en
Service manual (20
Wheel loader (10 points)
L544 - L580 2plus2 (10
en
Service manual (20
Wheel loader (10 points)
L544 - L580 2plus2 (10
Address Address:
LIEBHERR-WERK BISCHOFSHOFEN GMBH Dr. Hans Liebherr – Straße 4 A – 5500 BISCHOFSHOFEN, AUSTRIA
Product identification Manufacturer: Product group: Type: Construction number: Serial number:
LIEBHERR-WERK BISCHOFSHOFEN GMBH Wheel loader L 544 L 554 L 564 L 574 L 580 443 453 463 473 458 7477 7477 7477 7477 7477
Document identification Order number: Author: Document version: Manual number: Owner:
10013898 LBH / T-DOK department 03
General information
1
Product description
2
Maintenance
3
Diesel engine, pump distributor gear
4
Cooling system
5
Travel hydraulics
6
Working hydraulics
7
Steering system
8
Brake system
9
Electrical system
10
Transfer gear
11
Axles, drive shafts
12
Machine frame, ballast weight
13
Central lubrication system
14
Covering, cab access
15
Cab, heating, air-conditioning
16
Lift arm, quick-change device
17
Attachments, accessories
18
Repair work, troubleshooting
19
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 safety regulations .............................................1.1-2
1.2
L544 - 443 / from 7477 L554 - 453 / from 7477 L564 - 463 / from 7477 L574 - 473 / from 7477 L580 - 458 / from 7477
Special tools for maintenance and repair work...............................1.2-1 1.2.1
Special tools, general information ........................................1.2-1
1.2.2
Special tools for Liebherr diesel engines..............................1.2-1
1.2.3
Special tools for the hydraulic cylinders ...............................1.2-2
1.2.4
Special electrical tools ..........................................................1.2-2
1.2.5
Special tools for axles...........................................................1.2-3
1.2.6
Special tools for the transfer gear ........................................1.2-4
1.2.7
Central lubrication system ....................................................1.2-4
1.2.8
Special tools for the air conditioning system ........................1.2-5
1.2.9
Special tools for the cab windows ........................................1.2-5
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MJFCIFSS
1 . 0 - 1 of 2
Special tools for maintenance and repair work
General Information Safety regulations
1.1 Safety regulations Working on the machine poses safety risks to the operator, driver or maintenance technicians. You can considerably reduce the risk of accidents by carefully reading and observing the various safety instructions at regular intervals. 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 operational procedures could result in fatal accidents. Warning Warning that without appropriate precautions, certain operational procedures could result in severe physical injuries. Caution Warning that without appropriate precautions, certain operational procedures could result in minor physical injuries or damage to the machine. 2. Observance of these instructions does not relieve you of the responsibility to observe other rules and guidelines! The following should also be observed: – The safety rules in force at the operating site – Legally enforced road traffic regulations – Guidelines issued by trade associations
L544 - 443 / from 7477 L554 - 453 / from 7477 L564 - 463 / from 7477 L574 - 473 / from 7477 L580 - 458 / from 7477
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MJFCIFSS
1 . 1 - 1 of 2
General Information
Special tools for maintenance and repair work
Safety regulations
1.1.2
Overview of safety regulations A detailed description of these is included in the relevant section of the chapter on safety regulations in the operator's manual. The following sections are described in the operator's manual: 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
1 . 1 - 2 of 2
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 welding work on the machine
16
Instructions for working safely on machine attachments
17
Safety regulations when transporting the machine by crane
18
Safe maintenance of hydraulic hoses and hose lines
19
Attachments and accessories
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MJFCIFSS
L544 - 443 / from 7477 L554 - 453 / from 7477 L564 - 463 / from 7477 L574 - 473 / from 7477 L580 - 458 / from 7477
Special tools for maintenance and repair work
General Information Special tools for maintenance and repair work
1.2 Special tools for maintenance and repair work 1.2.1 Description
Special tools, general information ID no.
Digital second thermometer
7020372
All wheel loaders
DCA 4 coolant test kit
5608459
All wheel loaders
Anti-freeze and battery tester
7408922
All wheel loaders
24 Volt vacuum pump Charging and testing device with case 0-40 bar pressure gauge 0-250 bar pressure gauge 0-600 bar pressure gauge Pressure gauge connection 1500 mm high-pressure tube 4000 mm high-pressure tube Screw coupling M 10 x 1 Oil drain hose Outlet piece
7408148
All wheel loaders
Notes For taking temperature measurements during adjustment work For testing DCA 4 and antifreeze levels For testing the acid concentration (battery charge level) and testing the cooler anti-freeze For preventing oil loss
8145359
All wheel loaders
For testing the hydro accumulators
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 testing hydraulic pressures For testing hydraulic pressures For testing hydraulic pressures Connection for pressure gauge High-pressure tube for pressure gauge High-pressure tube for pressure gauge For testing hydraulic pressures For draining oil via an outlet valve For the oil drain hose For securing the valves on the variable displacement 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 valve block For adjusting the travel hydraulics For adjusting the travel hydraulics
Bodem software and dongle Bodem data cable
10285174 6905910
1.2.2 Description Compression tester Injection nozzle tester Adapter for compression tester High pressure hand pump with accessories Extracting device for injection nozzles Adapter for extracting device Krikit 2 V-belt gauge Fly cranking device for wheel Cranking device for the crankshaft Rotary angle extraction device L544 - 443 / from 7477 L554 - 453 / from 7477 L564 - 463 / from 7477 L574 - 473 / from 7477 L580 - 458 / from 7477
Use
L544 - L580 L544 - L580
Special tools for Liebherr diesel engines
ID no. 8008782 7361236
Use Notes L544 - L580 diesel engine For testing compression levels L544 - L580 diesel engine For testing injection nozzles
0524044
L544 - L580 diesel engine In place of the injection nozzle
7009318
L544 - L580 diesel engine
0524072
L544 - L580 diesel engine For removing the injection nozzles
0524029 8042829 0524045
L544 - L580 diesel engine For use with extracting device L544 - L580 diesel engine For testing the V-belt tension L544 - L580 diesel engine For turning the engine flywheel For turning the engine via the L544 - L580 diesel engine crankshaft For cylinder head, main bearing, and L544 - L580 diesel engine connection lug bearing screws
9183785 0524062
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MJFCIFSS
For testing the delivery begin of the injection pump
1 . 2 - 1 of 6
General Information
Special tools for maintenance and repair work
Special tools for maintenance and repair work
1.2.3 Description
Special tools for the hydraulic cylinders ID no.
80 mm installation sleeve
9227165
90 mm installation sleeve
9227161
130 mm installation sleeve
9998624
150 mm installation sleeve
9998622
170 mm installation sleeve
9107931
80 mm expansion tube
9227166
90 mm expansion tube
9227162
130 mm expansion tube
9110408
150 mm expansion tube
9110410
170 mm expansion tube
9110412
70/8 mm bearing head assembly wrench 75/12 mm bearing head assembly wrench
9210219 9239572
1.2.4 Description Digital multimeter Red testing probe Black testing probe Solenoid tester Wire stripping and crimping tool 0.5 – 6.0 mm² Insertion tool Extraction tool Manual crimping tool Wedge extraction tool Size 12 extraction tool for pin and bushing Size 16 extraction tool for pin and bushing Size 20 extraction tool for pin and bushing
1 . 2 - 2 of 6
Use Steering cylinder L544, L554 Steering cylinder L564, L574, L580 Lift cylinder L544, L554 Tilt cylinder L544, L554 Lift cylinder L564, L574, L580 Tilt cylinder L564, L574, L580 Steering cylinder L544, L554 Steering cylinder L564, L574, L580 Lift cylinder L544, L554 Tilt cylinder L544, L554 Lift cylinder L564, L574, L580 Tilt cylinder L564, L574, L580 Steering cylinder L544, L554 Steering cylinder L564, L574, L580
Notes 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 installation of the piston rod bearing For installation of the piston rod bearing
Special electrical tools ID no.
8502956
Use All wheel loaders
884191214 All wheel loaders 884191114 All wheel loaders 8145743 All wheel loaders
Notes For measuring electrical voltage, current, resistance and frequency For testing DEUTSCH plugs For testing DEUTSCH plugs 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
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MJFCIFSS
L544 - 443 / from 7477 L554 - 453 / from 7477 L564 - 463 / from 7477 L574 - 473 / from 7477 L580 - 458 / from 7477
Special tools for maintenance and repair work
General Information Safety regulations
1.2.5
Special tools for axles
Description
ID no.
Hand pump
8145835
Axles L544 - L580
Clamping pliers
7009536
Axles L554 - L580
Spring hook
8145767
Axles L554 - L580
260 mm slip bushing
7017559
315 mm slip bushing
7017556
Slip bushing M 90 x 1.5 mm
7017558
Slip bushing M 110 x 1.5 mm
7017557
Slip bushing M 130 x 1.5 mm
7017555
Handle Handle Installation tool
7017566 7011518 7017563
Installation tool
7017560
Centering shackle 111 mm grooved nut spanner
7013775 7009537
140 mm grooved nut spanner
7011251
169 mm grooved nut spanner
7013774
M 16 x 1.5 micrometer gauge
7019556
M 16 x 1.5 micrometer gauge
8145771
Clamping fork Installation tool
7011522 7013922
Front axle L554 Rear axle L554 Front axle L564, L574 Rear axle L564, L574, L580 Rear axle L554 Front axle L554 Rear axle L564, L574 Front axle L564, L574, L580; rear axle L580 Axles L544 - L580 Axles L544 - L580 Rear axle L554 Front axle L554, L564, L574, 580; rear axle L564, L574, L580 Axles L554 - L580 Rear axle L554 Front axle L554 Rear axle L564, L574 Front axle L564, L574, L580; rear axle L580 Front axle L554 Rear axle L554, L564, L574 Front axle L564, L574, L580; rear axle L580 Axles L554 - L580 Axles L554 - L580
81 mm grooved nut spanner
10017840
Axles L544 - L580
Installation tool (used with handle 7011518)
7624271
Installation tool
7624272
Centering shackle
10008138
Socket spanner
10008139
Socket spanner
10218794
Clamping fork Complete Hercules special tool kit
10008140
Axles L544 AP-409, MT-L 3085 Axles L544 AP-409, MT-L 3085 Axles L544 MT-L 3085 Rear axles L544, L554 MT-L 3085, Front axle L544 MT-L 3085 until Ser. No. 10666 Axles L554 - L574 MT-L 3085 Front Axle L544 MT-L 3085 from Ser.-No. 10667 Axles L544 MT-L 3085
10286181
Axles L580 Hercules
L544 - 443 / from 7477 L554 - 453 / from 7477 L564 - 463 / from 7477 L574 - 473 / from 7477 L580 - 458 / from 7477
Use
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MJFCIFSS
Notes For testing the tightness of disc brakes For locking or releasing the snap ring in the planetary drive For locking or releasing the return springs Installation aid for brake piston Installation aid for brake piston Installation aid for ring gear carrier Installation aid for ring gear carrier Installation aid for ring gear carrier Handle for installation tool Handle for various installation tools Installation aid for sealing ring cartridge Installation aid for sealing ring cartridge For grooved nut spanner For installation of grooved nuts For installation of grooved nuts For installation of grooved nuts For measuring wear on the brake discs For measuring wear on the brake discs For installation of the drive flange Installation aid for shaft sealing ring For installation of grooved nuts on the axle drive For fitting the axle input dust guard For fitting the axle input shaft sealing ring For removing the wheel end For removing the wheel end
For removing the wheel end For bevel pinion Contains items: 10286183 -10286198
1 . 2 - 3 of 6
General Information
Special tools for maintenance and repair work
Special tools for maintenance and repair work
Driver, 43R grease seal & oil seal 3" Sleeve driver, guide and handle Driver handle, outer lip seal and cup Driver, inner lip seal Wear sleeve driver with pilot Adjusting nut driver Seal retainer installation tool 43R Driver, bearing cups Driver, 43R grease seal & washer Wheel end rolling torque device Lifting device Installation tool--face seal
10286183
Axles L580 Hercules
Use with Handle 10286788
10286186
Axles L580 Hercules
Includes Handle 10286788
10286788
Axles L580 Hercules
Handle use with corresponding drivers
10286189 10286190 10286192
Axles L580 Hercules Axles L580 Hercules Axles L580 Hercules
Use with handle 10286788 For installation, wear sleeve For the adjusting nut
10286193
Axles L580 Hercules
For the seal retainer
10286194
Axles L580 Hercules
10286195
Axles L580 Hercules
For the bevel pinion For installation grease seal & washer, use with handle 10286788
10286196
Axles L580 Hercules
Checking rolling torque, wheel end
10286197 10286198
Axles L580 Hercules Axles L580 Hercules
Handling wheel end Installation „Lifetime“ sealing (face seal)
1.2.6 Description
Special tools for the transfer gear ID no.
Use
Fastening spanner
10016179
L544 – L580
Special nut
10016180
L544 – L580
Installation tool
10016181
L544 – L580
1.2.7 Description Filling press Filling connection Central lubrication BEKA MAX Data cable and software Central lubrication Groeneveld data cable Central lubrication Groeneveld adapter plug Central lubrication Gröneveld software
1 . 2 - 4 of 6
Notes For loosening and fastening the grooved nut on coupling 1 For loosening and fastening the grooved nut on coupling 1 For fitting and removing the snap ring on the couplings
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
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MJFCIFSS
Notes For quickly filling the reservoir For quickly filling the reservoir For testing the central lubrication system For testing the central lubrication system For testing the central lubrication system For testing the central lubrication system
L544 - 443 / from 7477 L554 - 453 / from 7477 L564 - 463 / from 7477 L574 - 473 / from 7477 L580 - 458 / from 7477
Special tools for maintenance and repair work
General Information Safety regulations
1.2.8 Description
Special tools for the air conditioning system ID no.
Use
Notes
Vacuum pump
7027552
All wheel loaders
For evacuating the air conditioning system
4-valve test set
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 set
Filling hose, yellow 1500 mm
7027554
All wheel loaders
For the test set
Filling hose, red 1500 mm
7027555
All wheel loaders
For the test set
Car coupling 253a
7027556
All wheel loaders
For the test set
Car coupling 254a
7027557
All wheel loaders
For the test set
1.2.9 Description Toolbox with suction pads
L544 - 443 / from 7477 L554 - 453 / from 7477 L564 - 463 / from 7477 L574 - 473 / from 7477 L580 - 458 / from 7477
Special tools for the cab windows ID no.
10021147
Use
Notes
All wheel loaders
For fitting and removing panes
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MJFCIFSS
1 . 2 - 5 of 6
2 Product Description 2.0 Chapter contents 2
Product Description............................................................. 2.0-1 2.1
L544 - 443 / from 7477 L554 - 453 / from 7477 L564 - 463 / from 7477 L574 - 473 / from 7477 L580 - 458 / from 7477
Technical data ................................................................................2.1-1 2.1.1
Complete machine................................................................2.1-1
2.1.2
Diesel engine, pump distributor gear....................................2.1-8
2.1.3
Cooling system ...................................................................2.1-16
2.1.4
Travel hydraulics ................................................................2.1-18
2.1.5
Working hydraulics .............................................................2.1-21
2.1.6
Steering system..................................................................2.1-27
2.1.7
Brake system......................................................................2.1-30
2.1.8
Electrical system.................................................................2.1-32
2.1.9
Transfer gear ......................................................................2.1-32
2.1.10
Axles, drive shafts ..............................................................2.1-33
2.1.11
Machine frame, ballast weight............................................2.1-40
2.1.12
Central Lubrication System ................................................2.1-40
2.1.13
Cab, heating, air-conditioning.............................................2.1-42
2.1.14
Lift arm, quick-change device.............................................2.1-43
2.1.15
Attachments, accessories ..................................................2.1-46
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2 . 0 - 1 of 2
Product description
Service Manual Technical data
2.1 Technical data 2.1.1
Complete machine Wheel loader with Z-bar lift arms
Valid for:
L544 - 443 / from 7477
The values stated refer to the standard version of the machine: – With Z-bar lift arm (2600 mm) without hydraulic quick-change device. – With 23.5 R25 Michelin XHA tyres. – The specified tipping loads and weights include all lubricants, full fuel tank, ROPS/FOPS cab and driver.
Description
Value Unit
Bucket capacity as per ISO 7546 Bucket width
2700 mm
Specific material weight
1.8 t/m³
A - Dump height at maximum lifting height and 45° tilt-out angle
2920 mm
B - Maximum dumping height
3500 mm
C - Maximum height of bucket base
3645 mm
D - Maximum height of bucket pivot point
3915 mm
E - Maximum height of bucket upper edge
5350 mm
F - Reach at maximum lifting height and 45° tilt-out angle
1040 mm
G - Digging depth
L544 - 443 / from 7477 L554 - 453 / from 7477 L564 - 463 / from 7477 L574 - 473 / from 7477 L580 - 458 / from 7477
3.0 m³
85 mm
H - Height above cab
3355 mm
I - Height above exhaust
3310 mm
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MJFCIFSS
2 . 1 - 1 of 48
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Product description
Service Manual
Technical Data
Description
Value Unit
J - Ground clearance
530 mm
K - Wheel base
3150 mm
L - Overall length
7785 mm
Turning radius over bucket outer edge
6235 mm
Lifting force (SAE)
170 kN
Breakout force (SAE)
125 kN
Tipping load when straight
12020 kg
Tipping load, articulated 35°
10910 kg
Tipping load, articulated 40°
10600 kg
Angle of articulation (to each side)
40 °
Operating weight
15300 kg
Tractive force
122.6 kN
Travel speed in travel range 1 forward and reverse
0 - 10 km/h
Travel speed – travel range 2 forward and reverse
0 - 20 km/h
Travel speed in travel range A1-2 (automatic), forward and reverse
0 - 20 km/h
Travel speed in travel range A1-3 (automatic), forward and reverse
0 - 40 km/h
Travel speed in travel range A2-3 (automatic), forward and reverse
0 - 40 km/h
Sound pressure level in the cab – L pA per ISO 6396
69 dB (A)
Wheel loader with Z-bar lift arms Valid for:
L554 - 453 / from 7477
The values stated refer to the standard version of the machine: – With Z-bar lift arm (2750 mm) without hydraulic quick-change device. – With 23.5 R25 Michelin XHA tyres. – The specified tipping loads and weights include all lubricants, full fuel tank, ROPS/FOPS cab and driver.
2 . 1 - 2 of 48
copyright by
MJFCIFSS
L544 - 443 / from 7477 L554 - 453 / from 7477 L564 - 463 / from 7477 L574 - 473 / from 7477 L580 - 458 / from 7477
Product description
Service Manual Technical data
Description
Value Unit
Bucket capacity as per ISO 7546 Bucket width
2700 mm
Specific material weight
1.8 t/m³
A - Dump height at maximum lifting height and 45° tilt-out angle
3085 mm
B - Maximum dumping height
3700 mm
C - Maximum height of bucket base
3920 mm
D - Maximum height of bucket pivot point
4180 mm
E - Maximum height of bucket upper edge
5740 mm
F - Reach at maximum lifting height and 45° tilt-out angle
1070 mm
G - Digging depth
110 mm
H - Height above cab
3355 mm
I - Height above exhaust
3310 mm
J - Ground clearance
530 mm
K - Wheel base
3150 mm
L - Overall length
8130 mm
Turning radius over bucket outer edge
6360 mm
Lifting force (SAE)
180 kN
Breakout force (SAE)
130 kN
Tipping load when straight
13925 kg
Tipping load, articulated 35°
12625 kg
Tipping load, articulated 40°
12270 kg
Angle of articulation (to each side)
L544 - 443 / from 7477 L554 - 453 / from 7477 L564 - 463 / from 7477 L574 - 473 / from 7477 L580 - 458 / from 7477
3.5 m³
40 °
Operating weight
17300 kg
Tractive force
136.4 kN copyright by
MJFCIFSS
2 . 1 - 3 of 48
Product description
Service Manual
Technical Data
Description
Value Unit
Travel speed in travel range 1 forward and reverse
0 - 10 km/h
Travel speed in travel range 2 forward and reverse
0 - 20 km/h
Travel speed in travel range A1-2 (automatic), forward and reverse
0 - 20 km/h
Travel speed in travel range A1-3 (automatic), forward and reverse
0 - 40 km/h
Travel speed in travel range A2-3 (automatic), forward and reverse
0 - 40 km/h
Sound pressure level in the cab – L pA per ISO 6396
69 dB (A)
Wheel loader with Z-bar lift arms Valid for:
L564 - 463 / from 7477
The values stated refer to the standard version of the machine: – With Z-bar lift arm (2920 mm) without hydraulic quick-change device. – With 26.5 R25 Michelin XHA tyres. – The specified tipping loads and weight include all lubricants, full fuel tank, ROPS/FOPS cab and driver.
Description
Value Unit
Bucket capacity as per DIN 7546 Bucket width
3000 mm
Specific material weight
2 . 1 - 4 of 48
4.0 m³ 1.8 t/m³
A - Dump height at maximum lifting height and 45° tilt-out angle
3220 mm
B - Maximum dumping height
3900 mm
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MJFCIFSS
L544 - 443 / from 7477 L554 - 453 / from 7477 L564 - 463 / from 7477 L574 - 473 / from 7477 L580 - 458 / from 7477