Warning or Caution.
1.1.1
Introduction 1. The symbols below have the following meanings:
Danger
Warning
Caution
Danger Warning that without appropriate precautions, certain procedures could result in fatal accidents.
Warning Warning that without appropriate precautions, certain procedures could result in severe physical injuries.
Caution Warning that without appropriate precautions, certain procedures could result in minor physical injuries or damage to the machine.
2. Observance of these instructions does not exempt you from following any additional rules and guidelines that may apply The following should also be observed: – The safety rules in force at the operating site – Legally enforceable road traffic regulations – Guidelines issued by trade associations
L524 - 438 / from 0101 L534 - 434 / from 0101 L538 - 432 / from 0101
MJFCIFSS
1.1-1 of 2
General Information
Service Manual
Safety regulations
1.1.2
Overview of the safety regulations A detailed description of these can be read in the relevant section of the safety regulations chapter in the operating manual. The following sections are included in the operating manual:
1.1-2 of 2
1
Introduction
2
General safety regulations
3
Proper use
4
Decals on the machine
5
Instructions on preventing crushing injuries and burns
6
Instructions on preventing fires and explosions
7
Safety instructions for start-up
8
Safety precautions during start-up
9
Instructions for safe working
10
Safety instructions for driving on slopes
11
Parking safely
12
Transporting the machine safely
13
Towing the machine safely
14
Measures for ensuring safe maintenance
15
Safety instructions for working on machines with hydro accumulators
16
Safety instructions for welding work on the machine
17
Instructions for working safely on the working attachment
18
Safety instructions for transporting the machine by crane
19
Safe maintenance of hydraulic hoses and hose lines
20
Attachments and accessories
MJFCIFSS
L524 - 438 / from 0101 L534 - 434 / from 0101 L538 - 432 / from 0101
Service Manual
General Information Special tools for maintenance and repair work
1.2 Special tools for maintenance and repair work 1.2.1 Description
Special tools in general ID no.
Digital thermometer
7020372
All wheel loaders
DCA 4 water testing kit
5608459
All wheel loaders
Anti-freeze and battery tester
7408922
All wheel loaders
24 volt vacuum pump Filling and testing device with case Manometer 0-40 bar Manometer 0-250 bar Manometer 0-600 bar Manometer connection High pressure hose 1500 mm High pressure hose 4000 mm Screw connection M 10 x 1 Draining hose Drain piece
7408148
All wheel loaders
Remarks For measuring temperature during adjustments For testing the DCA4 and antifreeze content For checking the acid concentration (battery charging state) and anti-freeze For preventing oil loss
8145359
All wheel loaders
For checking the hydro accumulator
7361288 5002932 5002866 7002436 7002475 7009134 5005180 7005660 7402657
All wheel loaders All wheel loaders All wheel loaders All wheel loaders All wheel loaders All wheel loaders All wheel loaders All wheel loaders All wheel loaders
Safety cap SW 10
7009315
All wheel loaders
Safety cap SW 13 Safety cap SW 17 Safety cap SW 19
7615515 7615589 7009317
All wheel loaders All wheel loaders All wheel loaders
Safety cap SW 17
7622068
All wheel loaders
For checking the hydraulic pressure For checking the hydraulic pressure For checking the hydraulic pressure Connection for the manometer High pressure hose for manometer High pressure hose for manometer For checking the hydraulic pressure For draining oil via a drain valve For the drain hose For securing the valves on the variable adjustment motor For securing the valves on the pumps For securing the valves on the pumps For securing the valves on the pumps For securing the valves on the control block
1.2.2
Use
Special tools for Liebherr diesel engines
Description Compression tester Nozzle tester Adapter for compression tester Adapter for compression tester Injection valve extraction tool Extraction tool adapter
ID no. 8008782 7361236 0524044 7090397 0524072 0524029
Use L524 - L538 engine L524 - L538 engine L538 engine L524 - L534 engine L538 engine L538 engine
Piston ring tensioning belt
8000952
All wheel loaders
Krikit 2 V-belt tester Flywheel cranking device
8042829 0524045
L524 - L538 engine L538 engine
Stopwatch
7022418
L538 engine
Measuring device
7022420
L538 engine
Adapter
7022419
L538 engine
L524 - 438 / from 0101 L534 - 434 / from 0101 L538 - 432 / from 0101
MJFCIFSS
Remarks For checking the compression For checking the injection valves Instead of the injection valve Instead of the injection valve For removing the injection valves For use with the extraction tool For pushing the piston rings together during installation of the pistons For testing the V-belt tension For cranking the engine via the flywheel For adjusting the start of delivery of the distributor injection pump For adjusting the start of delivery of the distributor injection pump For adjusting the start of delivery of the distributor injection pump
1.2-1 of 4
General Information
Service Manual
Special tools for maintenance and repair work
Description
ID no.
Use
Crankshaft turning device
0541887
L524, L534 engine
Crankshaft turning device
9183785
L538 engine
Installation pin Adjusting pin for injection pump DE10
7090360
L524, L534 engine L524, L534 engine with electronic injection
Extractor
7090374
L524, L534 engine
Shaft seal ring installation tool
7090373
L524, L534 engine
Extractor tool Extractor tool Seal remover
7090377 7090395 7090372
L524, L534 engine L524, L534 engine L524, L534 engine
Adjusting device
7090384
L524, L534 engine
Extractor tool
7090364
L524, L534 engine
Installation tool
7090382
L524, L534 engine
Cleaning tool
7090375
L524, L534 engine
Installation set
7090378
L524, L534 engine
Depth gauge
7090370
L524, L534 engine
Extractor tool
7090376
L524, L534 engine
Extractor tool
7090363
L524, L534 engine
Angle wrench
0524062
L538 engine
MURPHY GAGE diagnostic tool with cable
10030461
Adapter cable
9067863
1.2-2 of 4
7090592
L524, L534 engine with electronic injection L524, L534 engine with electronic injection
MJFCIFSS
Remarks For cranking the engine via the V-belt pulley For cranking the engine via the crankshaft For fixing the engine at UDC For static adjustment when installing the injection pump For removing the drive gearwheel of the Stanadyne injection pump For installing the front crankshaft oil seal For removing the front wear ring For removing the front wear ring For removing the front crankshaft oil seal For dynamically adjusting the start of delivery of the distributor injection pump For removing Stanadyne injection nozzles For inserting the carbon seal in the injection nozzle groove For cleaning the injection nozzle bore hole in the cylinder head For installing the rear oil seal ring and wear ring For measuring the valve depth in the cylinder head and the piston and bushing height For removing the rear crankshaft oil seal ring and wear ring For installing and removing the cylinder bushings For screws on cylinder head, main bearing and big end bearing For diagnosing controls and ECU (A14) engine controller For diagnosis with the MURPHY GAGE
L524 - 438 / from 0101 L534 - 434 / from 0101 L538 - 432 / from 0101
Service Manual
General Information Special tools for maintenance and repair work
1.2.3 Description
Special tools for hydraulic cylinders ID no.
Assembly sleeve 80 mm
9227165
Assembly sleeve 90 mm
9227161
Assembly sleeve 100 mm Assembly sleeve 110 mm
9998626 9170509
Assembly sleeve 120 mm
9998778
Assembly sleeve 140 mm
9998623
Expansion sleeve 80 mm
9227166
Expansion sleeve 90 mm
9227162
Expansion sleeve 100 mm Expansion sleeve 110 mm
9110405 9170511
Expansion sleeve 120 mm
9110407
Expansion sleeve 140 mm
9110409
Piston spanner
9211967
Piston spanner 80/12 mm
8007364
Piston spanner
4002681
Piston spanner 88/12 mm
8007365
Piston spanner 100/14 mm
8007366
1.2.4 Description Digital multimeter Test probe, red Test probe, black Magnet tester Stripping and crimping pliers 0.5 - 6.0 mm2 Insertion tool Extractor tool Crimping pliers Wedge extractor tool Extraction tool size 12 for pin and bushing Extraction tool size 16 for pin and bushing Extraction tool size 20 for pin
L524 - 438 / from 0101 L534 - 434 / from 0101 L538 - 432 / from 0101
Use L524 P kinematics tilt cylinder L524 - L538 steering cylinder L534, L538 P kinematics tilt cylinder L524 lift cylinder L534, L538 lift cylinder L524 Z kinematics tilt cylinder L534, L538 P Z kinematics tilt cylinder L524 P kinematics tilt cylinder L524 - L538 steering cylinder L534, L538 P kinematics tilt cylinder L524 lift cylinder L534, L538 lift cylinder L524 Z kinematics tilt cylinder L534, L538 P Z kinematics tilt cylinder L524 - L538 steering cylinder L524 - L538 lift cylinder L524 - L538 P kinematics tilt cylinder L524 Z kinematics tilt cylinder L534, L538 Z kinematics tilt cylinder
Remarks For fitting the seals
For fitting the seals For fitting the seals For fitting the seals For fitting the seals For fitting the seals For fitting the seals
For fitting the seals For fitting the seals For fitting the seals For fitting the seals For fitting the seals For fitting the piston For fitting the piston For fitting the piston For fitting the piston For fitting the piston
Special tools for electronics ID no.
8502956
Use All wheel loaders
884191214 All wheel loaders 884191114 All wheel loaders 8145743 All wheel loaders
Remarks For measuring voltage, current, resistance and frequency For testing DEUTSCH connectors For testing DEUTSCH connectors For checking solenoid valves
8460263
All wheel loaders
For MATE-N-LOK connectors
8145432 7366655 8503647 7026267
All wheel loaders All wheel loaders All wheel loaders All wheel loaders
For MATE-N-LOK connectors For MATE-N-LOK connectors For DEUTSCH connectors For DEUTSCH connectors
8145674
All wheel loaders
For DEUTSCH connectors
8145673
All wheel loaders
For DEUTSCH connectors
8503630
All wheel loaders
For DEUTSCH connectors
MJFCIFSS
1.2-3 of 4
General Information
Service Manual
Special tools for maintenance and repair work
Description and bushing Plug-in fuse tester Wide METRI-PACK extractor tool Narrow METRI-PACK extractor tool
ID no.
Use
Remarks
8145834
All wheel loaders
7091022
L524, L534
7091023
L524, L534
For checking the fuses For removing terminals on the main connector of the ECU engine controller For removing terminals on the main connector of the ECU engine controller
1.2.5 Description
Special tools for axles ID no.
Measuring tool
8145535
1.2.6 Description Filling press Filling connection BEKA MAX central lubrication data cable + software Gröneveld central lubrication
data cable Gröneveld central lubrication
plug adapter Gröneveld central lubrication
software
Use L524 - L538 front axle L524 - L538 rear axle
Remarks For measuring wear on the service brake discs
Central lubrication system
ID no. 10009239 7029283
Use All wheel loaders All wheel loaders
10008427
All wheel loaders
7624289
All wheel loaders
7624290
All wheel loaders
As below
All wheel loaders
Remarks For quickly filling the reservoir For inspecting the central lubrication system For inspecting the central lubrication system For inspecting the central lubrication system For inspecting the central lubrication system
The software for the Gröneveld central lubrication system must be purchased from Gröneveld and enabled with a registration code. Procedure and necessary data: – Company name and department – A six-digit number of your choice This data must be e-mailed to the following address: support@groeneveld.nl
1.2.7 Description
Special tools for the air conditioning system ID no.
Use
Remarks
Vacuum pump
7027552
All wheel loaders
For evacuating the air conditioning system
4-valve test fitting
7027558
All wheel loaders
For testing, evacuating and filling the air conditioning system
Filling hose, blue 1500 mm
7027553
All wheel loaders
For the test fitting
Filling hose, yellow 1500 mm
7027554
All wheel loaders
For the test fitting
Filling hose, red 1500 mm
7027555
All wheel loaders
For the test fitting
Car coupling 253a
7027556
All wheel loaders
For the test fitting
Car coupling 254a
7027557
All wheel loaders
For the test fitting
1.2-4 of 4
MJFCIFSS
L524 - 438 / from 0101 L534 - 434 / from 0101 L538 - 432 / from 0101
2 Product Description 2.0 Chapter contents 2
Product Description............................................................. 2.0-1 2.1
L524 - 438 / from 0101 L534 - 434 / from 0101 L538 - 432 / from 0101
Technical data ................................................................................2.0-1 2.1.1
Complete machine................................................................2.0-1
2.1.2
Diesel engine and pump distributor gear..............................2.0-9
2.1.3
Cooling system ...................................................................2.0-14
2.1.4
Travel hydraulics ................................................................2.0-15
2.1.5
Working hydraulics .............................................................2.0-17
2.1.6
Steering system..................................................................2.0-20
2.1.7
Brake system......................................................................2.0-21
2.1.8
Electrical system.................................................................2.0-22
2.1.9
Transfer gear ......................................................................2.0-22
2.1.10
Axles and tyres ...................................................................2.0-23
2.1.11
Machine frame and ballast weight......................................2.0-24
2.1.12
Cab, heating and air-conditioning.......................................2.0-24
2.1.13
Lift arms and quick-change device.....................................2.0-25
2.1.14
Equipment and accessories ...............................................2.0-26
MJFCIFSS
2.0-1 of 2
Service Manual
Product Description Technical data
2.1 Technical data 2.1.1 Wheel loader with Z lift arms
Complete machine Valid for:
L524 - 438 / from 0101
The values stated refer to the standard version of the machine: With Z lift arms (2400 mm), without hydraulic quick-change device. With 17.5 R25 Goodyear GP-2B tyres. Tipping loads and weights include all lubricants, full fuel tank, ROPS/FOPS cab and driver. Tyre sizes and additional attachments affect the operating weight and tipping load.
Dimensions - machine with Z lift arms Description Bucket capacity as per ISO 7546 Bucket width
L524 - 438 / from 0101 L534 - 434 / from 0101 L538 - 432 / from 0101
Value Unit 2.0 m³ 2500 mm
Specific material weight A Dump height at maximum lifting height and 45° tilt-out angle B Dump height
3335 mm
C Maximum bucket base height
3510 mm
D Maximum bucket pivot point height
3760 mm
E Maximum bucket top height F Reach at maximum lifting height and 42° tilt-out angle G Digging depth
4840 mm
H Height above the cab
3150 mm
I Height above exhaust
3090 mm
MJFCIFSS
1.8 t/m³ 2850 mm
870 mm 80 mm
2.0-1 of 26
Product Description
Service Manual
Technical data
Description J Ground clearance
520 mm
K Wheel base
2700 mm
L Overall length
6835 mm
Turning radius over bucket outer edge
5500 mm
Lifting force (SAE)
98 kN
Breakout force (SAE)
92 kN
Tipping load when straight
8030 kg
Tipping load articulated at 30°
7005 kg
Angle of articulation (to each side) Swing angle (to each side) Operating weight
40 ° 6 ° 10100 kg
Tractive force
76.2 daN
Travel speed in travel range 1, forward and reverse
0 - 8 km/h
Travel speed in travel range 2, forward and reverse
0 - 33 km/h
Sound pressure level in the cab LpA Wheel loader with P lift arms
Value Unit
Valid for:
75 dB (A)
L524 - 438 / from 0101
The values stated refer to the standard version of the machine: With P lift arms (2400 mm) and hydraulic quick-change device. With 17.5 R25 Goodyear GP-2B tyres. Tipping loads and weights include all lubricants, full fuel tank, ROPS/FOPS cab and driver. Tyre sizes and additional attachments affect the operating weight and tipping load.
Dimensions - machine with P lift arms
2.0-2 of 26
MJFCIFSS
L524 - 438 / from 0101 L534 - 434 / from 0101 L538 - 432 / from 0101
Service Manual
Product Description Technical data
Description Bucket capacity as per ISO 7546 Bucket width
1.7 m³ 2500 mm
Specific material weight A Dump height at maximum lifting height and 45° tilt-out angle B Dump height
3380 mm
C Maximum bucket base height
3500 mm
D Maximum bucket pivot point height
3750 mm
E Maximum bucket top height F Reach at maximum lifting height and 42° tilt-out angle G Digging depth
4895 mm
H Height above the cab
3150 mm
I Height above exhaust
3090 mm
J Ground clearance
1.8 t/m³ 2815 mm
1030 mm 55 mm
520 mm
K Wheel base
2700 mm
L Overall length
6890 mm
Turning radius over bucket outer edge
5530 mm
Lifting force (SAE)
89 kN
Breakout force (SAE)
80 kN
Tipping load when straight
7100 kg
Tipping load articulated at 40°
6250 kg
Angle of articulation (to each side) Swing angle (to each side) Operating weight Tractive force
40 ° 6 ° 10200 kg 76.2 kN
Travel speed in travel range 1, forward and reverse
0 - 8.0 km/h
Travel speed in travel range 2, forward and reverse
0 - 33.0 km/h
Sound pressure level in the cab LpA Wheel loader with Z lift arms
Value Unit
Valid for:
75 dB (A)
L534 - 434 / from 0101
The values stated refer to the standard version of the machine: With Z lift arms (2500 mm), without hydraulic quick-change device. With 20.5 R25 Goodyear GP-2B tyres. Tipping loads and weights include all lubricants, full fuel tank, ROPS/FOPS cab and driver. Tyre sizes and additional attachments affect the operating weight and tipping load.
L524 - 438 / from 0101 L534 - 434 / from 0101 L538 - 432 / from 0101
MJFCIFSS
2.0-3 of 26
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Product Description
Service Manual
Technical data
Dimensions - machine with Z lift arms Description Bucket capacity as per ISO 7546 Bucket width
2.4 m³ 2500 mm
Specific material weight A Dump height at maximum lifting height and 45° tilt-out angle B Dump height
3380 mm
C Maximum bucket base height
3650 mm
D Maximum bucket pivot point height
3900 mm
E Maximum bucket top height F Reach at maximum lifting height and 42° tilt-out angle G Digging depth
5450 mm
H Height above the cab
3250 mm
I Height above exhaust
3150 mm
J Ground clearance
1.8 t/m³ 2890 mm
945 mm 70 mm
460 mm
K Wheel base
2900 mm
L Overall length
7235 mm
Turning radius over bucket outer edge
5825 mm
Lifting force (SAE)
135 kN
Breakout force (SAE)
105 kN
Tipping load when straight
9745 kg
Tipping load articulated at 40°
8625 kg
Angle of articulation (to each side) Swing angle (to each side) Operating weight Tractive force
2.0-4 of 26
Value Unit
MJFCIFSS
40 ° 6 ° 12100 kg 87.8 kN L524 - 438 / from 0101 L534 - 434 / from 0101 L538 - 432 / from 0101
Service Manual
Product Description Technical data
Description
Value Unit
Travel speed in travel range 1, forward and reverse
0 - 8.0 km/h
Travel speed in travel range 2, forward and reverse
0 - 36.0 km/h
Sound pressure level in the cab LpA Wheel loader with P lift arms
Valid for:
75 dB (A)
L534 - 434 / from 0101
The values stated refer to the standard version of the machine: With P lift arms (2600 mm) and hydraulic quick-change device. With 20.5 R25 Goodyear GP-2B tyres. Tipping loads and weights include all lubricants, full fuel tank, ROPS/FOPS cab and driver. Tyre sizes and additional attachments affect the operating weight and tipping load.
Dimensions - machine with P lift arms Description Bucket capacity as per ISO 7546 Bucket width
L524 - 438 / from 0101 L534 - 434 / from 0101 L538 - 432 / from 0101
Value Unit 2.0 m³ 2500 mm
Specific material weight A Dump height at maximum lifting height and 45° tilt-out angle B Dump height
3470 mm
C Maximum bucket base height
3730 mm
D Maximum bucket pivot point height
3970 mm
E Maximum bucket top height F Reach at maximum lifting height and 42° tilt-out angle G Digging depth
5230 mm
MJFCIFSS
1.8 t/m³ 2930 mm
1060 mm 65 mm
2.0-5 of 26
Product Description
Service Manual
Technical data
Description H Height above the cab
3250 mm
I Height above exhaust
3150 mm
J Ground clearance
460 mm
K Wheel base
2900 mm
L Overall length
7535 mm
Turning radius over bucket outer edge
5925 mm
Lifting force (SAE) Breakout force (SAE)
95 kN 100 kN
Tipping load when straight
8550 kg
Tipping load articulated at 40°
7570 kg
Angle of articulation (to each side) Swing angle (to each side) Operating weight Tractive force
40 ° 6 ° 12290 kg 87.8 kN
Travel speed in travel range 1, forward and reverse
0 - 8.0 km/h
Travel speed in travel range 2, forward and reverse
0 - 36.0 km/h
Sound pressure level in the cab LpA
2.0-6 of 26
Value Unit
MJFCIFSS
75 dB (A)
L524 - 438 / from 0101 L534 - 434 / from 0101 L538 - 432 / from 0101