en
Service Manual (20
Wheel Loader (10 points)
L524 / L534 / L538(10
en
Service Manual (20
Wheel Loader (10 points)
L524 / L534 / L538 (10
Address LIEBHERR-WERK BISCHOFSHOFEN GMBH Dr. Hans Liebherr – Straße 4 A – 5500 BISCHOFSHOFEN
Product ID Manufacturer: Product group: Type: Production number: Serial number:
LIEBHERR-WERK BISCHOFSHOFEN GMBH Wheel loader L524 L534 L538 438 434 432 from 0101 from 0101 from 0101
Document ID Order number: Author: Document version: Manual number: Owner:
8450818 LBH / T-DOK department 02
Preface
Target group 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. Contents 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. 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 and French.
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 and certain 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
1
Product description
2
Maintenance
3
Diesel engine
4
Cooling system
5
Travel hydraulics
6
Working hydraulics
7
Steering system
8
Brake system
9
Electrical system
10
Transfer gear
11
Axles and cardan shaft
12
Machine frame and ballast weight
13
Central lubrication system
14
Coverings and access
15
Cab, heating and air-conditioning
16
Lift arms and quick-change device
17
Equipment and accessories
18
Repairs and troubleshooting
19
Options
20
1 General Information 1.0 Chapter contents 1
General Information ............................................................ 1.0-1 1.1
Safety regulations ...........................................................................1.1-1 1.1.1
Introduction...........................................................................1.1-1
1.1.2
Overview of the safety regulations .......................................1.1-2
1.2
L524 - 438 / from 0101 L534 - 434 / from 0101 L538 - 432 / from 0101
Special tools for maintenance and repair work...............................1.2-1 1.2.1
Special tools in general ........................................................1.2-1
1.2.2
Special tools for Liebherr diesel engines..............................1.2-1
1.2.3
Special tools for hydraulic cylinders .....................................1.2-3
1.2.4
Special tools for electronics..................................................1.2-3
1.2.5
Special tools for axles...........................................................1.2-4
1.2.6
Central lubrication system ....................................................1.2-4
1.2.7
Special tools for the air conditioning system ........................1.2-4
MJFCIFSS
1.0-1 of 2
Service Manual
General Information Safety regulations
1.1 Safety regulations Working on the machine poses safety risks to the operator, driver or maintenance engineers. You can prevent risks and accidents by regularly reading and observing the various safety instructions. This is especially important for personnel who only occasionally work on the machine, for example, carrying out rigging or maintenance work. The safety regulations listed below, if conscientiously followed, will ensure your own safety and that of others, and will prevent the machine from being damaged. Whenever tasks which could cause danger to personnel or damage to the machine are described, the necessary safety precautions are explained in this manual. These are indicated by the headings Danger, Warning or Caution.
1.1.1
Introduction 1. The symbols below have the following meanings:
Danger
Warning
Caution
Danger Warning that without appropriate precautions, certain procedures could result in fatal accidents.
Warning Warning that without appropriate precautions, certain procedures could result in severe physical injuries.
Caution Warning that without appropriate precautions, certain procedures could result in minor physical injuries or damage to the machine.
2. Observance of these instructions does not exempt you from following any additional rules and guidelines that may apply The following should also be observed: – The safety rules in force at the operating site – Legally enforceable road traffic regulations – Guidelines issued by trade associations
L524 - 438 / from 0101 L534 - 434 / from 0101 L538 - 432 / from 0101
MJFCIFSS
1.1-1 of 2
General Information
Service Manual
Safety regulations
1.1.2
Overview of the safety regulations A detailed description of these can be read in the relevant section of the safety regulations chapter in the operating manual. The following sections are included in the operating manual:
1.1-2 of 2
1
Introduction
2
General safety regulations
3
Proper use
4
Decals on the machine
5
Instructions on preventing crushing injuries and burns
6
Instructions on preventing fires and explosions
7
Safety instructions for start-up
8
Safety precautions during start-up
9
Instructions for safe working
10
Safety instructions for driving on slopes
11
Parking safely
12
Transporting the machine safely
13
Towing the machine safely
14
Measures for ensuring safe maintenance
15
Safety instructions for working on machines with hydro accumulators
16
Safety instructions for welding work on the machine
17
Instructions for working safely on the working attachment
18
Safety instructions for transporting the machine by crane
19
Safe maintenance of hydraulic hoses and hose lines
20
Attachments and accessories
MJFCIFSS
L524 - 438 / from 0101 L534 - 434 / from 0101 L538 - 432 / from 0101
Service Manual
General Information Special tools for maintenance and repair work
1.2 Special tools for maintenance and repair work 1.2.1 Description
Special tools in general ID no.
Digital thermometer
7020372
All wheel loaders
DCA 4 water testing kit
5608459
All wheel loaders
Anti-freeze and battery tester
7408922
All wheel loaders
24 volt vacuum pump Filling and testing device with case Manometer 0-40 bar Manometer 0-250 bar Manometer 0-600 bar Manometer connection High pressure hose 1500 mm High pressure hose 4000 mm Screw connection M 10 x 1 Draining hose Drain piece
7408148
All wheel loaders
Remarks For measuring temperature during adjustments For testing the DCA4 and antifreeze content For checking the acid concentration (battery charging state) and anti-freeze For preventing oil loss
8145359
All wheel loaders
For checking the hydro accumulator
7361288 5002932 5002866 7002436 7002475 7009134 5005180 7005660 7402657
All wheel loaders All wheel loaders All wheel loaders All wheel loaders All wheel loaders All wheel loaders All wheel loaders All wheel loaders All wheel loaders
Safety cap SW 10
7009315
All wheel loaders
Safety cap SW 13 Safety cap SW 17 Safety cap SW 19
7615515 7615589 7009317
All wheel loaders All wheel loaders All wheel loaders
Safety cap SW 17
7622068
All wheel loaders
For checking the hydraulic pressure For checking the hydraulic pressure For checking the hydraulic pressure Connection for the manometer High pressure hose for manometer High pressure hose for manometer For checking the hydraulic pressure For draining oil via a drain valve For the drain hose For securing the valves on the variable adjustment motor For securing the valves on the pumps For securing the valves on the pumps For securing the valves on the pumps For securing the valves on the control block
1.2.2
Use
Special tools for Liebherr diesel engines
Description Compression tester Nozzle tester Adapter for compression tester Adapter for compression tester Injection valve extraction tool Extraction tool adapter
ID no. 8008782 7361236 0524044 7090397 0524072 0524029
Use L524 - L538 engine L524 - L538 engine L538 engine L524 - L534 engine L538 engine L538 engine
Piston ring tensioning belt
8000952
All wheel loaders
Krikit 2 V-belt tester Flywheel cranking device
8042829 0524045
L524 - L538 engine L538 engine
Stopwatch
7022418
L538 engine
Measuring device
7022420
L538 engine
Adapter
7022419
L538 engine
L524 - 438 / from 0101 L534 - 434 / from 0101 L538 - 432 / from 0101
MJFCIFSS
Remarks For checking the compression For checking the injection valves Instead of the injection valve Instead of the injection valve For removing the injection valves For use with the extraction tool For pushing the piston rings together during installation of the pistons For testing the V-belt tension For cranking the engine via the flywheel For adjusting the start of delivery of the distributor injection pump For adjusting the start of delivery of the distributor injection pump For adjusting the start of delivery of the distributor injection pump
1.2-1 of 4
General Information
Service Manual
Special tools for maintenance and repair work
Description
ID no.
Use
Crankshaft turning device
0541887
L524, L534 engine
Crankshaft turning device
9183785
L538 engine
Installation pin Adjusting pin for injection pump DE10
7090360
L524, L534 engine L524, L534 engine with electronic injection
Extractor
7090374
L524, L534 engine
Shaft seal ring installation tool
7090373
L524, L534 engine
Extractor tool Extractor tool Seal remover
7090377 7090395 7090372
L524, L534 engine L524, L534 engine L524, L534 engine
Adjusting device
7090384
L524, L534 engine
Extractor tool
7090364
L524, L534 engine
Installation tool
7090382
L524, L534 engine
Cleaning tool
7090375
L524, L534 engine
Installation set
7090378
L524, L534 engine
Depth gauge
7090370
L524, L534 engine
Extractor tool
7090376
L524, L534 engine
Extractor tool
7090363
L524, L534 engine
Angle wrench
0524062
L538 engine
MURPHY GAGE diagnostic tool with cable
10030461
Adapter cable
9067863
1.2-2 of 4
7090592
L524, L534 engine with electronic injection L524, L534 engine with electronic injection
MJFCIFSS
Remarks For cranking the engine via the V-belt pulley For cranking the engine via the crankshaft For fixing the engine at UDC For static adjustment when installing the injection pump For removing the drive gearwheel of the Stanadyne injection pump For installing the front crankshaft oil seal For removing the front wear ring For removing the front wear ring For removing the front crankshaft oil seal For dynamically adjusting the start of delivery of the distributor injection pump For removing Stanadyne injection nozzles For inserting the carbon seal in the injection nozzle groove For cleaning the injection nozzle bore hole in the cylinder head For installing the rear oil seal ring and wear ring For measuring the valve depth in the cylinder head and the piston and bushing height For removing the rear crankshaft oil seal ring and wear ring For installing and removing the cylinder bushings For screws on cylinder head, main bearing and big end bearing For diagnosing controls and ECU (A14) engine controller For diagnosis with the MURPHY GAGE
L524 - 438 / from 0101 L534 - 434 / from 0101 L538 - 432 / from 0101
Service Manual
General Information Special tools for maintenance and repair work
1.2.3 Description
Special tools for hydraulic cylinders ID no.
Assembly sleeve 80 mm
9227165
Assembly sleeve 90 mm
9227161
Assembly sleeve 100 mm Assembly sleeve 110 mm
9998626 9170509
Assembly sleeve 120 mm
9998778
Assembly sleeve 140 mm
9998623
Expansion sleeve 80 mm
9227166
Expansion sleeve 90 mm
9227162
Expansion sleeve 100 mm Expansion sleeve 110 mm
9110405 9170511
Expansion sleeve 120 mm
9110407
Expansion sleeve 140 mm
9110409
Piston spanner
9211967
Piston spanner 80/12 mm
8007364
Piston spanner
4002681
Piston spanner 88/12 mm
8007365
Piston spanner 100/14 mm
8007366
1.2.4 Description Digital multimeter Test probe, red Test probe, black Magnet tester Stripping and crimping pliers 0.5 - 6.0 mm2 Insertion tool Extractor tool Crimping pliers Wedge extractor tool Extraction tool size 12 for pin and bushing Extraction tool size 16 for pin and bushing Extraction tool size 20 for pin
L524 - 438 / from 0101 L534 - 434 / from 0101 L538 - 432 / from 0101
Use L524 P kinematics tilt cylinder L524 - L538 steering cylinder L534, L538 P kinematics tilt cylinder L524 lift cylinder L534, L538 lift cylinder L524 Z kinematics tilt cylinder L534, L538 P Z kinematics tilt cylinder L524 P kinematics tilt cylinder L524 - L538 steering cylinder L534, L538 P kinematics tilt cylinder L524 lift cylinder L534, L538 lift cylinder L524 Z kinematics tilt cylinder L534, L538 P Z kinematics tilt cylinder L524 - L538 steering cylinder L524 - L538 lift cylinder L524 - L538 P kinematics tilt cylinder L524 Z kinematics tilt cylinder L534, L538 Z kinematics tilt cylinder
Remarks For fitting the seals
For fitting the seals For fitting the seals For fitting the seals For fitting the seals For fitting the seals For fitting the seals
For fitting the seals For fitting the seals For fitting the seals For fitting the seals For fitting the seals For fitting the piston For fitting the piston For fitting the piston For fitting the piston For fitting the piston
Special tools for electronics ID no.
8502956
Use All wheel loaders
884191214 All wheel loaders 884191114 All wheel loaders 8145743 All wheel loaders
Remarks For measuring voltage, current, resistance and frequency For testing DEUTSCH connectors For testing DEUTSCH connectors For checking solenoid valves
8460263
All wheel loaders
For MATE-N-LOK connectors
8145432 7366655 8503647 7026267
All wheel loaders All wheel loaders All wheel loaders All wheel loaders
For MATE-N-LOK connectors For MATE-N-LOK connectors For DEUTSCH connectors For DEUTSCH connectors
8145674
All wheel loaders
For DEUTSCH connectors
8145673
All wheel loaders
For DEUTSCH connectors
8503630
All wheel loaders
For DEUTSCH connectors
MJFCIFSS
1.2-3 of 4
General Information
Service Manual
Special tools for maintenance and repair work
Description and bushing Plug-in fuse tester Wide METRI-PACK extractor tool Narrow METRI-PACK extractor tool
ID no.
Use
Remarks
8145834
All wheel loaders
7091022
L524, L534
7091023
L524, L534
For checking the fuses For removing terminals on the main connector of the ECU engine controller For removing terminals on the main connector of the ECU engine controller
1.2.5 Description
Special tools for axles ID no.
Measuring tool
8145535
1.2.6 Description Filling press Filling connection BEKA MAX central lubrication data cable + software Gröneveld central lubrication
data cable Gröneveld central lubrication
plug adapter Gröneveld central lubrication
software
Use L524 - L538 front axle L524 - L538 rear axle
Remarks For measuring wear on the service brake discs
Central lubrication system
ID no. 10009239 7029283
Use All wheel loaders All wheel loaders
10008427
All wheel loaders
7624289
All wheel loaders
7624290
All wheel loaders
As below
All wheel loaders
Remarks For quickly filling the reservoir For inspecting the central lubrication system For inspecting the central lubrication system For inspecting the central lubrication system For inspecting the central lubrication system
The software for the Gröneveld central lubrication system must be purchased from Gröneveld and enabled with a registration code. Procedure and necessary data: – Company name and department – A six-digit number of your choice This data must be e-mailed to the following address: support@groeneveld.nl
1.2.7 Description
Special tools for the air conditioning system ID no.
Use
Remarks
Vacuum pump
7027552
All wheel loaders
For evacuating the air conditioning system
4-valve test fitting
7027558
All wheel loaders
For testing, evacuating and filling the air conditioning system
Filling hose, blue 1500 mm
7027553
All wheel loaders
For the test fitting
Filling hose, yellow 1500 mm
7027554
All wheel loaders
For the test fitting
Filling hose, red 1500 mm
7027555
All wheel loaders
For the test fitting
Car coupling 253a
7027556
All wheel loaders
For the test fitting
Car coupling 254a
7027557
All wheel loaders
For the test fitting
1.2-4 of 4
MJFCIFSS
L524 - 438 / from 0101 L534 - 434 / from 0101 L538 - 432 / from 0101
2 Product Description 2.0 Chapter contents 2
Product Description............................................................. 2.0-1 2.1
L524 - 438 / from 0101 L534 - 434 / from 0101 L538 - 432 / from 0101
Technical data ................................................................................2.0-1 2.1.1
Complete machine................................................................2.0-1
2.1.2
Diesel engine and pump distributor gear..............................2.0-9
2.1.3
Cooling system ...................................................................2.0-14
2.1.4
Travel hydraulics ................................................................2.0-15
2.1.5
Working hydraulics .............................................................2.0-17
2.1.6
Steering system..................................................................2.0-20
2.1.7
Brake system......................................................................2.0-21
2.1.8
Electrical system.................................................................2.0-22
2.1.9
Transfer gear ......................................................................2.0-22
2.1.10
Axles and tyres ...................................................................2.0-23
2.1.11
Machine frame and ballast weight......................................2.0-24
2.1.12
Cab, heating and air-conditioning.......................................2.0-24
2.1.13
Lift arms and quick-change device.....................................2.0-25
2.1.14
Equipment and accessories ...............................................2.0-26
MJFCIFSS
2.0-1 of 2
Service Manual
Product Description Technical data
2.1 Technical data 2.1.1 Wheel loader with Z lift arms
Complete machine Valid for:
L524 - 438 / from 0101
The values stated refer to the standard version of the machine: With Z lift arms (2400 mm), without hydraulic quick-change device. With 17.5 R25 Goodyear GP-2B tyres. Tipping loads and weights include all lubricants, full fuel tank, ROPS/FOPS cab and driver. Tyre sizes and additional attachments affect the operating weight and tipping load.
Dimensions - machine with Z lift arms Description Bucket capacity as per ISO 7546 Bucket width
L524 - 438 / from 0101 L534 - 434 / from 0101 L538 - 432 / from 0101
Value Unit 2.0 m³ 2500 mm
Specific material weight A Dump height at maximum lifting height and 45° tilt-out angle B Dump height
3335 mm
C Maximum bucket base height
3510 mm
D Maximum bucket pivot point height
3760 mm
E Maximum bucket top height F Reach at maximum lifting height and 42° tilt-out angle G Digging depth
4840 mm
H Height above the cab
3150 mm
I Height above exhaust
3090 mm
MJFCIFSS
1.8 t/m³ 2850 mm
870 mm 80 mm
2.0-1 of 26
Product Description
Service Manual
Technical data
Description J Ground clearance
520 mm
K Wheel base
2700 mm
L Overall length
6835 mm
Turning radius over bucket outer edge
5500 mm
Lifting force (SAE)
98 kN
Breakout force (SAE)
92 kN
Tipping load when straight
8030 kg
Tipping load articulated at 30°
7005 kg
Angle of articulation (to each side) Swing angle (to each side) Operating weight
40 ° 6 ° 10100 kg
Tractive force
76.2 daN
Travel speed in travel range 1, forward and reverse
0 - 8 km/h
Travel speed in travel range 2, forward and reverse
0 - 33 km/h
Sound pressure level in the cab LpA Wheel loader with P lift arms
Value Unit
Valid for:
75 dB (A)
L524 - 438 / from 0101
The values stated refer to the standard version of the machine: With P lift arms (2400 mm) and hydraulic quick-change device. With 17.5 R25 Goodyear GP-2B tyres. Tipping loads and weights include all lubricants, full fuel tank, ROPS/FOPS cab and driver. Tyre sizes and additional attachments affect the operating weight and tipping load.
Dimensions - machine with P lift arms
2.0-2 of 26
MJFCIFSS
L524 - 438 / from 0101 L534 - 434 / from 0101 L538 - 432 / from 0101
Service Manual
Product Description Technical data
Description Bucket capacity as per ISO 7546 Bucket width
1.7 m³ 2500 mm
Specific material weight A Dump height at maximum lifting height and 45° tilt-out angle B Dump height
3380 mm
C Maximum bucket base height
3500 mm
D Maximum bucket pivot point height
3750 mm
E Maximum bucket top height F Reach at maximum lifting height and 42° tilt-out angle G Digging depth
4895 mm
H Height above the cab
3150 mm
I Height above exhaust
3090 mm
J Ground clearance
1.8 t/m³ 2815 mm
1030 mm 55 mm
520 mm
K Wheel base
2700 mm
L Overall length
6890 mm
Turning radius over bucket outer edge
5530 mm
Lifting force (SAE)
89 kN
Breakout force (SAE)
80 kN
Tipping load when straight
7100 kg
Tipping load articulated at 40°
6250 kg
Angle of articulation (to each side) Swing angle (to each side) Operating weight Tractive force
40 ° 6 ° 10200 kg 76.2 kN
Travel speed in travel range 1, forward and reverse
0 - 8.0 km/h
Travel speed in travel range 2, forward and reverse
0 - 33.0 km/h
Sound pressure level in the cab LpA Wheel loader with Z lift arms
Value Unit
Valid for:
75 dB (A)
L534 - 434 / from 0101
The values stated refer to the standard version of the machine: With Z lift arms (2500 mm), without hydraulic quick-change device. With 20.5 R25 Goodyear GP-2B tyres. Tipping loads and weights include all lubricants, full fuel tank, ROPS/FOPS cab and driver. Tyre sizes and additional attachments affect the operating weight and tipping load.
L524 - 438 / from 0101 L534 - 434 / from 0101 L538 - 432 / from 0101
MJFCIFSS
2.0-3 of 26
Product Description
Service Manual
Technical data
Dimensions - machine with Z lift arms Description Bucket capacity as per ISO 7546 Bucket width
2.4 m³ 2500 mm
Specific material weight A Dump height at maximum lifting height and 45° tilt-out angle B Dump height
3380 mm
C Maximum bucket base height
3650 mm
D Maximum bucket pivot point height
3900 mm
E Maximum bucket top height F Reach at maximum lifting height and 42° tilt-out angle G Digging depth
5450 mm
H Height above the cab
3250 mm
I Height above exhaust
3150 mm
J Ground clearance
1.8 t/m³ 2890 mm
945 mm 70 mm
460 mm
K Wheel base
2900 mm
L Overall length
7235 mm
Turning radius over bucket outer edge
5825 mm
Lifting force (SAE)
135 kN
Breakout force (SAE)
105 kN
Tipping load when straight
9745 kg
Tipping load articulated at 40°
8625 kg
Angle of articulation (to each side) Swing angle (to each side) Operating weight Tractive force
2.0-4 of 26
Value Unit
MJFCIFSS
40 ° 6 ° 12100 kg 87.8 kN L524 - 438 / from 0101 L534 - 434 / from 0101 L538 - 432 / from 0101
Service Manual
Product Description Technical data
Description
Value Unit
Travel speed in travel range 1, forward and reverse
0 - 8.0 km/h
Travel speed in travel range 2, forward and reverse
0 - 36.0 km/h
Sound pressure level in the cab LpA Wheel loader with P lift arms
Valid for:
75 dB (A)
L534 - 434 / from 0101
The values stated refer to the standard version of the machine: With P lift arms (2600 mm) and hydraulic quick-change device. With 20.5 R25 Goodyear GP-2B tyres. Tipping loads and weights include all lubricants, full fuel tank, ROPS/FOPS cab and driver. Tyre sizes and additional attachments affect the operating weight and tipping load.
Dimensions - machine with P lift arms Description Bucket capacity as per ISO 7546 Bucket width
L524 - 438 / from 0101 L534 - 434 / from 0101 L538 - 432 / from 0101
Value Unit 2.0 m³ 2500 mm
Specific material weight A Dump height at maximum lifting height and 45° tilt-out angle B Dump height
3470 mm
C Maximum bucket base height
3730 mm
D Maximum bucket pivot point height
3970 mm
E Maximum bucket top height F Reach at maximum lifting height and 42° tilt-out angle G Digging depth
5230 mm
MJFCIFSS
1.8 t/m³ 2930 mm
1060 mm 65 mm
2.0-5 of 26
Product Description
Service Manual
Technical data
Description H Height above the cab
3250 mm
I Height above exhaust
3150 mm
J Ground clearance
460 mm
K Wheel base
2900 mm
L Overall length
7535 mm
Turning radius over bucket outer edge
5925 mm
Lifting force (SAE) Breakout force (SAE)
95 kN 100 kN
Tipping load when straight
8550 kg
Tipping load articulated at 40°
7570 kg
Angle of articulation (to each side) Swing angle (to each side) Operating weight Tractive force
40 ° 6 ° 12290 kg 87.8 kN
Travel speed in travel range 1, forward and reverse
0 - 8.0 km/h
Travel speed in travel range 2, forward and reverse
0 - 36.0 km/h
Sound pressure level in the cab LpA
2.0-6 of 26
Value Unit
MJFCIFSS
75 dB (A)
L524 - 438 / from 0101 L534 - 434 / from 0101 L538 - 432 / from 0101
Service Manual
Product Description Technical data
Wheel loader with Z lift arms
Valid for:
L538 - 432 / from 0101
The values stated refer to the standard version of the machine: With Z lift arms (2500 mm), without hydraulic quick-change device. With 20.5 R25 Goodyear GP-2B tyres. Tipping loads and weights include all lubricants, full fuel tank, ROPS/FOPS cab and driver. Tyre sizes and additional attachments affect the operating weight and tipping load.
Dimensions - machine with Z lift arms Description Bucket capacity as per ISO 7546 Bucket width
2.5 m³ 2500 mm
Specific material weight A Dump height at maximum lifting height and 45° tilt-out angle B Dump height
3380 mm
C Maximum bucket base height
3650 mm
D Maximum bucket pivot point height
3900 mm
E Maximum bucket top height F Reach at maximum lifting height and 42° tilt-out angle G Digging depth
5150 mm
H Height above the cab
3250 mm
I Height above exhaust
3150 mm
J Ground clearance
L524 - 438 / from 0101 L534 - 434 / from 0101 L538 - 432 / from 0101
Value Unit
1.8 t/m³ 2870 mm
970 mm 70 mm
460 mm
K Wheel base
2900 mm
L Overall length
7135 mm
Turning radius over bucket outer edge
5795 mm
MJFCIFSS
2.0-7 of 26
Product Description
Service Manual
Technical data
Description Lifting force (SAE)
135 kN
Breakout force (SAE)
105 kN
Tipping load when straight Tipping load articulated at 40° Angle of articulation (to each side) Operating weight Tractive force
10160 kg 9000 kg 40 ° 12300 kg 87.8 daN
Travel speed in travel range 1, forward and reverse
0 - 8.0 km/h
Travel speed in travel range 2, forward and reverse
0 - 36.0 km/h
Sound pressure level in the cab LpA Wheel loader with P lift arms
Value Unit
Valid for:
75 dB (A)
L538 - 432 / from 0101
The values stated refer to the standard version of the machine: With P lift arms (2600 mm) and hydraulic quick-change device. With 20.5 R25 Goodyear GP-2B tyres. Tipping loads and weights include all lubricants, full fuel tank, ROPS/FOPS cab and driver. Tyre sizes and additional attachments affect the operating weight and tipping load.
Dimensions - machine with P lift arms Description Bucket capacity as per ISO 7546 Bucket width Specific material weight
2.0-8 of 26
MJFCIFSS
Value Unit 2.1 m³ 2500 mm 1.8 t/m³
L524 - 438 / from 0101 L534 - 434 / from 0101 L538 - 432 / from 0101
Service Manual
Product Description Technical data
Description A Dump height at maximum lifting height and 45° tilt-out angle B Dump height
Value Unit 2910 mm 3470 mm
C Maximum bucket base height
3730 mm
D Maximum bucket pivot point height
3970 mm
E Maximum bucket top height F Reach at maximum lifting height and 42° tilt-out angle G Digging depth
5230 mm
H Height above the cab
3250 mm
I Height above exhaust
3150 mm
J Ground clearance
1075 mm 65 mm
460 mm
K Wheel base
2900 mm
L Overall length
7435 mm
Turning radius over bucket outer edge
5880 mm
Lifting force (SAE) Breakout force (SAE)
95 kN 100 kN
Tipping load when straight
8640 kg
Tipping load articulated at 40°
7650 kg
Angle of articulation (to each side)
40 °
Swing angle (to each side) Operating weight Tractive force
6 ° 12250 kg 87.8 kN
Travel speed in travel range 1 forward and reverse
0 - 8.0 km/h
Travel speed in travel range 2 forward and reverse
0 - 36.0 km/h
Sound pressure level in the cab LpA
2.1.2
75 dB (A)
Diesel engine and pump distributor gear Diesel engine
Valid for:
L524 - 438 / 0101 - 8795; ID no. 9739010
Description Engine model
Value Unit D 504 T
Number of cylinders Capacity Rated power as per ISO 9249 Rated speed Maximum torque at 1400 min-1 Lower idle speed Upper idle speed
4500 cm³ 81 / 110 kW / PS 2400 min-1 424 Nm 850
50
min-1
2500 +80 min-1
Inlet valve play (cold)
0.35 mm
Outlet valve play (cold)
0.45 mm
Control thermostat opening temperature L524 - 438 / from 0101 L534 - 434 / from 0101 L538 - 432 / from 0101
4
MJFCIFSS
82 °C
2.0-9 of 26
Product Description
Service Manual
Technical data
Description Longitudinal / traverse inclinability
30 / 30 °C
Starter operating voltage
24 V
Starter power consumption
7.8 kW
Alternator voltage output
27 V
Alternator current output
55 A
Emission thresholds comply with Valid for:
Value Unit
EU RL 97/68 EC Stage I
L524 - 438 / from 8796; ID no. 9739021
Description Engine model
Value Unit D 504 TI - 02
Number of cylinders Firing order
4500 cm³
Cylinder bore
106.5 mm 127 mm
Rated power as per ISO 9249 Rated speed Maximum torque at 1400 min-1 Lower idle speed Upper idle speed Combustion pressure Injection nozzle pressure Injection nozzles, maximum pressure difference between cylinders
81 / 110 kW / PS 2400 min-1 422 Nm 850
50
min-1
2550 +80 min-1 24 +3 bar 241 ±6 bar 7 bar
Inlet valve play (cold)
0.35 mm
Outlet valve play (cold)
0.45 mm
Direction of rotation, looking at flywheel Number of teeth on flywheel gear Control thermostat opening temperature Longitudinal / traverse inclinability
Anticlockwise 129 82 °C 30 / 30 °
Starter operating voltage
24 V
Starter power consumption
7.8 kW
Alternator voltage output
27 V
Alternator current output
55 A
Auxiliary power take-off transmission Weight
1:1.0333 387 kg
Emission thresholds comply with
EU RL 97/68/EC Stage II
L534 - 434 / 0101 - 8961; ID no. 9739011
Description Engine model Number of cylinders Capacity Rated power as per ISO 9249
2.0-10 of 26
1-3-4-2
Capacity Stroke
Valid for:
4
MJFCIFSS
Value Unit D 504 TI 4 4500 cm³ 100 / 136 kW / PS L524 - 438 / from 0101 L534 - 434 / from 0101 L538 - 432 / from 0101
Service Manual
Product Description Technical data
Description
Value Unit
Rated speed
2400 min-1
Maximum torque at 1400 min-1 Lower idle speed Upper idle speed
50
min-1
2550 +80 min-1 0.35 mm
Outlet valve play (cold)
0.45 mm 30 / 30 °C
Starter operating voltage
24 V
Starter power consumption
7.8 kW
Alternator voltage output
27 V
Alternator current output
55 A
Emission thresholds comply with
EU RL 97/68 EC Stage I
L534 - 434 / from 8962; ID no. 9739022
Description Engine model Number of cylinders Firing order
Value Unit D 504 TI - 02 4 1-3-4-2
Capacity
4500 cm³
Cylinder bore
106.5 mm
Stroke Rated power as per ISO 9249 Rated speed Maximum torque at 1400 min-1
127 mm 100 / 136 kW / PS 2400 min-1 494 Nm
Lower idle speed
850±50 min-1
Upper idle speed
2550+80 min-1
Combustion pressure Injection nozzle pressure Injection nozzles, maximum pressure difference between cylinders
min. 24+3 bar 241±6 bar 7 bar
Inlet valve play (cold)
0.35 mm
Outlet valve play (cold)
0.45 mm
Direction of rotation, looking at flywheel Number of teeth on flywheel gear Control thermostat Longitudinal / traverse inclinability
Anticlockwise 129 82 °C 30 / 30 °
Starter operating voltage
24 V
Starter power consumption
7.8 kW
Alternator voltage output
27 V
Alternator current output
55 A
Auxiliary power take-off transmission Weight Emission thresholds comply with
L524 - 438 / from 0101 L534 - 434 / from 0101 L538 - 432 / from 0101
850
Inlet valve play (cold) Longitudinal / traverse inclinability
Valid for:
498 Nm
MJFCIFSS
1:1.0333 396 kg EU RL 97/68/EC Stage II
2.0-11 of 26
Product Description
Service Manual
Technical data
Valid for:
L538 - 432 / 0101 -8507; ID no. 9880051
Description Engine model
Value Unit D924T-E-A1
Number of cylinders Capacity Rated power as per ISO 9249 Rated speed Maximum torque at 1400 min-1 Lower idle speed Upper idle speed
4 6640 cm³ 100 / 136 kW / PS 2000 min-1 597 Nm 850
Inlet valve play (cold)
0.25 mm
Outlet valve play (cold)
0.30 mm
Longitudinal / traverse inclinability
79 °C 45 / 45 °C
Starter operating voltage
24 V
Starter power consumption
5.4 kW
Alternator voltage output
28 V
Alternator current output
55 A
Emission thresholds comply with
EU RL 97/68 EC Stage I
L538 - 432 / from 8508; ID no. 9076608
Description Engine model
Value Unit D 924TI-E-A1
Number of cylinders Firing order Capacity
4 1-3-4-2 6640 cm³
Cylinder bore
122 mm
Stroke
142 mm
Rated power as per ISO 9249 Rated speed Maximum torque at 1150 min-1 Lower idle speed
100 / 136 kW / PS 2000 min-1 645 Nm 850
50
min-1
Upper idle speed
2100+80 min-1
Start of delivery
1.4 0.05 mm
Compression ratio Combustion pressure Injection nozzle pressure Injection nozzles, maximum pressure difference between cylinders
17.2:1 20 - 26 bar 225±6 bar 7 bar
Inlet valve play (cold)
0.25 mm
Outlet valve play (cold)
0.30 mm
Direction of rotation, looking at flywheel Number of teeth on flywheel gear Control thermostat opening temperature Longitudinal / traverse inclinability
2.0-12 of 26
min-1
2100 +80 min-1
Control thermostat
Valid for:
50
MJFCIFSS
Anticlockwise 147 79 °C 45 / 45 °
L524 - 438 / from 0101 L534 - 434 / from 0101 L538 - 432 / from 0101
Service Manual
Product Description Technical data
Description
Value Unit
Starter operating voltage
24 V
Starter power consumption
5.4 kW
Alternator voltage output
28 V
Alternator current output
55 A
Auxiliary power take-off transmission
1:1.275
Weight Emission levels comply with
740 kg EU RL 97/68/EC Stage II
Fuel tank Valid for:
L524 - 438 / from 0101; L534 - 434 / from 0101; L538 - 432 / from 0101; ID no. 7622943
Description Tank capacity, FULL
Value Unit 160 l
Tank capacity, RESERVE
30 l
Fuel pre-filter (stage I) Valid for:
L524 - 438 / 0101 - 8795; L534 - 434 / 0101 - 8961; ID no. 7090480
Description Filtration grade
Valid for:
Value Unit min. 0.6 mm max. 0.8 mm
L538 - 432 / 0101 -8507; ID no. 7381876
Description Filtration grade
Value Unit min. 0.6 mm max. 0.8 mm
Fuel pre-filter (stage II) Valid for:
L524 - 438 / from 8796; L534 - 434 / from 8962; ID no. 7090562
Description
Value Unit
Filtration grade Valid for:
10 µm
L538 - 432 / from 8508; ID no. 7382133
Description
Value Unit
Filtration grade
30 µm
Fuel fine filter (stage I) Valid for:
L524 - 438 / from 0101; L534 - 434 / from 0101; ID no. 7090528
Description Filtration grade Valid for:
5 µm
L538 - 432 / 0101 - 8507; ID no. 7381643
Description Filtration grade
L524 - 438 / from 0101 L534 - 434 / from 0101 L538 - 432 / from 0101
Value Unit
MJFCIFSS
Value Unit 5 µm
2.0-13 of 26
Product Description
Service Manual
Technical data
Fuel fine filter (stage II) Valid for:
L524 - 438 / from 0101; L534 - 434 / from 0101; ID no. 7090528
Description Filtration grade Valid for:
Value Unit 5 µm
L538 - 432 / from 8508; ID no. 7382102
Description Filtration grade
Value Unit 5 µm
Vacuum switch Valid for:
L524 - 438 / from 0101; L534 -434 / from 0101; L538 - 432 / from 0101; ID no. 6906001
Description Air filter contamination vacuum switch activation point
Value Unit 50 mbar
Coupling Valid for:
L524 - 438 / from 0101; L534 - 434 / from 0101; ID no. 5717325, 10010559
Description Glue for torsion 8 absorber bolts
Valid for:
49 Nm
Hub star fastening screw tightening torque
50 Nm
L538 - 432 / from 0101; ID no. 5607974
Glue for torsion 8 absorber bolts Tightening torque for 8 torsion absorber bolts
Value Unit 241 Loctite 68 Nm
L538 - 432 / from 8508; ID no. 7382102
Description Filtration grade
2.1.3
241 Loctite
Tightening torque for 8 torsion absorber bolts
Description
Valid for:
Value Unit
Value Unit 2 µm
Cooling system Cooling system Gear pump
Valid for:
L524 - 438 / 0101 -6316; ID no. 5717137
Description Capacity
2.0-14 of 26
MJFCIFSS
Value Unit 14 cm³
L524 - 438 / from 0101 L534 - 434 / from 0101 L538 - 432 / from 0101
Service Manual
Product Description Technical data
Valid for:
L524 - 438 / from 6317; L534 - 434 / from 0101; ID no. 5717323
Description Capacity Valid for:
Value Unit 16 cm³
L538 - 432 / from 0101; ID no. 5716912
Description Capacity
Value Unit 14 cm³
Gear motor Valid for:
L524 - 438 / from 0101; L534 - 434 / from 0101; L538 - 432 / from 0101; ID no. 5717099
Description Gear motor displacement Pressure relief valve
Value Unit 16 cm³ 5
175
bar
Temperature sensor Valid for:
L524 - 438 / from 0101; L534 - 434 / from 0101; L538 - 432 / from 0101; ID no. 5717099
Description Measuring range Resistance at 20°C
2.1.4
Value Unit -30 to +30 °C 1112
Travel hydraulics Variable displacement pump
Valid for:
L524 - 438 / from 0101
Description Control type
DA
Maximum capacity
90 cm³
Flow rate at rated speed Power Weight
19.6 cm³ 60 kg
Pressure cut-off
430
5
bar
L534 - 434 / from 0101
Description
Value Unit
Control type
DA
Maximum capacity
125 cm³
Flow rate at rated speed
246 l/min
Power
90 kW
Replenishing pump capacity Weight
19.6 cm³ 60 kg
Pressure cut-off
L524 - 438 / from 0101 L534 - 434 / from 0101 L538 - 432 / from 0101
212 l/min 72 kW
Replenishing pump capacity
Valid for:
Value Unit
MJFCIFSS
430
5
bar
2.0-15 of 26
Product Description
Service Manual
Technical data
Valid for:
L538 - 432 / from 0101
Description
Value Unit
Control type
DA
Maximum capacity
125 cm³
Flow rate at rated speed
246 l/min
Power
90 kW
Replenishing pump capacity Weight
28.3 cm³ 80 kg
Pressure cut-off
430
5
bar
Variable displacement motor 1 Valid for:
L524 - 438 / from 0101
Description Control type
DA
Maximum displacement
107 cm³
Minimum displacement
43 cm³
Maximum speed Torque (Dp 400 bar) Weight
230
5
bar
Value Unit
Control type
DA
Maximum displacement
140 cm³
Minimum displacement
38 cm³
Maximum speed Torque (Dp 400 bar) Weight
4800 min-1 891 Nm 60 kg
Control range while driving
260
5
bar
L538 - 432 / from 0101
Description
Value Unit
Control type
DA
Maximum displacement
140 cm³
Minimum displacement
46 cm³
Maximum speed Torque (Dp 400 bar) Weight
4800 min-1 891 Nm 60 kg
Control range while driving
2.0-16 of 26
594 Nm
L534 - 434 / from 0101
Description
Valid for:
5490 min-1 47 kg
Control range while driving Valid for:
Value Unit
MJFCIFSS
230
5
bar
L524 - 438 / from 0101 L534 - 434 / from 0101 L538 - 432 / from 0101
Service Manual
Product Description Technical data
Variable displacement motor 2 Valid for:
L524 - 438 / from 0101; L538 - 432 / from 0101
Description
Value Unit
Control type
HD1D
Maximum displacement
160 cm³
Minimum displacement
0 cm³
Maximum speed
4800 min-1
Torque (Dp 400 bar)
1119 Nm
Weight
Valid for:
64 kg
Control pressure start of regulation
6.0
1
bar
High pressure start of regulation
260
5
bar
L534 - 434 / from 0101
Description
Value Unit
Control type
HD1D
Maximum displacement
160 cm³
Minimum displacement
0 cm³
Maximum speed
4800 min-1
Torque (Dp 400 bar)
1119 Nm
Weight
64 kg
Control pressure start of regulation High pressure start of regulation
6.0
1
bar
290
5
bar
Motor scavenging pump Valid for:
L524 - 438 / from 0101; L534 - 434 / from 0101
Description
Valid for:
Flow rate at rated speed
32.5 l
Speed at rated speed
2322 min -1
L538 - 432 / from 0101
Description
2.1.5
Value Unit
Value Unit
Flow rate at rated speed
35.7 l
Speed at rated speed
2550 min -1
Working hydraulics Working hydraulics pump
Valid for:
L524 - 438 / from 0101
Description
Value Unit
Control type
DFLR
Maximum capacity Flow rate at rated speed Power
105 l/min 40 kW
Flow regulator (delta p) L524 - 438 / from 0101 L534 - 434 / from 0101 L538 - 432 / from 0101
45 cm³
MJFCIFSS
28
1
bar
2.0-17 of 26
Product Description
Service Manual
Technical data
Valid for:
Description
Value Unit
Weight
215
bar
L534 - 434 / from 0101
Description
Value Unit
Control type
DFLR
Maximum capacity Flow rate at rated speed Power
60 cm³ 141 l/min 57 kW
Flow regulator (delta p) Weight Valid for:
1
25
1
bar
215
1
bar
L538 - 432 / from 0101
Description
Value Unit
Control type
DFLR
Maximum capacity Flow rate at rated speed Power
71 cm³ 137 l/min 57 kW
Flow regulator (delta p) Weight
25
1
bar
215
1
bar
Control block Valid for:
L524 - 438 / from 0101
Description Piston diameter LS working hydraulics pressure cut-off LS steering pressure cut-off Valid for:
Value Unit 14.3 mm 305
5
bar
210
5
bar
L534 - 434 / from 0101; L538 - 432 / from 0101
Description Piston diameter LS pressure relief valve
Value Unit 18 mm 305
5
bar
Pilot control hydro accumulator Description Hydro accumulator volume Preload pressure (nitrogen filling)
Value Unit 320 cm³ 15 bar
Float position pressure switch Valid for:
L534 - 434 / from 0101; L538 - 432 / from 0101
Description Switch type Switch point, rising
2.0-18 of 26
MJFCIFSS
Value Unit Normally open 23
2
bar
L524 - 438 / from 0101 L534 - 434 / from 0101 L538 - 432 / from 0101
Service Manual
Product Description Technical data
Stabilisation module
Valid for:
Description
Value Unit
Cut-off valve
150
2
cmÂł
L524 - 438 / from 0101
Description Piston diameter
Value Unit 100 mm
Rod diameter
60 mm
Stroke length
735 mm
Lift cylinder Valid for:
L524 - 438 / from 0101
Description Piston diameter
Value Unit 110 mm
Rod diameter
60 mm
Stroke length
735 mm
Z kinematics tilt cylinder Valid for:
L524 - 438 / from 0101
Description Piston diameter
Valid for:
Value Unit 120 mm
Rod diameter
70 mm
Stroke length
440 mm
L534 - 434 / from 0101; L538 - 432 / from 0101
Description Piston diameter
Value Unit 140 mm
Rod diameter
80 mm
Stroke length
440 mm
P kinematics tilt cylinder Valid for:
L524 - 438 / from 0101
Description
Valid for:
Piston diameter
80 mm
Rod diameter
50 mm
Stroke length
775 mm
L534 - 434 / from 0101; L538 - 432 / from 0101
Description
L524 - 438 / from 0101 L534 - 434 / from 0101 L538 - 432 / from 0101
Value Unit
Value Unit
Piston diameter
90 mm
Rod diameter
50 mm
Stroke length
970 mm
MJFCIFSS
2.0-19 of 26
Product Description
Service Manual
Technical data
Return suction filter Description
Value Unit
Filtration grade
10 µm
Return strainer Description
Value Unit
Filtration grade
40 µm
Bleeder filter Description
Value Unit
Filtration grade
10 µm
Inlet opening pressure
0.03 bar
Outlet opening pressure
2.1.6
0.5 bar
Steering system Servostat Description
Value Unit
Displacement
462 cm³
Secondary pressure relief
285 ±10 bar
Volume flow boost
1 : 1.6
Steering cylinder Description
Value Unit
Piston diameter
90 mm
Rod diameter
40 mm
Stroke length
500 mm
Emergency steering pump Description
Value Unit
Capacity
11 cm² 55 ±5 bar
Pressure relief valve
Emergency steering pump pressure switch Description Switch type
Value Unit Normally open 10 ±1 bar
Switch point, rising
Emergency steering check pressure switch Description Switch type Switch point, rising
2.0-20 of 26
MJFCIFSS
Value Unit Normally open 5 ±0.5 bar L524 - 438 / from 0101 L534 - 434 / from 0101 L538 - 432 / from 0101
Service Manual
Product Description Technical data
2.1.7
Brake system Brake system gear pump
Valid for:
L524 - 438 / to 6316
Description
Valid for:
Flow rate at rated speed
32.5 l/min
Speed at rated speed
2322 min -1
L524 - 438 / from 6317; L534 - 434 / from 0101
Description
Valid for:
Value Unit
Value Unit
Flow rate at rated speed
37.2 l/min
Speed at rated speed
2322 min -1
L538 - 432 / from 0101
Description
Value Unit
Flow rate at rated speed
35.7 l/min
Speed at rated speed
2550 min -1
Compact brake valve Description
Value Unit
Accumulator charge valve activation pressure
145 ±5 bar
Accumulator charge valve deactivation pressure
175 ±5 bar
Maximum service brake pressure
65 ±5 bar
Service brake hydro accumulator Description Hydro accumulator volume Preload pressure (nitrogen filling)
Value Unit 750 cm³ 50 bar
Brake light pressure switch Description Switch type Switching point, falling
Value Unit Normally open 90 ±5 bar
Disc brake
L524 - 438 / from 0101 L534 - 434 / from 0101 L538 - 432 / from 0101
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
MJFCIFSS
2.0-21 of 26
Product Description
Service Manual
Technical data
Parking brake hydro accumulator Description
Value Unit
Hydro accumulator volume
160 cmÂł
Preload pressure (nitrogen filling)
30 bar
Parking brake pressure switch Description Switch type
Value Unit Change-over switch 100 Âą5 bar
Switching point, falling
2.1.8
Electrical system Electrical system with circuit diagrams Description
Value Unit
System voltage
24 V
Battery Valid for:
L524 - 438 / from 0101; L534 - 434 / from 0101
Description Battery voltage
12 V
Battery capacity
100 Ah
Acid density of charged battery Valid for:
Value Unit
1.26 - 1.28 kg/l
L538 - 432 / from 0101
Description Battery voltage
12 V
Battery capacity
110 Ah
Acid density of charged battery
2.1.9
Value Unit
1.26 - 1.28 kg/l
Transfer gear Transfer gear
Valid for:
L524 - 438 / from 0101
Description
Value Unit
Variable displacement motor 1 transmission
1.829 -
Variable displacement motor 2 transmission
1.641 -
Cardan speed at 34 km/h
2640 min-1
Speed sensor Valid for:
2.0-22 of 26
Inductive
L534 - 434 / from 0101; L538 - 432 / from 0101
Description
Value Unit
Variable displacement motor 1 transmission
1.641 -
Variable displacement motor 2 transmission
1.641 -
MJFCIFSS
L524 - 438 / from 0101 L534 - 434 / from 0101 L538 - 432 / from 0101
Service Manual
Product Description Technical data
Description Cardan speed at 34 km/h Speed sensor
Value Unit 2895 min -1 Inductive
Speed sensor Description Type
Inductive sensor -
Distance to spur gear A
2.1.10
Value Unit min. 1.2 mm max. 1.8 mm
Axles and tyres Front axle
Valid for:
L524 - 438 / from 0101
Description Self-locking differential level Width
45 % 1900 mm
Wheel lug tightening torque Wheel lug spanner size Weight Valid for:
Value Unit
650 Nm 30 mm 490 kg
L534 - 434 / from 0101; L538 - 432 / from 0101
Description Self-locking differential level Width
Value Unit 45 % 1900 mm
Wheel lug tightening torque Wheel lug spanner size Weight
650 Nm 30 mm 600 kg
Rear axle Valid for:
L524 - 438 / from 0101
Description Self-locking differential level Swing angle (to each side) Width Wheel lug spanner size Weight
6 ° 650 Nm 30 mm 600 kg
L534 - 434 / from 0101; L538 - 432 / from 0101
Description Self-locking differential level Swing angle (to each side) Width
L524 - 438 / from 0101 L534 - 434 / from 0101 L538 - 432 / from 0101
45 % 1900 mm
Wheel lug tightening torque
Valid for:
Value Unit
Value Unit 45 % 6 ° 1900 mm
MJFCIFSS
2.0-23 of 26
Product Description
Service Manual
Technical data
Description Wheel lug tightening torque Wheel lug spanner size Weight
2.1.11
Value Unit 650 Nm 30 mm 680 kg
Machine frame and ballast weight Ballast weight
Valid for:
L524 - 438 / from 0101
Description
Valid for:
Left ballast weight
570 kg
Right ballast weight
650 kg
L534 - 434 / from 0101
Description
Valid for:
Value Unit
Left ballast weight
825 kg
Right ballast weight
975 kg
L538 - 432 / from 0101
Description
2.1.12
Value Unit
Value Unit
Left ballast weight
740 kg
Right ballast weight
810 kg
Cab, heating and air-conditioning Heating and ventilation Description Blower speeds Heating power
Value Unit 3 4.0 kW
Blower Description Air flow Blower speeds Voltage
Value Unit 630 m³/h 3 24 V
Current consumption (max) free blowing
10.5 A
Power consumption (min) free blowing
245 W
Air filter Description Filter class
2.0-24 of 26
Value Unit EU3
Filtration grade
10 µ
Filter surface (effective)
1.8 m²
MJFCIFSS
L524 - 438 / from 0101 L534 - 434 / from 0101 L538 - 432 / from 0101
Service Manual
Product Description Technical data
Air-conditioning system Description Coolant oil
2.1.13
Value Unit ZXL 100PG
Cooling power
4.8 kW
Coolant filling quantities
1,4 kg
Temperature switch activation temperature
4 ±1 °C
Temperature switch deactivation temperature
1 ±1 °C
Low pressure switch OFF
1.5 bar
Low pressure switch ON
2.9 bar
High pressure switch OFF
25.0 bar
High pressure switch ON
19.0 bar
Lift arms and quick-change device Lift arms with Z kinematics
Valid for:
L524 - 438 / from 0101
Description L - length Valid for:
Value Unit 2400 mm
L534 - 434 / from 0101; L538 - 432 / from 0101
Description L - length
Value Unit 2500 mm
Lift arms with P kinematics Valid for:
L524 - 438 / from 0101
Description L - length Valid for:
Value Unit 2400 mm
L534 -434 / from 0101; L538 - 432 / from 0101
Description L - length
Value Unit 2600 mm
Hydraulic quick-change device for Z lift arms (hydraulic actuation) Description A system connection size Weight
Value Unit 1000 mm 300 kg
Hydraulic quick-change device for Z lift arms (electrohydraulic actuation) Description A system connection size Weight
L524 - 438 / from 0101 L534 - 434 / from 0101 L538 - 432 / from 0101
Value Unit 1000 mm 300 kg
MJFCIFSS
2.0-25 of 27
Product Description
Service Manual
Technical data
Hydraulic quick-change device for P lift arms (electrohydraulic actuation) Description A system connection size Weight
2.1.14
Value Unit 1000 mm 230 kg
Equipment and accessories Bucket
Valid for:
L524 - 438 / from 0101
Description B bucket width
Valid for:
2500 mm
Specific material weight
1.8 t/m³
Heaped bucket capacity (ISO 7546)
2.0 m³
L534 - 434 / from 0101
Description B bucket width
Valid for:
Value Unit
Value Unit 2500 mm
Specific material weight
1.8 t/m³
Heaped bucket capacity (ISO 7546)
2.4 m³
L538 - 432 / from 0101
Description B bucket width
Value Unit 2500 mm
Specific material weight
1.8 t/m³
Heaped bucket capacity (ISO 7546)
2.5 m³
Forklift Description Fork carrier prong size Prong length
Value Unit FEM III 1200 mm
High dump bucket (optional) Description B bucket width
2.0-26 of 26
Value Unit 2700 mm
Specific material weight (L524-438 with P kinematics)
0.9 t/m³
Specific material weight (L534-434 with P kinematics)
1.0 t/m³
Specific material weight (L538-432 with P kinematics)
1.1 t/m³
Bucket capacity as per ISO 7546
3.0 m³
Maximum operating pressure for attachment hydraulics
250 bar
MJFCIFSS
L524 - 438 / from 0101 L534 - 434 / from 0101 L538 - 432 / from 0101
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) ...........................................3.4-1
3.4.2
Table of filling quantities (L534) ...........................................3.4-1
3.4.3
Table of filling quantities (L538) ...........................................3.4-2
3.4.4
Lubrication chart ...................................................................3.4-3
3.5
L524 - 438 / from 0101 L534 - 434 / from 0101 L538 - 432 / from 0101
Maintenance tasks..........................................................................3.5-1 3.5.1
Preparatory tasks for maintenance ......................................3.5-1
3.5.2
Checking the machine for external damage.........................3.5-6
3.5.3
Making sure the bolted connections are tight.......................3.5-6
3.5.4
Sealing leaks ........................................................................3.5-6
3.5.5
Checking the engine oil level (L524, L534) ..........................3.5-7
3.5.6
Changing the engine oil (L524, L534) ..................................3.5-8
3.5.7
Changing the engine oil filter (L524, L534) ........................3.5-10
3.5.8
Changing the engine oil filter (L538) ..................................3.5-11
3.5.9
Checking the V-ribbed belt (L524, L534)............................3.5-11
3.5.10
Checking the V-ribbed belt (L538)......................................3.5-12
3.5.11
Checking the engine valve play (L524, L534) ....................3.5-15
3.5.12
Checking the engine valve play (L538) ..............................3.5-18
3.5.13
Checking the flame glow system (L538) ............................3.5-19
3.5.14
Greasing the ring gear on the engine flywheel (L538) .......3.5-20
3.5.15
Changing the diesel engine oil separator (L538) ...............3.5-20
3.5.16
Bleeding the fuel system (L524, L534)...............................3.5-21
3.5.17
Bleeding the fuel system (L538).........................................3.5-22
3.5.18
Bleeding the fuel system (L538).........................................3.5-23
3.5.19
Replacing the fuel pre-filter (L524, L534) ...........................3.5-24
3.5.20
Replacing the fuel pre-filter (L538) .....................................3.5-25
3.5.21
Replacing the filter insert in the fuel separator (L538) .......3.5-26
MJFCIFSS
3.0-1 of 4
Maintenance
3.0-2 of 4
Service Manual 3.5.22
Replacing the fuel fine filter (L524, L534).......................... 3.5-27
3.5.23
Changing the fuel fine filter (L538) .................................... 3.5-29
3.5.24
Draining off condensate from the fuel filter (L524, L534 fine filter) ............................................................................ 3.5-30
3.5.25
Draining off condensate from the fuel filter (L538) ............ 3.5-32
3.5.26
Draining off condensate from the fuel separator (L538).... 3.5-33
3.5.27
Draining off condensate and sediment from the fuel tank .................................................................................... 3.5-33
3.5.28
Checking the air suction hoses for leaks and tight fitting .. 3.5-34
3.5.29
Cleaning the air filter service cap and dust extraction valve................................................................................... 3.5-34
3.5.30
Checking that the air filter vacuum switch works............... 3.5-35
3.5.31
Changing the air filter main element when indicated by the vacuum switch ............................................................. 3.5-36
3.5.32
Checking the exhaust lines for leaks and tight fitting (L524)................................................................................. 3.5-37
3.5.33
Checking the exhaust lines for leaks and tight fitting (L534)................................................................................. 3.5-38
3.5.34
Checking the exhaust lines for leaks and tight fitting (L538)................................................................................. 3.5-39
3.5.35
Checking the coolant level................................................. 3.5-40
3.5.36
Changing the coolant filter (L538) ..................................... 3.5-40
3.5.37
Checking the coolant antifreeze concentration (L524, L534).................................................................................. 3.5-41
3.5.38
Checking the coolant antifreeze and DCA 4 concentration (L538).......................................................... 3.5-45
3.5.39
Cleaning the cooling system.............................................. 3.5-49
3.5.40
Changing coolant with antifreeze (L524, L534) ................ 3.5-50
3.5.41
Changing the coolant with anti-freeze and DCA 4 (L538)................................................................................. 3.5-51
3.5.42
Lubricating the pilot control unit, cleaning the magnets and lubricating the universal joint (L524)........................... 3.5-52
3.5.43
Lubricating the pilot control unit, cleaning the magnets and lubricating the universal joint (L534, L538)................. 3.5-53
3.5.44
Checking the oil level in the hydraulic tank........................ 3.5-53
3.5.45
Draining water and sediment from the hydraulic tank ....... 3.5-54
3.5.46
Changing the hydraulic oil ................................................. 3.5-54
3.5.47
Checking and cleaning the magnetic rod on the hydraulic tank..................................................................... 3.5-55
3.5.48
Changing the hydraulic tank return suction filter ............... 3.5-55
3.5.49
Changing the hydraulic tank bleeder filter ......................... 3.5-56
3.5.50
Checking the steering ........................................................ 3.5-56
3.5.51
Lubricating the bearing points on the steering cylinders ... 3.5-56
3.5.52
Checking the service brake and parking brake ................. 3.5-57
3.5.53
Checking the gap and wear on the parking brake linings.. 3.5-57
MJFCIFSS
L524 - 438 / from 0101 L534 - 434 / from 0101 L538 - 432 / from 0101
Service Manual
Maintenance 3.5.54
Checking the indicator lamps and lighting..........................3.5-58
3.5.55
Checking the batteries, fluid level and terminals................3.5-59
3.5.56
Checking the transfer gear oil level ....................................3.5-60
3.5.57
Changing the transfer gear oil ............................................3.5-60
3.5.58
Checking the axle oil levels ................................................3.5-61
3.5.59
Changing the axle gear oil..................................................3.5-62
3.5.60
Checking the tightness of the wheels (once after 50, 100 and 250 h) ...................................................................3.5-63
3.5.61
Checking and lubricating the drive shaft ............................3.5-64
3.5.62
Checking and adjusting the tyre pressure ..........................3.5-64
3.5.63
Lubricating the articulation bearing and rear oscillating bearing................................................................................3.5-65
3.5.64
Greasing the cab door hinges ............................................3.5-65
3.5.65
Cleaning or replacing the fresh air and recirculated air filter .....................................................................................3.5-65
3.5.66
Checking the indicator and filling level beads in the dryer-collector unit of the air conditioner ............................3.5-66
3.5.67
Checking and lubricating the bearings and lubrication points on Z lift arms ............................................................3.5-67
3.5.68
Checking and lubricating the bearings and lubrication points on P lift arms ............................................................3.5-68
3.5.69
Checking and lubricating the bucket bearing on Z lift arms....................................................................................3.5-70
3.5.70
Checking and lubricating the bucket bearing on P lift arms....................................................................................3.5-71
3.5.71
Checking the bucket stops on Z lift arms ...........................3.5-72
3.6
L524 - 438 / from 0101 L534 - 434 / from 0101 L538 - 432 / from 0101
Testing and adjustment tasks .........................................................3.6-1 3.6.1
Preparing for testing and adjustment ...................................3.6-1
3.6.2
Checking the engine speed L524, L534...............................3.6-2
3.6.3
Checking the engine speed L538.........................................3.6-3
3.6.4
Checking the fan motor and fan control pressure relief valve .....................................................................................3.6-4
3.6.5
Checking the travel hydraulics blocked condition ................3.6-6
3.6.6
Checking the travel pump replenishing pressure .................3.6-7
3.6.7
Checking the start of regulation of the variable displacement pump ..............................................................3.6-7
3.6.8
Checking the output of the travel pump................................3.6-8
3.6.9
Checking the pressure relief and replenishing valve of the travel pump.....................................................................3.6-9
3.6.10
Checking the pressure cut-off of the travel pump ..............3.6-10
3.6.11
Checking the variable displacement motor 1 in the control range.......................................................................3.6-11
3.6.12
Checking the servo pressure regulation of variable displacement motor 2 .........................................................3.6-12
MJFCIFSS
3.0-3 of 4
Maintenance
Service Manual 3.6.13
Checking the pressure regulation of variable displacement motor 2 ........................................................ 3.6-12
3.6.14
Checking the working hydraulics pump flow controller...... 3.6-13
3.6.15
Checking the secondary pressure relief valves on the control block L524.............................................................. 3.6-14
3.6.16
Checking the secondary pressure relief valves on the control block L534, L538.................................................... 3.6-14
3.6.17
Checking the LS pressure cut-off on the control block L524 ................................................................................... 3.6-15
3.6.18
Checking the LS pressure cut-off on the control block L534, L538 ......................................................................... 3.6-15
3.6.19
Checking the P kinematics pre-tension valve on the control block L534, L538.................................................... 3.6-16
3.6.20
Checking the opening and closing pressure of the compact brake valve.......................................................... 3.6-16
3.6.21
Checking the accumulator charge pressure ...................... 3.6-17
3.6.22
Checking the brake pressure on the compact brake valve................................................................................... 3.6-17
3.6.23
Checking the brake light pressure switch .......................... 3.6-18
3.6.24
Checking the capacity of the brake accumulator............... 3.6-19
3.6.25
Checking the inch/brake system overlap........................... 3.6-19
3.7
3.0-4 of 4
Lubricants and fuels....................................................................... 3.7-1 3.7.1
Handling lubricants and fuels............................................... 3.7-1
3.7.2
Lubricating oils for diesel engines ....................................... 3.7-2
3.7.3
Diesel fuels .......................................................................... 3.7-4
3.7.4
Engine coolants (L524, L534).............................................. 3.7-5
3.7.5
Coolants for diesel engines (L538) ...................................... 3.7-6
3.7.6
Hydraulic oils........................................................................ 3.7-9
3.7.7
Lubricating oils for the transmission .................................. 3.7-10
3.7.8
Grease for general lubrication points................................. 3.7-11
MJFCIFSS
L524 - 438 / from 0101 L534 - 434 / from 0101 L538 - 432 / from 0101
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