Page 1

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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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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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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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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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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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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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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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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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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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

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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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L544 - 443 / from 7477 L554 - 453 / from 7477 L564 - 463 / from 7477 L574 - 473 / from 7477 L580 - 458 / from 7477

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Liebherr L544-443 Wheel Loader Service Repair Manual SN:7477  

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