Liebherr l524 659 wheel loader service repair manual sn：from 17890 by 163757

Service Manual (20

Wheel loader (10 points)

L524 â&#x20AC;&#x201C; L542 2plus1

Service Manual (20

Wheel loader (10 points)

L524 – L542 2plus1 (10

Address 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 L528 L538 L542 659 660 433 435 17890 17891 17893 17895

Document ID Order number: Author: Document version: Manual number: Owner:

10411314 LBH / Technical Documentation Department 01

Preface

Intended readership

Contents

This service manual is addressed to anyone whose task it is to ensure that the machines are ready for everyday use. This especially includes mechanics and workshop staff of Liebherr dealers and branches. The first chapter contains information on safety regulations and on the special tools needed for maintenance and repairs. Chapter 2 gives you an overview of all the most important technical data of the machine as a whole and its individual assemblies. Next comes the maintenance chapter, with the maintenance and inspection schedule, the testing and adjustment checklists, lubrication charts, description of maintenance tasks, testing and adjustment tasks and specifications of fuel and lubricants. The technical description of the machine is in the following chapters, structured according to fifteen function groups. The layout, function and technical data of the groups, components and parts are explained. Chapter 19 contains information on troubleshooting, the service code table and a description of the “SCULI” service software. Chapter 20 will be gradually updated with the latest options.

Instructions on use

This manual describes several types and versions of machines. The information generally applies to the types and serial numbers stated at the bottom of the page. The exception to this is information which only applies to specific types and serial numbers, which are stated at the beginning of the section concerned (for example technical data of parts). Where possible, the ID numbers of parts and components are stated in the heading. This manual is available in German, English, French, Spanish, Italian and Russian.

Working instructions

Always follow the safety regulations whenever you work on the machine. You will find a reference to this in the “General Information” section. In order to perform these tasks you need a complete set of basic tools andcertain special tools, all in perfect working order. All tasks require absolute cleanliness. Replace seals such as O-rings and surface seals during repairs.

DVD edition

Please note that this manual is not only available in printed form, but is also available as electronic documentation on DVD (Lidos).

General information

Product description

Maintenance

Diesel engine and pump distributor gear

Cooling system

Travel hydraulics

Working hydraulics

Steering system

Brake system

Electrical system

Transfer gear

Axles and cardan shaft

Machine frame and ballast weight

Central lubrication system

Coverings and access

Cab, heating and air-conditioning

Lift arms and quick-change device

Equipment and accessories

Service codes and diagnosis

Options

1 General informations 1.0 Chapter contents 1

General informations........................................................... 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

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 .....................................1.2-2

1.2.4

Special tools for electronics..................................................1.2-3

1.2.5

Special tools for axles...........................................................1.2-3

1.2.6

Central lubrication system ....................................................1.2-4

1.2.7

Special tools for the air conditioning system ........................1.2-4

1.3

Standard .........................................................................................1.3-1 1.3.1

L524 - 659 / from 17890 L528 - 660 / from 17890 L538 - 433 / from 17890 L542 - 435 / from 17890

Anziehmomente fĂźr SchraubenFehler! Textmarke nicht definiert.

MJFCIFSS

1.0-1 of 2

Service manual

General informations 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. T These are indicated by the headings Danger, Warning, Caution or Notice.

1.1.1

Introduction 1. The symbols below have the following meanings: DANGER Denotes an urgent, dangerous situation. Will result in death or serious injury. Actions to avert the danger.

WARNING Denotes a dangerous situation. Can result in death or serious injury. Actions to avert the danger.

CAUTION Risk of personal injury. Denotes a potentially dangerous situation which can lead to slight injury if not avoided. Actions to avert the danger.

NOTICE Risk of damage to the machine. Denotes actions or circumstances which may result in damage to the machine. Actions to avert the danger.

Note Useful information Denotes information on correctly handling the machine and the lubricants and fuels used. Actions to implement.

L524 - 659 / from 17890 L528 - 660 / from 17890 L538 - 433 / from 17890 L542 - 435 / from 17890

MJFCIFSS

1.1-1 of 2

General informations

Service manual

Safety regulations

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

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

Introduction

General safety regulations

Proper use

Decals on the machine

Instructions on preventing crushing injuries and burns

Instructions on preventing fires and explosions

Safety instructions for start-up

Safety precautions during start-up

Instructions for safe working

Safety instructions for driving on slopes

Parking safely

Transporting the machine safely

Towing the machine safely

Measures for ensuring safe maintenance

Safety instructions for working on machines with hydro accumulators

Safety instructions for welding work on the machine

Instructions for working safely on the working attachment

Safety instructions for transporting the machine by crane

Safe maintenance of hydraulic hoses and hose lines

Attachments and accessories

Protection against vibrations

MJFCIFSS

L524 - 659 / from 17890 L528 - 660 / from 17890 L538 - 433 / from 17890 L542 - 435 / from 17890

Service manual

General informations Safety regulations

1.2 Special tools for maintenance and repair work 1.2.1 Description

Special tools in general ID no.

Use

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 Draining hose Drain piece

7408148 8145359 7361288 5002932 5002866 7002436 7002475 7009134 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 All wheel loaders

Safety cap 10 mm

7009315

All wheel loaders

Safety cap 13 mm Safety cap 17 mm Safety cap 19 mm

7615515 7615589 7009317

All wheel loaders All wheel loaders All wheel loaders

Safety cap 17 mm

7622068

All wheel loaders

USB dongle

10333608

L524 - L586

Diagnostic data cable

9067426

L524 - L586

Adapter cable RS232<>USB

1.2.2

693190714

All wheel loaders

Special tools for Liebherr diesel engines

Description Compression tester Nozzle tester Adapter for compression tester Injection valve extraction tool Extraction tool adapter

ID no. 8008782 7361236 0524044 0524072 0524029

Use Engine L538, L542 engine L538, L542 engine L538, L542 engine L538, L542 engine

Piston ring tensioning belt

8000952

All wheel loaders

Krikit 2 V-belt tester Flywheel cranking device Shaft seal ring installation tool Extractor tool Extractor tool Seal remover

8042829 0524045 7090373 7090377 7090395 7090372

L524 - L542 engine L538, L542 engine L524, L528 engine L524, L528 engine L524, L528 engine L524, L528 engine

Installation set

7090378

L524, L528 engine

L524 - 659 / from 17890 L528 - 660 / from 17890 L538 - 433 / from 17890 L542 - 435 / from 17890

Remarks For checking the acid concentration (battery charging state) and anti-freeze For preventing oil loss For checking the hydro accumulator 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 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 With SERVICE authorisation For adjusting the travel hydraulics, and testing the electrical system and options For communicating with the wheel loader electronics if there is an error with the RS232 interface on the notebook.

MJFCIFSS

Remarks For checking the compression For checking the injection valves 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 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 installing the rear oil seal ring and wear ring

1.2-1 of 4

General informations

Service manual

Special tools for maintenance and repair work

Description

ID no.

Depth gauge

7090370

L524 - L542 engine

Extractor tool

7090376

L524, L528 engine

Extractor tool

7090363

L524, L528 engine

Angle wrench

0524062

L538, L542 engine

1.2.3 Description

Remarks For measuring the valve depth in the cylinder head and for measuring 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

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 80/12 mm

8007364

Piston spanner 88/12 mm

8007365

Piston spanner 100/14 mm

8007366

Piston nut spanner

9921123

Piston nut spanner

9921124

Piston spanner 52/10 mm

9131359

Piston rod bearing spanner

9210219

Piston spanner 60/14 mm

9131362

Piston rod bearing spanner 76/9 mm

0541665

1.2-2 of 4

Use

Use L524, L528 P kinematics tilt cylinder L524 - L542 steering cylinder L538, L542 P kinematics tilt cylinder L524, L528 lift cylinder L538, L542 lift cylinder L524, L528 Z kinematics tilt cylinder L538, L542 Z kinematics tilt cylinder L524, L528 P kinematics tilt cylinder L524 - L542 steering cylinder L538, L542 P kinematics tilt cylinder L524, L528 lift cylinder L538, L542 lift cylinder L524, L528 Z kinematics tilt cylinder L538, L542 Z kinematics tilt cylinder L524 - L542 lift cylinder L524, L528 Z kinematics tilt cylinder L538, L542 Z kinematics tilt cylinder L524 - L542 lift cylinder L524 - L542 P Z kinematics tilt cylinder L524, L528 P kinematics tilt cylinder L524, L528 P kinematics tilt cylinder L538, L542 P kinematics tilt cylinder L524 - L542 steering cylinder L538, L542 P kinematics tilt cylinder L524 - L542 steering cylinder

MJFCIFSS

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 nut For fitting the piston nut For fitting the piston For fitting the piston rod bearing For fitting the piston

For fitting the piston rod bearing

L524 - 659 / from 17890 L528 - 660 / from 17890 L538 - 433 / from 17890 L542 - 435 / from 17890

Service manual

General informations Safety regulations

1.2.4 Description

Special tools for electronics ID no.

Digital multimeter

8502956

Test probe, red Test probe, black Magnet tester Stripping and crimping pliers 0.5 - 6.0 mm2 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 and bushing Plug-in fuse tester Wide METRI-PACK extractor tool Narrow METRI-PACK extractor tool

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

8503647 7026267

All wheel loaders All wheel loaders

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

8145834

All wheel loaders

7091022

L524, L528

7091023

L524, L528

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

Special tools for axles

Description

ID no.

Hand pump

8145835

Feeler gauge

8145535

Set of 5 spanners

10220617

Driver, Øa=185 mm

10220623

Slotted nut spanner

10220633

Handle for driver

10220624

Slotted nut spanner with adapter

10220626

Driver, Øa=62.5 mm

10220631

Driver, Øa=90 mm

10220632

L524 - 659 / from 17890 L528 - 660 / from 17890 L538 - 433 / from 17890 L542 - 435 / from 17890

Use

Use L524 - L542 axles L524 - L542 axles L524 - L542 axles L524 - L542 axles L524 - L542 axles L524 - L542 axles L524 - L542 axles L524 - L542 axles L524 - L542 axles

MJFCIFSS

Remarks For relieving the disc springs and for testing the tightness of the disc brakes For inspecting the wear on the wet disc brake (T1-2313) For gripping whilst installing or removing the bevel gear shaft (T5-2386) For installing the shaft seal ring in the hub (T10-3502) For removing and fitting the differential gear (T13-3333) Required for holding the driver For removing and fitting the bevel gear shaft (T22-3317/A) For installing the shaft seal ring in the axle casing (T34-2322) For installing the shaft seal ring in the bearing bushing of the axle (T5-3342)

1.2-3 of 4

General informations

Service manual

Special tools for maintenance and repair work

1.2.6 Description BEKA MAX filling press BEKA MAX filling port Groeneveld filling press Groeneveld central lubrication data cable

Central lubrication system

ID no. 10009239 7029283 10333342

Use All wheel loaders All wheel loaders All wheel loaders

Remarks For quickly filling the For filling the reservoir For quickly filling the reservoir

7624289

All wheel loaders

For inspecting the central lubrication system

Groeneveld central lubrication plug adapter

7624290

All wheel loaders

For inspecting the central lubrication system

Groeneveld central lubrication software

As below

All wheel loaders

For inspecting the central lubrication system

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 - 659 / from 17890 L528 - 660 / from 17890 L538 - 433 / from 17890 L542 - 435 / from 17890

Service manual

General informations Mjfcifss - Standard

1.3 Standard 1.3.1

Tightening torques for screws Pre-loading forces and tightening torques for screws with standard and fine metric threads.

Standard and fine metric threads All figures are for bolted connections with at least one Dacromet 500 coated element (screws, washers, nuts…) Surface: - DACROMET 500

Thread

Class

Assembly preloading forces FM in N

Tightening torques MA in Nm

Standard and fine metric threads. All figures are for bolted connections without any Dacromet 500 coated elements (screws, washers, nuts…) Surface: - black finish or phosphated - zinc-plated Thread

Class

for avg. coefficient of friction µG= 0.10

M8x1

M9x1

M10

M10x1

M10x1,25

M12

M12x1,25

M12x1,5

M14

M14x1,5

4 200 6 200 7 300 6 900 10 100 11 900 9 700 14 300 16 700 14 200 20 900 24 500 17 900 26 000 30 500 19 600 28 500 33 500 25 500 38 000 44 000 28 500 42 000 49 000 32 500 48 000 56 000 30 500 45 000 53 000 41 500 61 000 71 000 46 500 68 000 80 000 44 000 65 000 76 000 57 000 84 000 98 000 63 000 92 000 108 000

2,5 3,7 4,3 4,9 7,3 8,5 8,5 12,5 14,5 14,0 20,5 24,0 20,5 30 35 22 32 38 32 46 54 41 60 71 45 67 78 43 64 74 71 104 121 77 112 130 74 108 125 113 165 195 121 175 205

Tightening torques MA in Nm

for avg. coefficient of friction µG= 0.12

M8x1

M9x1

M10

M10x1

M10x1,25

M12

M12x1,25

M12x1,5

M14

M14x1,5

This document must not be copied or reproduced without prior permission. This document has been electronically prepared and is valid without requiring a signature. L524 - 659 / from 17890 L528 - 660 / from 17890 L538 - 433 / from 17890 L542 - 435 / from 17890

Assembly preloading forces FM in N

MJFCIFSS

4 050 6 000 7 000 6 600 9 700 11 400 9 400 13 700 16 100 13 700 20 100 23 500 17 200 25 000 29 500 18 800 27 500 32 500 24 800 36 500 42 500 27 500 40 000 47 000 31 500 46 500 54 000 29 500 43 000 51 000 40 000 59 000 69 000 45 000 66 000 77 000 42 500 62 000 73 000 55 000 80 000 94 000 61 000 89 000 104 000

2,8 4,1 4,8 5,5 8,1 9,5 9,5 14,0 16,5 15,5 23,0 27 23 34 40 24,5 36 43 36 53 62 46 68 79 52 76 89 49 72 84 79 117 135 87 125 150 83 122 145 125 185 215 135 200 235

Liebherr-Norm_DE_V001.dot

1.3-1 of 4

General informations

Service manual

Mjfcifss - Standard

Thread

Class

Assembly preloading forces FM in N

Tightening torques MA in Nm

Thread

Class

for avg. coefficient of friction ÂľG= 0.10

M16

M16x1,5

M18

M18x1,5

M18x2

M20

M20x1,5

M22

M22x1,5

M24

M24x1,5

M24x2

M27

M27x1,5

M27x2

M30

M30x1,5

M30x2

M33

M33x1,5

M33x2

M36

8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9

78 000 115 000 134 000 85 000 125 000 147 000 98 000 140 000 164 000 114 000 163 000 191 000 106 000 151 000 177 000 126 000 180 000 210 000 144 000 206 000 240 000 157 000 224 000 260 000 177 000 255 000 295 000 182 000 260 000 305 000 215 000 306 000 358 000 203 000 290 000 340 000 239 000 340 000 400 000 276 000 394 000 461 000 265 000 375 000 440 000 290 000 415 000 485 000 346 000 493 000 576 000 332 000 472 000 553 000 360 000 520 000 600 000 423 000 603 000 705 000 410 000 580 000 680 000 425 000 600 000 710 000

170 250 300 180 270 310 245 350 410 270 390 450 260 370 430 350 490 580 380 540 630 470 670 780 510 720 840 600 850 1000 700 990 1170 640 920 1070 880 1250 1450 1010 1440 1690 940 1350 1550 1190 1700 2000 1410 2000 2340 1370 1940 2270 1600 2300 2700 1880 2670 3130 1750 2500 2900 2100 3000 3500

Tightening torques MA in Nm

for avg. coefficient of friction ÂľG= 0.12

M16

M16x1,5

M18

M18x1,5

M18x2

M20

M20x1,5

M22

M22x1,5

M24

M24x1,5

M24x2

M27

M27x1,5

M27x2

M30

M30x1,5

M30x2

M33

M33x1,5

M33x2

M36

This document must not be copied or reproduced without prior permission. This document has been electronically prepared and is valid without requiring a signature.

1.3-2 of 4

Assembly preloading forces FM in N

75 000 111 000 130 000 82 000 121 000 141 000 94 000 135 000 157 000 110 000 157 000 184 000 102 000 146 000 170 000 121 000 173 000 202 000 139 000 199 000 232 000 152 000 216 000 250 000 171 000 245 000 285 000 175 000 249 000 290 000 207 000 295 000 346 000 196 000 280 000 325 000 230 000 330 000 385 000 267 000 381 000 445 000 255 000 365 000 425 000 280 000 400 000 465 000 335 000 477 000 558 000 321 000 457 000 534 000 350 000 495 000 580 000 410 000 584 000 683 000 395 000 560 000 660 000 410 000 580 000 680 000

195 280 330 205 300 360 280 390 460 310 440 520 290 420 490 390 560 650 430 620 720 530 750 880 580 820 960 670 960 1 120 760 1 090 1 270 730 1 040 1 220 1 000 1 400 1 650 1 110 1 580 1 850 1 070 1 500 1 800 1 350 1 900 2250 1 540 2 190 2 560 1 490 2 120 2 480 1 850 2 600 3 000 2 050 2 920 3 420 2 000 2 800 3 300 2 350 3 300 3 900

Liebherr-Norm_DE_V001.dot L524 - 659 / from 17890 L528 - 660 / from 17890 L538 - 433 / from 17890 L542 - 435 / from 17890

Service manual

General informations Mjfcifss - Standard

Thread

Class

Assembly preloading forces FM in N

Tightening torques MA in Nm

Thread

Class

for avg. coefficient of friction ÂľG= 0.10

M36x1,5

M36x3

M39

M39x1,5

M39x3

8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9

508 000 724 000 847 000 455 000 650 000 760 000 510 000 730 000 850 000 601 000 857 000 1 002 000 550 000 780 000 910 000

2450 3490 4090 2200 3100 3600 2700 3800 4500 3140 4470 5230 2800 4000 4700

Assembly preloading forces FM in N

Tightening torques MA in Nm

for avg. coefficient of friction ÂľG= 0.12

M36x1,5

M36x3

M39

M39x1,5

M39x3

8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9

492 000 701 000 820 000 440 000 630 000 740 000 490 000 700 000 820 000 582 000 830 000 971 000 530 000 750 000 880 000

2 680 3 820 4 470 2 500 3 500 4 100 3 000 4 300 5 100 3 430 4 890 5 720 3 200 4 600 5 300

Comments concerning this standard: The tightening torques indicated on the drawings supersede the standard works values. These must be observed and adhered to. This standard only applies to Liebherr wheel loaders.

MJFCIFSS

Liebherr-Norm_DE_V001.dot

1.3-3 of 4

2 Product description 2.0 Chapter contents 2

Product description ............................................................. 2.0-1 2.1

L524 - 659 / from 17890 L528 - 660 / from 17890 L538 - 433 / from 17890 L542 - 435 / from 17890

Technical data ................................................................................ 2.0-1 2.1.1

Complete machine ................................................................ 2.0-1

2.1.2

Engine and splitter box ......................................................... 2.0-6

2.1.3

Cooling system ..................................................................... 2.0-8

2.1.4

Travel hydraulics .................................................................. 2.0-9

2.1.5

Working hydraulics ............................................................. 2.0-11

2.1.6

Steering system .................................................................. 2.0-15

2.1.7

Brake system ...................................................................... 2.0-16

2.1.8

Electrical system................................................................. 2.0-17

2.1.9

Transmission ...................................................................... 2.0-18

2.1.10

Axles and cardan shaft ....................................................... 2.0-18

2.1.11

Machine frame and ballast weight ...................................... 2.0-20

2.1.12

Cab, heating and air-conditioning ....................................... 2.0-20

2.1.13

Lift arms and quick-change device ..................................... 2.0-22

2.1.14

Equipment and accessories ............................................... 2.0-23

MJFCIFSS

2.0-1 of 2

Service manual

Product description Technical data

2.1 Technical data 2.1.1

Complete machine

Valid for:

L524 - 659 / from 17890

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 5R25 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 of machine with Z and P lift arms Item

Description

Unit Load geometry

A B C D E F G H I J

Bucket capacity as per ISO 7546 Bucket width Specific material weight Dump height at maximum lifting height and 45° tilt-out angle Dump height Maximum bucket base height Maximum bucket pivot point height Maximum bucket top height Reach at maximum lifting height and 42° tilt-out angle Digging depth Height above the cab Height above exhaust Ground clearance

L524 - 659 / from 17890 L528 - 660 / from 17890 L538 - 433 / from 17890 L542 - 435 / from 17890

MJFCIFSS

m³ mm t/m³ mm mm mm mm mm mm mm mm mm mm

Value Z bar 2.0 2500 1.8 2870 3335 3530 3775 4860 850 80 3200 2860 460

P bar 1.7 2500 1.8 2845 3370 3590 3830 4980 1010 61 3200 2860 460

2.0-1 of 23

Product description

Service manual

Technical data

Item

Description

Unit Load geometry

K L

Wheel base Overall length Turning radius over bucket outer edge Lifting force (SAE) Breakout force (SAE) Tipping load when straight Tipping load articulated at 40° Angle of articulation (to each side) Swing angle (to each side) Operating weight Tractive force Travel speed in travel range 1, forward and reverse Travel speed in travel range 2, forward and reverse Travel speed in travel range 3, forward and reverse Sound pressure level in cab according to ISO 6396 L pA Valid for:

mm mm mm kN kN kg kg ° ° kg daN km/h km/h km/h dB (A)

Value Z bar 2750 6720 5520 100 91 8310 7300 40 6 10300 81.48 0-6 0 - 16 0 - 40 69

P bar 2750 6965 5610 71 83 7150 6300 40 6 10525 81.48 0-6 0 - 16 0 - 40 69

L528 - 660 / from 17890

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 of machine with Z and P lift arms

2.0-2 of 23

MJFCIFSS

L524 - 659 / from 17890 L528 - 660 / from 17890 L538 - 433 / from 17890 L542 - 435 / from 17890

Service manual

Product description Technical data

Item

A B C D E F G H I J K L

Description

Unit

Load geometry Bucket capacity as per ISO 7546 Bucket width Specific material weight Dump height at maximum lifting height and 45° tilt-out angle Dump height Maximum bucket base height Maximum bucket pivot point height Maximum bucket top height Reach at maximum lifting height and 42° tilt-out angle Digging depth Height above the cab Height above exhaust Ground clearance Wheel base Overall length Turning radius over bucket outer edge Lifting force (SAE) Breakout force (SAE) Tipping load when straight Tipping load articulated at 40° Angle of articulation (to each side) Swing angle (to each side) Operating weight Tractive force Travel speed in travel range 1, forward and reverse Travel speed in travel range 2, forward and reverse Travel speed in travel range 3, forward and reverse Sound pressure level in cab according to ISO 6396 L pA

m³ mm t/m³ mm mm mm mm mm mm mm mm mm mm mm mm mm kN kN kg kg ° ° kg daN km/h km/h km/h dB (A)

Valid for:

Value Z bar 2.2 2500 1.8 2800 3335 3530 3775 4960 935 80 3200 2860 460 2850 6930 5660 99 80 9180 8100 40 6 10710 87.05 0-6 0 - 16 0 - 40 69

P bar 2.0 2500 1.8 2765 3370 3590 3830 4985 1090 55 3200 2860 460 2850 7170 5740 70 74 7780 6840 40 6 11050 87.05 0-6 0 - 16 0 - 40 69

L538 - 433 / from 17890

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 - 659 / from 17890 L528 - 660 / from 17890 L538 - 433 / from 17890 L542 - 435 / from 17890

MJFCIFSS

2.0-3 of 23

Product description

Service manual

Technical data

Dimensions of machine with Z and P lift arms Item

A B C D E F G H I J K L

Description

Unit

m³ mm t/m³ mm mm mm mm mm mm mm mm mm mm mm mm mm kN kN kg kg ° ° kg daN km/h km/h km/h dB (A)

2.0-4 of 23

MJFCIFSS

Value Z bar 2.5 2500 1.8 2900 3480 3680 3930 5170 960 80 3250 2910 490 2975 7150 5840 145 113 10210 9020 40 6 12430 96.05 0-6 0 - 16 0 - 40 69

P bar 2.2 2500 1.8 2770 3430 3640 3890 5190 1060 55 3250 2910 490 2975 7315 5900 95 107 9300 8200 40 6 12410 96.05 0-6 0 - 16 0 - 40 69

L524 - 659 / from 17890 L528 - 660 / from 17890 L538 - 433 / from 17890 L542 - 435 / from 17890

Service manual

Product description Technical data

Valid for:

L542 - 435 / from 17890

Dimensions of machine with Z and P lift arms Item

Description

Unit Load geometry

A B C D E F G H I J K L

L524 - 659 / from 17890 L528 - 660 / from 17890 L538 - 433 / from 17890 L542 - 435 / from 17890

MJFCIFSS

m³ mm t/m³ mm mm mm mm mm mm mm mm mm mm mm mm mm kN kN

Value Z bar 2.7 2500 1.8 2845 3480 3680 3930 5260 1005 80 3250 2910 490 2975 7225 5870 144 105

P bar 2.4 2500 1.8 2725 3430 3640 3890 5255 1095 55 3250 2910 490 2975 7350 5920 94 101

2.0-5 of 23

Product description

Service manual

Technical data

Item

Description

Unit

Value Z bar P bar 11040 10120 9760 8940 40 40 6 6 13040 13070 100.47 100.47 0-6 0-6 0 - 16 0 - 16 0 - 40 0 - 40 69 69

Load geometry Tipping load when straight Tipping load articulated at 40° Angle of articulation (to each side) Swing angle (to each side) Operating weight Tractive force Travel speed in travel range 1, forward and reverse Travel speed in travel range 2, forward and reverse Travel speed in travel range 3, forward and reverse Sound pressure level in cab according to ISO 6396 L pA

2.1.2

kg kg ° ° kg daN km/h km/h km/h dB (A)

Engine and splitter box Engine

Valid for:

L524 - 659 / from 17890; L528 - 660 / from 17890;

Description Engine model

Value

Unit

Liebherr D 504 TI / John Deere CD 4045

Number of cylinders Capacity

4500

Rated power as per ISO 9249 Rated speed Maximum torque at 1500 min-1

4500 cm³

86 / 117

86 / 117 kW / hp

2400

2400 min-1

430

430 Nm

Lower idle speed

850

Upper idle speed

2550

850

min-1

2550

min-1

Inlet valve play (cold)

0,36

0,36 mm

Outlet valve play (cold)

0,46

0,46 mm

Control thermostat opening temperature Longitudinal / traverse inclinability Starter operating voltage Starter power consumption

82 °C

30 / 30

30 / 30 °

24 V

7 kW

Alternator voltage output

27,8

27,8 V

Alternator current output

55 A

Emission thresholds comply with

EU RL 97/68 EC Stage IIIa

Engine Valid for:

L538 - 433 / from 17890; L542 - 435 / from 17890; ID 1011 8823

Description

Value Unit

Engine model Number of cylinders Firing order

4 1-3-4-2

Capacity

2.0-6 of 23

D 934 S A6

6360 cm³

Cylinder bore

122 mm

Stroke

136 mm

MJFCIFSS

L524 - 659 / from 17890 L528 - 660 / from 17890 L538 - 433 / from 17890 L542 - 435 / from 17890

Service manual

Product description Technical data

Description

Value Unit

Rated power as per ISO 9249

105 / 143 kW / hp 2000 min-1

Rated speed Maximum torque at 1000 - 1300 min-1

770 Nm

Lower idle speed

900

min-1

Upper idle speed

2060

min-1

Start of delivery

Electronic

Compression ratio Combustion pressure Injection nozzle pressure

17:1 20 - 34 bar 300 +8/-3 bar

Inlet valve play (cold)

0.30 mm

Outlet valve play (cold)

0.40 mm

Direction of rotation, looking at flywheel

Anticlockwise

Number of teeth on flywheel gear

147 Qty.

Control thermostat opening temperature Longitudinal / traverse inclinability

79 °C 45 / 45 °

Starter operating voltage

24 V

Starter power consumption

5.4 kW

Alternator voltage output

27,8 V

Alternator current output

80 A

Auxiliary power take-off transmission

1:1.234

Weight

965 kg

Emission levels comply with

EU RL 97/68/EC Stage IIIa

Fuel tank Description

Value Unit

Tank capacity, FULL

180 l

Tank capacity, RESERVE

30 l

Fuel pre-filter Valid for:

L524 - 659 / from 17890; L528 - 660 / from 17890; ID 9739 323

Description

Value Unit

Filtration grade Valid for:

30 µm

L538 - 433 / from 17890; L542 - 435 / from 17890; ID 1011 8823

Description

Value Unit

Filtration grade

10 µm

Fuel fine filter Description

Value Unit

Filtration grade

L524 - 659 / from 17890 L528 - 660 / from 17890 L538 - 433 / from 17890 L542 - 435 / from 17890

2 µm

MJFCIFSS

2.0-7 of 23

Product description

Service manual

Technical data

Vacuum switch Description

Value Unit

Air filter contamination vacuum switch activation point

50 mbar

Clutch Valid for:

L524 - 659 / from 17890; L528 - 660 / from 17890; ID 9739 323

Description

Value Unit

Torsion damper screw adhesive

Valid for:

Torsion damper screw tightening torque

49 Nm

Hub star fastening screw tightening torque

86 Nm

L538 - 433 / from 17890; L542 - 435 / from 17890; ID 1011 8823

Description

2.1.3

241 Loctite

Value Unit

Torsion damper screw adhesive

241 Loctite

Torsion damper screw tightening torque

117 Nm

Cooling system Gear pump

Valid for:

L524 - 659 / from 17890; L528 - 660 / from 17890; ID 1029 6814

Description

Value Unit

Capacity

16 cm続

Rotary speed at rated engine speed Valid for:

2323 min-1

L538 - 433 / 17890 - 19018; L542 - 435 / 17890 - 19018; ID 1029 5259

Description

Value Unit

Capacity

14 cm続

Rotary speed at rated engine speed Valid for:

2468 min

-1

L538 - 433 / from 19019; L542 - 435 / from 19019; ID 1041 2918

Description

Value Unit

Capacity

16 cm続

Rotary speed at rated engine speed

2468 min-1

Gear motor Valid for:

ID 5717 099

Description

Value Unit

Gear motor displacement Pressure relief valve Coil resistance Screw tightening torque

2.0-8 of 23

MJFCIFSS

16 cm続 175

bar

4.5 Ohm 124

L524 - 659 / from 17890 L528 - 660 / from 17890 L538 - 433 / from 17890 L542 - 435 / from 17890

Service manual

Product description Technical data

Temperature sensor (B8, B21) Description

Value Unit

Measuring range Resistance at

0 °C

1000 Ohm

Resistance at

20 °C

1112 Ohm

Resistance at

30 °C

1171 Ohm

Resistance at

55 °C

1322 Ohm

Resistance at

73 °C

1437 Ohm

Resistance at

78 °C

1469 Ohm

Resistance at

84 °C

1509 Ohm

Resistance at

94 °C

1577 Ohm

Resistance at

102 °C

1632 Ohm

Screw thread

M 14 x 1.5 mm

Protection class

IP 65

Max. tightening torque Plug connection

2.1.4

min. -30 °C max. 130 °C

30 Nm Bosch Jet plug, 2-pin (Gold contacts)

Travel hydraulics Variable displacement pump

Valid for:

L524 - 659 / from 17890; L528 - 660 / from 17890

Description

Value Unit

Control type

Maximum capacity

90 cm³

Flow rate at rated speed

212 l/min

Power

72 kW

Replenishing pump capacity Replenishing pump flow rate (at rated speed)

43 l/min

Inlet restrictor

1.8 mm

Travel direction solenoid current consumption

1.2 A

Travel direction solenoid resistance

22 Ohm

Control pressure proportional valve resistance

12 Ohm

Pressure relief and replenishing valves Pressure cut-off

bar

60 kg

L538 - 433 / from 17890; L542 - 435 / from 17890

Description

Value Unit

Control type

Maximum capacity

125 cm³

Flow rate at rated speed

246 l/min

Power

L524 - 659 / from 17890 L528 - 660 / from 17890 L538 - 433 / from 17890 L542 - 435 / from 17890

470 440

Weight Valid for:

19.6 cm³

90 kW

MJFCIFSS

2.0-9 of 23

Product description

Service manual

Technical data

Description

Value Unit

Replenishing pump capacity

28.3 cm³

Replenishing pump flow rate (at rated speed)

53 l/min

Inlet restrictor

1.8 mm

Travel direction solenoid current consumption

1.2 A

Travel direction solenoid resistance

22 Ohm

Control pressure proportional valve resistance

12 Ohm

Pressure relief and replenishing valves Pressure cut-off Weight

470 440

bar

75 kg

Variable displacement motor 1 Valid for:

L524 - 659 / from 17890; L528 - 660 / from 17890

Description

Value Unit

Control type

HA1R

Maximum displacement

55 cm³

Minimum displacement

40 cm³

Maximum swivel angel

25 °

Minimum swivel angle

18.1 °

Maximum speed

5220 min-1

Torque ( p 400 bar) Start of regulation

Valid for:

250

bar

Current consumption of travel direction solenoid valve

1,2 A

Resistance of travel direction solenoid valve

22 Ohm

Current consumption of travel range 1 solenoid valve

1,4 A

Resistance of travel range 1 solenoid valve

19 Ohm

Weight

26 kg

L538 - 433 / from 17890; L542 - 435 / from 17890

Description

Value Unit

Control type

HA1R

Maximum displacement

80 cm³

Minimum displacement

52 cm³

Maximum swivel angel

25 °

Minimum swivel angle

16.3 °

Maximum speed

4560 min-1

Torque ( p 400 bar) Start of regulation

2.0-10 of 23

356 Nm

520 Nm 250

bar

Current consumption of travel direction solenoid valve

1,2 A

Resistance of travel direction solenoid valve

22 Ohm

MJFCIFSS

L524 - 659 / from 17890 L528 - 660 / from 17890 L538 - 433 / from 17890 L542 - 435 / from 17890

Service manual

Product description Technical data

Description

Value Unit

Current consumption of travel range 1 solenoid valve

1,4 A

Resistance of travel range 1 solenoid valve

19 Ohm

Weight

34 kg

Variable displacement motor 2 Valid for:

L524 - 659 / from 17890; L528 - 660 / from 17890

Description

Value Unit

Control type

Maximum displacement Maximum swivel angel

25 °

Minimum swivel angle

0 °

Maximum speed Torque ( p 400 bar)

Valid for:

5490 min-1 653 Nm

Maximum discharge valve capacity

15 l/min

Discharge valve orifice diameter

2.5 mm

Weight

47 kg

L538 - 433 / from 17890; L542 - 435 / from 17890

Description

Value Unit

Control type

Maximum displacement

140 cm³

Maximum swivel angel

25 °

Minimum swivel angle

0 °

Maximum speed Torque ( p 400 bar)

2.1.5

107 cm³

5030 min-1 855 Nm

Maximum discharge valve capacity

15 l/min

Discharge valve orifice diameter

2.5 mm

Weight

60 kg

Working hydraulics Working hydraulics pump

Valid for:

L524 - 659 / from 17890; L528 - 660 / from 17890

Description

Value Unit

Control type

DFLR

Maximum capacity Flow rate at rated speed Power

45 cm³ 105 l/min 40 kW

Flow regulator (delta p) Weight

bar

21 kg

   L524 - 659 / from 17890 L528 - 660 / from 17890 L538 - 433 / from 17890 L542 - 435 / from 17890

MJFCIFSS

2.0-11 of 23

Product description

Service manual

Technical data

Valid for:

L538 - 433 / from 17890; L542 - 435 / from 17890

Description

Value Unit

Control type

LRDS

Maximum capacity

75 cmÂł

Flow rate at rated speed

143 l/min

Power

51 kW

Power controller start of regulation Flow regulator (delta p)

190 bar 32

Weight

bar

45 kg

Control block Description

Value Unit

Piston diameter

18 mm

Lift arm up/down control piston flow

140 / 60 l/min

Tilt in/out control piston (Z kinematics) flow rate

120 / 80 l/min

Tilt in/out control piston (P kinematics) flow rate

140 / 90 l/min

LS pressure cut-off / Working hydraulics

L524, L528 L538, L542

315 330

LS pressure cut-off / Steering

L524, L528 L538, L542

230 250

Pressure relief valve pre-tension Weight

bar bar bar bar bar

32 kg

Pilot control valve Description

Value Unit

Retaining solenoid current consumption

0,4 A

Retaining solenoid resistance

70 Ohm

Weight

5,7 kg

Working hydraulics lockout solenoid valve Description

Value Unit

Current consumption

0,7 A

Resistance

40 Ohm

Pilot control hydro accumulator Valid for:

ID 7619 063

Description

Value Unit

Hydro accumulator volume Preload pressure (nitrogen filling)

2.0-12 of 23

MJFCIFSS

320 cmÂł 15 bar

L524 - 659 / from 17890 L528 - 660 / from 17890 L538 - 433 / from 17890 L542 - 435 / from 17890

Service manual

Product description Technical data

Stabilisation module Description

Value Unit

Control piston diameter

16 mm

Cut-off pressure (LFD off) Safety valve Restrictor check valve diameter

120

bar

330

bar

2.0 / 0.4 mm

Solenoid valve current consumption

0.7 A

Solenoid valve resistance

40 Ohm

Weight

13 kg

Ride control hydro accumulator Description

Value Unit

Hydro accumulator volume

2000 cmÂł

Preload pressure (nitrogen filling)

Oil filling

bar

350 cmÂł

Lift cylinder Valid for:

L524 - 659 / from 17890; L528 - 660 / from 17890; ID 9609 285

Description

Value Unit

Piston diameter

100 mm

Rod diameter

60 mm

Stroke length

735 mm

Minimum installation length Weight

80 kg

Lifting at rated load

6.0 sec

Lowering empty

4.0 sec

Piston rod bearing tightening torque (hex screws)

290 Nm

Piston tightening torque Valid for:

WN - 4121-091 -

L538 - 433 / from 17890; L542 - 435 / from 17890; ID 9655 214

Description

Value Unit

Piston diameter

110 mm

Rod diameter

60 mm

Stroke length

735 mm

Minimum installation length

1170 mm

Weight

89 kg

Lifting at rated load

6.0 sec

Lowering empty

4.0 sec

Piston rod bearing tightening torque (hex screws)

290 Nm

Piston tightening torque

L524 - 659 / from 17890 L528 - 660 / from 17890 L538 - 433 / from 17890 L542 - 435 / from 17890

1170 mm

MJFCIFSS

WN - 4121-092 -

2.0-13 of 23

Product description

Service manual

Technical data

Z kinematics tilt cylinder Valid for:

L524 - 659 / from 17890; L528 - 660 / from 17890; ID 9609 286

Description

Value Unit

Piston diameter Rod diameter

70 mm

Stroke length

440 mm

Minimum installation length

870 mm

Weight

70 kg

Tilt in/out empty

3.0 sec

Piston rod bearing tightening torque (hex screws)

290 Nm

Piston tightening torque Valid for:

120 mm

WN - 4121-091 -

L538 - 433 / from 17890; L542 - 435 / from 17890; ID 9655 215

Description

Value Unit

Piston diameter

140 mm

Rod diameter

80 mm

Stroke length

440 mm

Minimum installation length

870 mm

Weight

110 kg

Tilt in/out empty

3.0 sec

Piston rod bearing tightening torque (hex screws)

290 Nm

Piston tightening torque

WN - 4121-173 -

P kinematics tilt cylinder Valid for:

L524 - 659 / from 17890; L528 - 660 / from 17890; ID 1030 1136

Description

Value Unit

Piston diameter

80 mm

Rod diameter

50 mm

Stroke length

935 mm

Minimum installation length

1240 mm

Weight

53.5 kg

Tilt in/out empty Valid for:

L538 - 433 / from 17890; L542 - 435 / from 17890; ID 1030 1135

Description

Value Unit

Piston diameter

90 mm

Rod diameter

50 mm

Stroke length

935 mm

Minimum installation length Weight

2.0-14 of 23

3.5 sec

1240 mm 57 kg

MJFCIFSS

L524 - 659 / from 17890 L528 - 660 / from 17890 L538 - 433 / from 17890 L542 - 435 / from 17890

Service manual

Product description Technical data

Filter unit Description

Value Unit

Filtration grade

10 µm

Pre-tension valve

0.5 bar

Replenishing valve

0.05 bar

Replenishing strainer

160 µm

Bypass valve

2.5 bar

Return strainer

80 µm

Bleeder filter Description

Value Unit

Filtration grade

Inlet opening pressure

2.1.6

0.03 bar

Outlet opening pressure

0.5 bar

Thread

3/4 inch

Steering system Servostat Description

Value Unit

Displacement

370 cm³ 10

Secondary pressure relief

285

Flow booster

1 : 1.6

bar

Steering cylinder Valid for:

ID 1029 1027

Description

Value Unit

Piston diameter

90 mm

Rod diameter

45 mm

Stroke length

500 mm

Weight

26.2 kg

Emergency steering pump Description

Value Unit

Capacity

11 cm² 55 ±5 bar

Pressure relief valve

Emergency steering pump pressure switch Description

Value Unit Electronic pressure switch

Type Switch type

Normally open

Switching point L524 - 659 / from 17890 L528 - 660 / from 17890 L538 - 433 / from 17890 L542 - 435 / from 17890

16 Copyright

MJFCIFSS

bar

2.0-15 of 23

Product description

Service manual

Technical data

Description

Value Unit

Thread

M 12 x 1.5 mm

Emergency steering check pressure switch Description

Value Unit Electronic pressure switch

Type Switch type

Normally open

Switching point Thread

2.1.7

bar

M 12 x 1.5 mm

Brake system Brake system gear pump

Valid for:

L524 - 659 / from 17890; L528 - 660 / from 17890

Description

Value Unit

Capacity

4 cm³

Flow rate at rated speed Speed at rated speed Valid for:

9.3 l/min 2322 min-1

L538 - 433 / from 17890; L542 - 435 / from 17890

Description

Value Unit

Capacity

4 cm³

Flow rate at rated speed Speed at rated speed

9.9 l/min 2474 min-1

Compact brake valve Valid for:

ID 1029 5965

Description

Value Unit

Accumulator charge valve activation pressure

130 ±5 bar

Accumulator charge valve deactivation pressure

160 ±5 bar

Maximum service brake pressure

2.0-16 of 23

60 ±5 bar

Parking brake solenoid valve current consumption

0.6 A

Parking brake solenoid valve resistance

40 Ohm

Pedal start angle

42°

Pedal stop angle

15°

MJFCIFSS

L524 - 659 / from 17890 L528 - 660 / from 17890 L538 - 433 / from 17890 L542 - 435 / from 17890

Service manual

Product description Technical data

Service brake hydro accumulator Valid for:

ID 7619 022

Description

Value Unit

Number of hydro accumulators Hydro accumulator volume Preload pressure (nitrogen filling)

2 Qty. 750 cm³ 50 bar

Brake light pressure switch Valid for:

ID 6905 535

Description

Value Unit

Switch type

Normally open

Switch point, rising Thread

5 ±0.5 bar M 12 x 1.5 mm

Disc brake Description

Value Unit

Brake pad gap

1.0 ±0.5 mm

Brake lining thickness, new

4.5 mm

Minimum brake lining thickness

1.0 mm

Parking brake hydro accumulator Valid for:

ID 1028 8602

Description

Value Unit

Hydro accumulator volume Preload pressure (nitrogen filling)

320 cm³ 80 bar

Accumulator charge pressure switch Valid for:

ID 1035 3432

Description

Value Unit

Type

Electronic pressure switch

Switch type

Normally open

Switching point, falling

2.1.8

90 ±5 bar

Electrical system Battery Description

Value Unit

Battery voltage

12 V

Battery capacity

135 Ah

Acid density of charged battery Cold test current (at -18 °C EN 60095-1)

L524 - 659 / from 17890 L528 - 660 / from 17890 L538 - 433 / from 17890 L542 - 435 / from 17890

MJFCIFSS

1.26 - 1.28 kg/l 950 A

2.0-17 of 23

Product description

Service manual

Technical data

2.1.9

Transmission Transmission

Valid for:

L524 - 659 / from 17890; L528 - 660 / from 17890

Description

Valid for:

Value Unit

Type

319

Variable displacement motor 1 transmission

1.55 -

Variable displacement motor 2 transmission

3.83 -

Cardan speed at 40 km/h

3098 min-1

L538 - 433 / from 17890; L542 - 435 / from 17890

Description

Value Unit

Type

319

Variable displacement motor 1 transmission

1.55 -

Variable displacement motor 2 transmission

3.83 -

Cardan speed at 40 km/h

2795 min-1

Speed sensors Description

Value Unit

Type

Inductive sensor -

Resistance at 20 Â°C

2.1.10

1050 Âą100 Ohm

Axles and cardan shaft Front axle

Valid for:

L524 - 659 / from 17890; L528 - 660 / from 17890

Description

Value Unit

Type

123/60

Self-locking differential level Width

1960 mm

Overall transmission

18.6

Differential transmission

10/31

Wheel hub transmission

1/6

Wheel lug tightening torque

650 Nm

Wheel lug spanner size Flange size

570 kg

L538 - 433 / from 17890; L542 - 435 / from 17890

Description

Value Unit

Type

113/58

Self-locking differential level Width

2.0-18 of 23

30 mm 1920 mm

Weight Valid for:

45 %

45 % 1900 mm

MJFCIFSS

L524 - 659 / from 17890 L528 - 660 / from 17890 L538 - 433 / from 17890 L542 - 435 / from 17890

Service manual

Product description Technical data

Description

Value Unit

Overall transmission

18.54

Differential transmission

11/34

Wheel hub transmission

1/6

Wheel lug tightening torque

650 Nm

Wheel lug spanner size Flange size

30 mm 1920 mm

Weight

720 kg

Rear axle Valid for:

L524 - 659 / from 17890; L528 - 660 / from 17890

Description

Value Unit

Type

123/51

Self-locking differential level Width

1960 mm

Overall transmission

18.6

Differential transmission

10/31

Wheel hub transmission

1/6

Wheel lug tightening torque

650 Nm

Wheel lug spanner size Swing angle (to each side) Flange size

30 mm 6 Â° 1920 mm

Weight Valid for:

45 %

680 kg

L538 - 433 / from 17890; L542 - 435 / from 17890

Description

Value Unit

Type

113/50

Self-locking differential level

45 %

Width

1900 mm

Overall transmission

18.54

Differential transmission

11/34

Wheel hub transmission

1/6

Wheel lug tightening torque

650 Nm

Wheel lug spanner size Swing angle (to each side) Flange size

30 mm 6 Â° 1920 mm

Weight

840 kg

Cardan shaft Valid for:

L524 - 659 / from 17890; L528 - 660 / from 17890

Description

L524 - 659 / from 17890 L528 - 660 / from 17890 L538 - 433 / from 17890 L542 - 435 / from 17890

Value Unit

Minimum length

1875 mm

Width

2020 mm

Weight

27.5 kg

MJFCIFSS

2.0-19 of 23

Product description

Service manual

Technical data

Valid for:

L538 - 433 / from 17890; L542 - 435 / from 17890

Description

2.1.11

Value Unit

Minimum length

1967 mm

Width

2122 mm

Weight

30.5 kg

Machine frame and ballast weight Ballast weight

Valid for:

L524 - 659 / from 17890; L538 - 433 / from 17890

Description

Valid for:

Value Unit

Left ballast weight

515 kg

Right ballast weight

565 kg

L528 - 660 / from 17890

Description

Valid for:

Value Unit

Left ballast weight

795 kg

Right ballast weight

565 kg

L542 - 435 / from 17890

Description

2.1.12

Value Unit

Left ballast weight

795 kg

Right ballast weight

801 kg

Cab, heating and air-conditioning Heating, ventilation, air conditioning Description

Value Unit

Rated voltage

24 V

Number of blower levels

Maximum fan current consumption

15.7 A

Maximum air flow

600 mÂł/h

Heating power

11 kW

Air conditioning system Valid for:

L524 - 659 / from 17890; L528 - 660 / from 17890

Description

Value Unit

Refrigerant

R134a

Refrigerant oil (PAG oil)

2.0-20 of 23

ZXL 100 PG

Coolant quantity

1050+50 g

Cooling power

9.7

MJFCIFSS

10%

L524 - 659 / from 17890 L528 - 660 / from 17890 L538 - 433 / from 17890 L542 - 435 / from 17890

Service manual

Product description Technical data

Valid for:

L538 - 433 / from 17890; L542 - 435 / from 17890

Description

Value Unit

Refrigerant

R134a

Refrigerant oil (PAG oil)

ZXL 100 PG

Coolant quantity

1250+50 g

Cooling power

9.7

10%

Air conditioning compressor Description

Value Unit

Type

SD7H15

Capacity

154.9 cm³

Refrigerant oil (PAG oil)

ZXL 100 PG (SP 10)

Filling quantity

200 cm³

Maximum current consumption

2.63 A

Weight without oil

6.9 kg

Condenser Description

Value Unit

Maximum air flow

4000 m³/h

Heating power

9.7 ±1 kW

Test pressure

35 bar

Dryer collector unit Description

Value Unit

Contents

0.70 l

Filtration grade

7 µm

Leak test

30 bar

Dryer water consumption

16 g

Burst pressure

130 bar

Pressure switch Description

Value Unit

Low pressure OFF

1.5 ±0.5 bar

Low pressure ON

L524 - 659 / from 17890 L528 - 660 / from 17890 L538 - 433 / from 17890 L542 - 435 / from 17890

3.5 bar

High pressure OFF

25 ±2 bar

High pressure ON

18 ±1.5 bar

Fan OFF

15 ±1 bar

Fan ON

19 ±1 bar

MJFCIFSS

2.0-21 of 23

Product description

Service manual

Technical data

Evaporator Description

Value Unit

Cooling power

9.7 kW

Temperature sensor activation temperature Temperature sensor deactivation temperature

5.5

±10%

°C

4.5

±10%

°C

Temperature sensor B26 Description

Value Unit

Operating temperature Resistance at

-5 °C

42330 Ohm

Resistance at

0 °C

32670 Ohm

Resistance at

5 °C

25410 Ohm

Resistance at

10 °C

19920 Ohm

Resistance at

15 °C

15730 Ohm

Resistance at

20 °C

12500 Ohm

Protection class

2.1.13

-40 - +125 °C

IP 68

Lift arms and quick-change device Lift arms with Z kinematics

Valid for:

L524 - 659 / from 17890; L528 - 660 / from 17890

Description

Value Unit

L length

2400 mm

Weight Valid for:

962 kg

L538 - 433 / from 17890; L542 - 435 / from 17890

Description

Value Unit

L length

2500 mm

Weight

1072 kg

Lift arms with P kinematics Valid for:

L524 - 659 / from 17890; L528 - 660 / from 17890

Description

Valid for:

Value Unit

L length

2500 mm

L high lift length

3000 mm

Weight (without QCD)

1165 kg

L538 - 433 / from 17890; L542 - 435 / from 17890

Description

2.0-22 of 23

Value Unit

L length

2500 mm

L high lift length

3000 mm

Weight (without QCD)

1165 kg

MJFCIFSS

L524 - 659 / from 17890 L528 - 660 / from 17890 L538 - 433 / from 17890 L542 - 435 / from 17890

Service manual

Product description Technical data

Hydraulic quick-change device for Z lift arms. Description

Value Unit

A system connection size

1000 mm

Weight

300 kg

Hydraulic quick-change device for P lift arms. Description

Value Unit

A system connection size Weight

2.1.14

1000 mm 230 kg

Equipment and accessories Bucket

Valid for:

L524 - 659 / from 17890

Description

Value Unit

B bucket width Specific material weight Heaped bucket capacity (ISO 7546) Valid for:

2 m³

Value Unit

B bucket width

2500 mm

Specific material weight

1.8 t/m³

Heaped bucket capacity (ISO 7546)

2.2 m³

L538 - 433 / from 17890

Description

Value Unit

B bucket width

Valid for:

1.8 t/m³

L528 - 660 / from 17890

Description

Valid for:

2500 mm

Specific material weight

1.8 t/m³

Heaped bucket capacity (ISO 7546)

2.5 m³

L542 - 435 / from 17890

Description

Value Unit

B bucket width

2500 mm

Specific material weight

1.8 t/m³

Heaped bucket capacity (ISO 7546)

2.7 m³

Forklift Description

Value Unit

Fork carrier prong size Prong length

L524 - 659 / from 17890 L528 - 660 / from 17890 L538 - 433 / from 17890 L542 - 435 / from 17890

FEM III 1200 mm

MJFCIFSS

2.0-23 of 23

3 Maintenance 3.0 Chapter contents 3

Maintenance........................................................................ 3.0-1 3.1

Maintenance and inspection schedule ...........................................3.1-1

3.2

Testing and adjustment plan...........................................................3.2-1

3.3

Testing and adjustment checklists..................................................3.3-1

3.4

Lubrication chart and filling quantities ............................................3.4-1 3.4.1

Table of filling quantities L524, L528....................................3.4-1

3.4.2

Table of filling quantities L538, L542....................................3.4-2

3.4.3

Lubrication chart L524, L528................................................3.4-4

3.4.4

Lubrication chart L538, L542................................................3.4-6

3.5

L524 - 659 / from 17890 L528 - 660 / from 17890 L538 - 433 / from 17890 L542 - 435 / from 17890

Maintenance tasks..........................................................................3.5-1 3.5.1

Preparatory tasks for maintenance ......................................3.5-1

3.5.2

Removing loose parts, dirt, ice and snow from the machine ................................................................................3.5-5

3.5.3

Checking the machine for external damage.........................3.5-5

3.5.4

Making sure the bolted connections are tight.......................3.5-5

3.5.5

Sealing leaks ........................................................................3.5-5

3.5.6

Checking the engine oil level L524, L528.............................3.5-6

3.5.7

Checking the engine oil level L538, L542.............................3.5-6

3.5.8

Changing the engine oil L524, L528.....................................3.5-7

3.5.9

Changing the engine oil L538, L542.....................................3.5-8

3.5.10

Changing the engine oil filterL524, L528..............................3.5-9

3.5.11

Changing the engine oil filterL538, L542............................3.5-10

3.5.12

Checking the V-ribbed belt L524, L528 ..............................3.5-11

3.5.13

Checking the V-ribbed belt L538, L542 ..............................3.5-12

3.5.14

Checking the valve play L524, L528 ..................................3.5-14

3.5.15

Checking the valve play L538, L542 ..................................3.5-16

3.5.16

Checking the heating flange L524, L528............................3.5-18

3.5.17

Checking the heating flange L538, L542............................3.5-18

3.5.18

Greasing the ring gear on the flywheel L538, L542 ...........3.5-19

3.5.19

Changing the oil separator filter insert L538, L542 ............3.5-20

3.5.20

Checking the bearings and condition of the engine control units L524, L528 .....................................................3.5-20

MJFCIFSS

3.0-1 of 4

Maintenance

3.0-2 of 4

Service manual 3.5.21

Checking the bearings and condition of the engine control units L538, L542 .................................................... 3.5-21

3.5.22

Checking the sensors and cable connections L524, L528 ................................................................................... 3.5-21

3.5.23

Checking the sensors and cable connections L538, L542 ................................................................................... 3.5-22

3.5.24

Changing the fuel pre-filter L524, L528 ............................. 3.5-23

3.5.25

Changing the fuel pre-filter L538, L542 ............................. 3.5-24

3.5.26

Changing the fuel fine filter L524, L528............................. 3.5-25

3.5.27

Changing the fuel fine filter L538, L542............................. 3.5-26

3.5.28

Draining off condensate from the fuel filter L524,L52........ 3.5-27

3.5.29

Draining off condensate from the fuel filter L538,L542...... 3.5-28

3.5.30

Bleeding the fuel system L524, L528 ................................ 3.5-29

3.5.31

Bleeding the fuel system L538, L542 ................................ 3.5-30

3.5.32

Draining off condensate and sediment from the fuel tank .................................................................................... 3.5-32

3.5.33

Cleaning the air filter service cap and dust extraction valve................................................................................... 3.5-32

3.5.34

Test the air filter vacuum switch ........................................ 3.5-33

3.5.35

Changing the air filter main element when indicated by the vacuum switch ............................................................. 3.5-33

3.5.36

Changing the air filter secondary element ......................... 3.5-34

3.5.37

Checking the air suction hoses for leaks and tight fitting .. 3.5-35

3.5.38

Checking the exhaust lines for leaks and tight fitting ........ 3.5-36

3.5.39

Checking the coolant antifreeze and corrosion inhibitor concentration ..................................................................... 3.5-36

3.5.40

Cleaning the cooling system.............................................. 3.5-40

3.5.41

Changing the coolant L524, L528...................................... 3.5-41

3.5.42

Changing the coolant L538, L542...................................... 3.5-42

3.5.43

Checking the oil level in the hydraulic tank........................ 3.5-43

3.5.44

Draining off condensate and sediment from the hydraulic tank..................................................................... 3.5-43

3.5.45

Changing the oil in the hydraulic tank................................ 3.5-44

3.5.46

Checking and cleaning the magnetic rod on the hydraulic tank..................................................................... 3.5-46

3.5.47

Changing the hydraulic tank return suction filter ............... 3.5-46

3.5.48

Changing the hydraulic tank bleeder filter ......................... 3.5-47

3.5.49

Lubricating the pilot control device solenoids, universal joints and tappets............................................................... 3.5-47

3.5.50

Testing the steering ........................................................... 3.5-48

3.5.51

Lubricating the bearing points on the steering cylinders ... 3.5-48

3.5.52

Testing the service brake and parking brake..................... 3.5-48

3.5.53

Checking the gap and wear on the parking brake linings.. 3.5-49

3.5.54

Checking the indicator lamps and lighting ......................... 3.5-50

MJFCIFSS

L524 - 659 / from 17890 L528 - 660 / from 17890 L538 - 433 / from 17890 L542 - 435 / from 17890

Service manual

Maintenance 3.5.55

Checking the batteries, fluid level and terminals................3.5-51

3.5.56

Checking the transfer gear oil level ....................................3.5-52

3.5.57

Changing the transmission oil ............................................3.5-52

3.5.58

Checking the wheel tightness.............................................3.5-53

3.5.59

Checking the axle oil levels ................................................3.5-53

3.5.60

Changing the axle oil ..........................................................3.5-55

3.5.61

Checking the tyre pressure ................................................3.5-56

3.5.62

Lubricating the articulation bearing and rear oscillating bearing................................................................................3.5-57

3.5.63

Greasing the cab door hinges ............................................3.5-57

3.5.64

Checking / topping up the windscreen washer reservoir....3.5-58

3.5.65

Cleaning the fresh air and recirculated air filter..................3.5-58

3.5.66

Changing the fresh air and recirculated air filter ................3.5-59

3.5.67

Checking the indicator and filling level beads in the dryer-collector unit (optional) of the air conditioner ............3.5-60

3.5.68

Lubricating the lift arms and attachment (Z kinematics).....3.5-61

3.5.69

Lubricating the lift arms and attachment (P kinematics) ....3.5-61

3.5.70

Checking the lift arm bearing bushings ..............................3.5-62

3.5.71

Checking the lift arm bucket stops (Z kinematics)..............3.5-63

3.5.72

Lubricating and testing the quick-change device ...............3.5-64

3.6

L524 - 659 / from 17890 L528 - 660 / from 17890 L538 - 433 / from 17890 L542 - 435 / from 17890

Testing and adjustment tasks .........................................................3.6-1 3.6.1

Preparing for testing and adjustment ...................................3.6-1

3.6.2

Bringing the machine up to operating temperature ..............3.6-2

3.6.3

Checking the fan motor and fan control pressure relief valve ............................................................................3.6-2

3.6.4

Calibrating the pedals...........................................................3.6-4

3.6.5

Checking the engine speed..................................................3.6-4

3.6.6

Checking the replenishing pressure of the variable displacement pump L524, L528 ...........................................3.6-5

3.6.7

Checking the replenishing pressure of the variable displacement pump L538, L542 ...........................................3.6-5

3.6.8

Checking the pressure relief and replenishing valve of the variable displacement pump...........................................3.6-5

3.6.9

Checking the pressure cut-off of the variable displacement pump L524, L528 ...........................................3.6-6

3.6.10

Checking the pressure cut-off of the variable displacement pump L538, L542 ...........................................3.6-7

3.6.11

Calibrating the block curve L524, L528 ................................3.6-8

3.6.12

Calibrating the block curve L538, L542 ................................3.6-9

3.6.13

Checking the start of regulation for variable displacement motor 1 L524, L528 ......................................3.6-10

3.6.14

Checking the start of regulation for variable displacement motor 1 L538, L542 ......................................3.6-10

MJFCIFSS

3.0-3 of 4

Maintenance

Service manual 3.6.15

Calibrating variable displacement motor 2 ........................ 3.6-11

3.6.16

Checking the engine output ............................................... 3.6-12

3.6.17

Checking the secondary pressure relief valves on the control block L524, L528.................................................... 3.6-13

3.6.18

Checking the secondary pressure relief valves on the control block L538, L542.................................................... 3.6-14

3.6.19

Checking the LS pressure cut-off on the control block L524, L528 ......................................................................... 3.6-14

3.6.20

Checking the LS pressure cut-off on the control block L538, L542 ......................................................................... 3.6-15

3.6.21

Checking the flow controller of the working hydraulics pump L524, L528.............................................. 3.6-15

3.6.22

Checking the flow controller of the working hydraulics pumpL538, L542............................................... 3.6-16

3.6.23

Depressurising ride control and the hydro accumulators .. 3.6-16

3.6.24

Checking the cut-off pressure in the stabilisation module ............................................................................... 3.6-16

3.6.25

Checking the nitrogen in the ride control hydro accumulator........................................................................ 3.6-17

3.6.26

Checking the opening and closing pressure of the compact brake valve.......................................................... 3.6-18

3.6.27

Checking the brake pressure at the axles ......................... 3.6-18

3.6.28

Checking the capacity of the brake accumulators ............. 3.6-19

3.6.29

Check the accumulator charge pressure........................... 3.6-19

3.6.30

Check the brake light pressure switch and brake lights .... 3.6-20

3.7

3.0-4 of 4

Lubricants and fuels....................................................................... 3.7-1 3.7.1

Diesel fuels .......................................................................... 3.7-2

3.7.2

Lubricating oils for diesel engines ....................................... 3.7-3

3.7.3

Coolant for the engine ......................................................... 3.7-5

3.7.4

Hydraulic fluid ...................................................................... 3.7-8

3.7.5

Lubricating oils for the transmission .................................. 3.7-11

3.7.6

Grease for general lubrication points................................. 3.7-12

MJFCIFSS

L524 - 659 / from 17890 L528 - 660 / from 17890 L538 - 433 / from 17890 L542 - 435 / from 17890

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