Page 1

en

Service Manual (20

Wheel loader (10 points)

L544 - L554 2plus2 (10


en

Service Manual (20

Wheel loader (10 points)

L544 - L554 2plus2 (10

Address Address:

LIEBHERR-WERK BISCHOFSHOFEN GMBH Dr. Hans Liebherr – Straße 4 A – 5500 BISCHOFSHOFEN, AUSTRIA

Product identification Manufacturer: Product group: Type: Construction number: Serial number:

LIEBHERR-WERK BISCHOFSHOFEN GMBH Wheel loader L 544 L 554 443 453 6190 - 7476 0501 - 7476

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

10022903 LBH / TD - department 01


Foreword

Target group

This Service Manual has been written for those whose job it is to ensure that the machines remain operational on a daily basis. This includes the mechanics and workshop specialists at Liebherr branch offices and Dealers.

Contents

In the first chapter you will find information about safety regulations as well as specifications for the special tools needed for maintenance and repair. Chapter 2 provides an overview of important technical data for the entire machine and the individual assemblies. The following chapter, entitled Maintenance, contains the maintenance and inspection schedule, testing and adjustment schedule, lubrication chart and filling quantities, a description of maintenance procedures and specifications for prescribed lubricants and fuels. The technical description of the machine in the following chapters is divided into 15 function groups. The design, function, and technical data for each component and part are explained. Chapter 19 is a new one and in it, you will find a list of available repair manuals, troubleshooting hints, the service code table and a description of the BODEM service software.

How to use this manual

This manual describes a variety of machine types as well as optional equipment. In general, this information applies to the types and serial number groups specified in the footnotes. One exception is that specific type and serial number data are indicated at the beginning of each section (e.g. the technical specifications of the components). Whenever possible, parts and components are supplemented by indication of the identification number in the heading. This manual is available in German, English and French.

Working instructions

It is imperative that safety regulations be observed with all tasks done on the machine. You will find information on this in the General Information chapter. A complete set of tools in perfect condition is required for work on the machine, along with any special tools that might be needed. Absolute cleanliness must be observed with all tasks! Sealing material such as O-rings and surface seals should be replaced whenever repairs are carried out.

CD edition

We would particularly like to draw your attention to the fact that this book is available not only in printed form, but also as an electronic document on CD.


General information

1

Product description

2

Maintenance

3

Diesel engine, splitter box

4

Cooling system

5

Travel hydraulics

6

Working hydraulics

7

Steering system

8

Brake system

9

Electrical system

10

Transmission

11

Axles, tyres

12

Machine frame, counterweight

13

Central lubrication system

14

Coverings, cab access

15

Cab, heating, air-conditioning

16

Lift arm, quick-coupling device

17

Attachments, accessories

18

Repairs, troubleshooting

19


1 General information Chapter contents 1.1

Safety regulations

1.1.1

Introduction

1.1 – 1

1.1.2

Overview of safety regulations

1.1 – 2

1.2

L544 - 443 / 6190 - 7476 L554 - 453 / 0501 - 7476

1.1 - 1

Special tools for maintenance and repair work

1.2 - 1

1.2.1

Special tools, general information

1.2 – 1

1.2.2

Special tools for Liebherr diesel engines

1.2 – 1

1.2.3

Special tools for the hydraulic cylinders

1.2 – 2

1.2.4

Special electrical tools

1.2 – 2

1.2.5

Special tools for axles

1.2 – 3

1.2.6

Special tools for the transfer gear

1.2 – 4

1.2.7

Central lubrication system

1.2 – 4

1.2.8

Special tools for the air conditioning system

1.2 – 4

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Service Manual

General Information Safety regulations

1.1

Safety regulations Working on the machine poses safety risks to the operator, driver or maintenance technicians. Carefully reading and observing the various safety instructions at regular intervals can considerably reduce the risk of accidents. This is especially important for personnel who only occasionally work on the machine, for example, carrying out repair or maintenance work. The safety regulations listed below, if followed precisely, will ensure their 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 will be explained. These are indicated by the headings Danger, Warning or Caution.

1.1.1.

Introduction

1. The symbols below have the following meanings: Danger Warning that without appropriate precautions, certain operational procedures could result in fatal accidents. Warning Warning that without appropriate precautions, certain operational procedures could result in severe physical injuries. Caution Warning that without appropriate precautions, certain operational procedures could result in minor physical injuries or damage to the machine. 2. Observance of these instructions does not relieve you of the responsibility to observe other rules and guidelines! The following should also be observed: – The safety rules enforced at the operating site – Legally enforced traffic regulations – Guidelines issued by trade associations

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1.0 - 1 of 2


General Information

Service Manual

Safety regulations

1.1.2 1.

Overview of safety regulations A detailed description of these is included in the relevant section of the "Safety regulations" chapter in the operator's manual. The following sections are described in the operator's manual: 1 Introduction

1.0 - 2 of 2!

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 welding on the machine

16

Instructions for working safely on machine attachments

17

Safety regulations when transporting the machine by crane

18

Safe maintenance of hydraulic hoses and hose lines

19

Attachments and accessories

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Service Manual

General Information Special tools for maintenance and repair work

1.2 Special tools for maintenance and repair work 1.2.1

Special tools, general information

Description Digital thermometer

ID no. 7020372

DCA 4 coolant test kit

5608459

Anti-freeze and battery tester

7408922

24 Volt vacuum pump

7408148 8145359

Use Notes All wheel loaders For taking temperature measurements during adjustment work All wheel loaders For testing DCA 4 and antifreeze levels For testing the acid concentration (battery All wheel loaders charge level) and testing the cooler antifreeze All wheel loaders For preventing oil loss All wheel loaders For testing the hydro accumulators

0-40 bar pressure gauge 0-250 bar pressure gauge 0-600 bar pressure gauge Pressure gauge connection 1500 mm high-pressure tube 4000 mm high-pressure tube Screw coupling M 10 x 1 Oil drain hose Outlet piece Safety cap SW 10

7361288 5002932 5002866 7002436 7002475 7009134 5005180 7005660 7402657 7009315

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 SW 13 Safety cap SW 17 Safety cap SW 19 Safety cap SW 17

7615515 7615589 7009317 7622068

All wheel loaders All wheel loaders All wheel loaders All wheel loaders

Bodem data cable Software + dongle

10285174 69059ďƒŻďƒ°

L544 - L580 L544 - L580

Charging and testing device with case

1.2.2

For testing hydraulic pressures For testing hydraulic pressures For testing hydraulic pressures Connection for pressure gauge High-pressure tube for pressure gauge High-pressure tube for pressure gauge For testing hydraulic pressures For draining oil via an outlet valve For the oil drain hose For securing the valves on the variable displacement motor For securing the valves on the pumps For securing the valves on the pumps For securing the valves on the pumps For securing the valves on the control valve block For adjusting the travel hydraulics, cooling system, joystick steering, and for reading service codes

Special tools for Liebherr diesel engines

Description Compression tester Injection nozzle tester Adapter for compression tester High pressure hand pump with accessories Extracting device for injection nozzles Adapter for extracting device Rotary angle extraction device

ID no. 8008782 7361236 0524044 7009318

Use L544 - L580 diesel engine L544 - L580 diesel engine L544 - L580 diesel engine L544 - L580 diesel engine

0524072

L544 - L580 diesel engine

0524029 0524062

L544 - L580 diesel engine L544 - L580 diesel engine

Krikit 2 V-belt gauge Engine turning tool Engine turning tool

8042829 0524045 9183785

L544 - L580 diesel engine L544 - L580 diesel engine L544 - L580 diesel engine

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Notes For testing compression levels For testing injection nozzles In place of the injection nozzle For testing the delivery begin of the injection pump For removing injection nozzles For use with extracting device For cylinder head, main bearing, and connection lug bearing screws For testing the V-belt tension For turning the engine at the flywheel For turning the engine via the crank shaft

1.2 - 1 of 4


General Information

Service Manual

Special tools for maintenance and repair work

1.2.3 Description 80 mm installation sleeve 90 mm installation sleeve

Special tools for the hydraulic cylinders

ID no. 9227165 9227161

Use Steering cylinder L544, L554 Steering cylinder L564, L574, L580 Lift cylinder L544, L554 Tilt cylinder L544, L554 Lift cylinder L564, L574, L580 Tilt cylinder L564, L574, L580 Steering cylinder L544, L554 Steering cylinder L564, L574, L580 Lift cylinder L544, L554 Tilt cylinder L544, L554 Lift cylinder L564, L574, L580 Tilt cylinder L564, L574, L580 Steering cylinder L544, L554

130 mm installation sleeve 9998624 150 mm installation sleeve 9998622 170 mm installation sleeve 9107931 80 mm expansion tube 9227166 90 mm expansion tube 9227162 130 mm expansion tube 150 mm expansion tube

9110408 9110410

170 mm expansion tube 70/8 mm bearing head assembly wrench 75/12 mm bearing head assembly wrench

9110412 9210219 9239572

1.2.4

Steering cylinder L564, L574, L580

Notes For fitting the seals For fitting the seals For fitting the seals For fitting the seals For fitting the seals For fitting the seals For fitting the seals For fitting the seals For fitting the seals For fitting the seals For fitting the bearing head For fitting the bearing head

Special electrical tools

Description Digital multimeter

ID no. 8502956

Test pin red Test pin black Solenoid tester RS 232 interface Two SUB-D data cables Wire stripping and crimping tool 0.5 – 6.0 mm² Insertion tool Extraction tool Manual crimping tool Wedge extraction tool Size 12 extraction tool for pin and bushing Size 16 extraction tool for pin and bushing

884191214 884191114 8145743 6905859 6905860 8460263

Use Notes All wheel loaders For measuring electrical voltage, current, resistance and frequency All wheel loaders To measure in the DEUTSCH plug All wheel loaders To measure in the DEUTSCH plug All wheel loaders For checking solenoid valves L544 - L554 For reading the service codes L544 - L554 For reading the service codes All wheel loaders For MATE-N-LOK connectors

8145432 7366655 8503647 7026267 8145674

All wheel loaders All wheel loaders All wheel loaders All wheel loaders All wheel loaders

8145673

All wheel loaders For DEUTSCH connectors

1.2 - 2 of 4!

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For MATE-N-LOK connectors For MATE-N-LOK connectors For DEUTSCH connectors For DEUTSCH connectors For DEUTSCH connectors

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Service Manual

General Information Special tools for maintenance and repair work

1.2.5

Special tools for axles

Description Hand pump Clamping pliers

ID no. 8145835 7009536

Use Axles L544 - L580 Axles L554 - L580

Spring hook

8145767

Axles L554 - L580

260 mm slip bushing

7017559

Front axle L554 Rear axle L554 Rear axle L554

Slip bushing M 90 x 1.5 7017558 mm Slip bushing M 110 x 7017557 1.5 mm

Front axle L554 Rear axle L564, L574 Axles L544 - L580 Axles L544 - L580

Handle Handle

7017566 7011518

Installation tool Installation tool

7017563 7017560

Centring shackle 111 mm grooved nut spanner 140 mm grooved nut spanner

7013775 7009537

M 16 x 1.5 gauge

7019556

Clamping fork Installation tool

7011522 7013922

Front axle L554 Rear axle L564, L574 Front axle L554 Rear axle L554, L564, L574 Axles L554 - L580 Axles L554 - L580

84 mm grooved nut spanner 81 mm grooved nut spanner Installation tool (used with handle 7011518) Installation tool

7013773

Axles L554 - L580

10017840

Axles L554 - L580

7624271

Axles L544 AP-409, MT-L 3085

7624272

Axles L544 AP-409, MT-L 3085

Centring shackle Socket spanner Clamping fork

10008138 10008139 10008140

Axles L544 MT-L 3085 Axles L544 MT-L 3085 Axles L544 MT-L 3085

L544 - 443 / 6190 - 7476 L554 - 453 / 0501 - 7476

7011251

Rear axle L554 Front axle L554, L564, L574, 580 Rear axle L564, L574, L580 Axles L554 - L580 Rear axle L554

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Notes For testing the disc brake seals For locking or releasing the snap ring For locking or releasing the return springs Installation aid for brake piston Installation aid for ring gear carrier Installation aid for ring gear carrier Handle for installation tool Handle for various installation tools For installation of grooved nuts Installation aid for sealing ring cartridge For grooved nut spanner For installation of grooved nuts For installation of grooved nuts For measuring wear on the brake discs Installation aid for shaft sealing ring For installation of grooved nuts on the axle drive For installation of grooved nuts on the axle drive For fitting the axle input dust guard For fitting the axle input shaft sealing ring For removing the output For removing the output For removing the output

1.2 - 3 of 4


General Information

Service Manual

Special tools for maintenance and repair work

1.2.6

Special tools for the transfer gear

Description Support tool

ID no. 10016179

Use L544 – L580

Special socket

10016180

L544 – L580

Installation tool

10016181

L544 – L580

1.2.7 Description Central lubrication BEKA MAX data cable + software Central lubrication Groeneveld data cable Groeneveld Plug Adapter Central greasing system Groeneveld Software

Notes Stops the 1 st coupling shaft from moving when tightening the grooved nut For tightening and loosening the grooved nut on the 1st coupling shaft For compressing the piston return springs when fitting and removing the snap ring

Central lubrication system ID no. 10008427

Use Notes All wheel loaders For testing the central lubrication system

7624289

All wheel loaders For testing the central lubrication system

7624290 As below

All wheel loaders For testing the central lubrication system All wheel loaders For testing the central lubrication system

The Groeneveld central greasing system software is ordered directly from Groeneveld. The software is activated by means of an activation code. Steps and necessary data: Company name and department The activation code consists of 6 digits (numbers supplied by user). This data must be sent via E-Mail to the following address: support@groeneveld.nl

1.2.8

Special tools for the air conditioning system

Description

ID no.

Use

Notes

Vacuum pump

7027552

All wheel loaders

For evacuating the air conditioning system

4-valve test set

7027558

All wheel loaders

For testing, evacuating and filling the air conditioning system

Filling hose, blue 1500 mm

7027553

All wheel loaders

For the test set

Filling hose, yellow 1500 mm

7027554

All wheel loaders

For the test set

Filling hose, red 1500 mm

7027555

All wheel loaders

For the test set

Car coupling 253a

7027556

All wheel loaders

For the test set

Car coupling 254a

7027557

All wheel loaders

For the test set

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2 Product description Chapter contents 2 2.1

L544 - 443 / 6190 - 7476 L554 - 453 / 0501 - 7476

Product description

2.0 - 1

Technical data

2.1 - 1

2.1.1

Complete machine

2.1 - 1

2.1.2

Diesel engine, pump distributor gear

2.1 - 4

2.1.3

Cooling system

2.1 - 5

2.1.4

Travel hydraulics

2.1 - 5

2.1.5

Working hydraulics

2.1 - 6

2.1.6

Steering system

2.1 - 7

2.1.7

Brake system

2.1 - 8

2.1.8

Electrical system

2.1 - 9

2.1.9

Transfer gear

2.1 - 9

2.1.10

Axles, tyres

2.1 - 9

2.1.11

Machine frame, counterweight

2.1 - 10

2.1.12

Cab, heating, air-conditioning

2.1 - 11

2.1.13

Lift arm, quick-change device

2.1 - 11

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Service Manual

Product description Technical data

2.1 2.1.1 Wheel loader with Z-bar lift arm

Technical data Complete machine Valid for: L544 - 443 / 6190 - 7476

The values stated refer to the standard version of the machine: – With Z-bar lift arm (2600 mm) without hydraulic quick-change device. – With 23.5 R25 Michelin XHA tyres. – The specified tipping loads and weights include all lubricants, full fuel tank, ROPS/FOPS cab and operator.

Description Bucket capacity as per ISO 7546 Bucket width Specific material density A - Dump height at max. lift and 45° tiltout angle B - Max. dumping height C - Max. height of bucket base D - Max. height of bucket pivot point E - Max. height of bucket upper edge F - Reach at max. lift and 45° tilt-out angle G - Digging depth H - Height of cab I - Height of exhaust J - Ground clearance K - Wheel base

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Value 3.0 2700 1.8 2920

Unit m³ mm t/m³ mm

3500 3645 3915 5350 1040

mm mm mm mm mm

85 3355 3310 530 3150

mm mm mm mm mm

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Product description

Service Manual

Technical data

Description L - Overall length Turning radius over bucket outer edge Lifting force (SAE) Breakout force (SAE) Tipping load when straight Tipping load, articulated 35° Tipping load, articulated 40° Angle of articulation (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 A1-2 (automatic), forward and reverse Travel speed in travel range A1-3 (automatic), forward and reverse Travel speed in travel range A2-3 (automatic), forward and reverse Sound pressure level in the cab – L pA Wheel loader with Z-bar lift arm

Value 7785 6235 170 125 12020 10910 10600 40 15300 122.6 0 - 10

Unit mm mm kN kN kg kg kg ° kg kN km/h

0 - 20 km/h 0 - 20 km/h 0 - 40 km/h 0 - 40 km/h 73 dB

Valid for: L554 - 453 / 0501 - 7476

The values stated refer to the standard version of the machine: – With Z-bar lift arm (2750 mm) without hydraulic quick-change device. – With 23.5 R25 Michelin XHA tyres. – The specified tipping loads and weights include all lubricants, full fuel tank, ROPS/FOPS cab and operator.

2.1 - 2 of 12!

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Service Manual

Product description Technical data

Description Bucket capacity as per ISO 7546 Bucket width Specific material density A - Dump height at max. lift and 45° tiltout angle B - Max. dumping height C - Max. height of bucket base D - Max. height of bucket pivot point E - Max. height of bucket upper edge F - Reach at max. lift and 45° tilt-out angle G - Digging depth H - Height of cab I - Height of exhaust J - Ground clearance K - Wheel base L - Overall length Turning radius over bucket outer edge Lifting force (SAE) Breakout force (SAE) Tipping load when straight Tipping load, articulated 35° Tipping load, articulated 40° Angle of articulation (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 A1-2 (automatic), forward and reverse Travel speed in travel range A1-3 (automatic), forward and reverse Travel speed in travel range A2-3 (automatic), forward and reverse Sound pressure level in the cab – L pA

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Value 3.5 2700 1.8 3085

Unit m³ mm t/m³ mm

3700 3920 4180 5740 1070

mm mm mm mm mm

110 3355 3310 530 3150 8130 6360 180 130 13925 12625 12270 40 17300 136.4 0 - 10

mm mm mm mm mm mm mm kN kN kg kg kg ° kg kN km/h

0 - 20 km/h 0 - 20 km/h 0 - 40 km/h 0 - 40 km/h 73 dB

2.0 - 3 of 12


Product description

Service Manual

Technical data

2.1.2 Diesel engine

Diesel engine, pump distributor gear Valid for:

L544 - 443 / 6190 - 7476

Description Engine type Number of cylinders Cylinder volume Rated power according to ISO 9249 Rated speed Max. torque at 1200 min-1 Lower idling speed Upper idling speed Inlet valve play (cold) Outlet valve play (cold) Max. operating angle Power consumption of starter Output voltage of alternator Current output from alternator Emission limit values comply with Diesel engine

Valid for:

Value Unit D924T-E A2 4 6640 cm³ 121 / 165 kW / hp 2000 min-1 690 Nm -1 800 50 min 2100 +80 min-1 0.25 mm 0.30 mm 45 ° 5.4 kW 28 V 55 A EU – RL 97/68 EG – level 1

L554 - 453 / 0501 - 7476

Description Engine type Number of cylinders Cylinder volume Rated power according to ISO 9249 Rated speed Max. torque at 1200 min-1 Lower idling speed Upper idling speed Inlet valve play (cold) Outlet valve play (cold) Max. operating angle Power consumption of starter Output voltage of alternator Current output from alternator Emission limit values comply with

Value Unit D924T-E A2 4 6640 cm³ 137 / 186 kW / hp 2000 min-1 847 Nm -1 800 50 min 2100 +80 min-1 0.25 mm 0.30 mm 45 ° 5.4 kW 28 V 55 A EU – RL 97/68 EG – level 1

Fuel system Description Tank level FULL Tank level RESERVE Soot particle filter (optional)

2.1 - 4 of 12!

Value Unit 260 l 45 l

This equipment is optional, but is standard with the tunnel version of the machine Description Value Unit Max. permissible exhaust gas counter0.2 bar pressure Additive mixing ratio in litres 1:1000

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Service Manual

Product description Technical data

Refuelling pump (optional)

This equipment is optional. Description Flow rate Max. duty cycle Max. suction height

2.1.3

Value 50 15 4

Unit l/min minutes m

Cooling system

Gear pump Description Displacement RPM at rated engine speed

Value Unit 14 cm³ 2550 min -1

Gear motor Description Displacement of the gear motor Pressure relief valve

2.1.4 Variable displacement pump

Travel hydraulics Valid for:

544 - 443 / 6190 - 7476

Description Control type Max. displacement Flow at rated engine speed RPM at rated engine speed Power output Displacement of the replenishing pump Weight Pressure cut-off Variable displacement pump

Value Unit 16 cm³ 175 10 bar

Valid for:

Value EZ 90 222 2542 111 19.6 60 430 5

Unit cm³ l/min min -1 kW cm³ kg bar

554 - 453 / 0501 - 7476

Description Control type Max. displacement Flow at rated engine speed RPM at rated engine speed Power output Displacement of the replenishing pump Weight Pressure cut-off

Value EZ 90 222 2542 122 19.6 60 430 5

Description Control type Max. displacement Max. speed Torque ( p 400 bar) Weight

Value EP 80 5900 489 34

Unit cm³ l/min min -1 kW cm³ kg bar

Variable displacement motor 1

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Unit cm³ min-1 Nm kg

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Product description

Service Manual

Technical data

Variable displacement motor 2

Variable displacement motor 2

Valid for: L544 - 443 / 6190 - 7476 Description Control type Max. displacement Max. speed Torque ( p 400 bar) Weight Valid for:

Value EP 80 5900 489 34

Unit cm³ min-1 Nm kg

L554 - 453 / 0501 - 7476

Description Control type Max. displacement Max. speed Torque ( p 400 bar) Weight

Value EP 107 5292 653 47

Unit

Description Displacement RPM at rated engine speed

Value Unit 8 cm³ 2550 min -1

cm³ min-1 Nm kg

Scavenging gear pump Variable displacement motors 2

2.1.5

Working hydraulics

Variable displacement pump Description Control type Max. displacement Flow at rated engine speed Power output Flow controller ( p) Power controller at regulation begin Control valve block

Valid for:

Value LRDS 95 234 80 22 2 180 10

Unit cm³ l/min kW bar bar

Value 25 240 / 130 130 / 130 360 5

Unit mm l/min l/min bar

L544 - 443 / from 7477

Description Control piston diameter Control piston lift arm up / down flow rate Control piston tilt in / out flow rate Primary pressure relief valve Pilot control unit

Pilot control hydro accumulator

2.1 - 6 of 12!

Description Float position valve switching pressure

Value Unit 22 bar

Description Hydro accumulator volume Preload pressure (nitrogen filling)

Value Unit 320 cm³ 15 bar

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Service Manual

Product description Technical data

Stabilisation module

Description Cut-off valve Actuator cylinder switching point Safety valve

Value 170 20 260+20 300+10

Unit bar bar bar

Description Number of hydraulic accumulators Hydro accumulator volume Preload pressure (nitrogen filling) Oil filling

Value 5 750 25 2 150

Unit Units cm³ bar cm³

Description Piston diameter Rod diameter Stroke length

Value 130 80 745

Unit mm mm mm

Description Piston diameter Rod diameter Stroke length

Value 150 80 455

Unit mm mm mm

Return suction filter

Description Filtration grade

Value Unit 10 µm

Return strainer

Description Filtration grade

Value Unit 40 µm

Description Filtration grade Inlet opening pressure Outlet opening pressure

Value 10 0.03 0.5

Unit µm bar bar

Value DFR 45 111 37 210 5

Unit

LFD hydro accumulator

Lift cylinder

Tilt cylinder

Breather filter

2.1.6

Steering system

Steering pump Description Type Max. displacement Flow at rated engine speed Power output Pressure cut-off

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cm³ l/min kW bar

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Product description

Service Manual

Technical data

Steering valve Description Displacement Secondary pressure relief Flow amplification

Value Unit 462 cm続 285 10 bar 1 : 1.6

Steering cylinder

Emergency steering pump

Emergency steering pressure switch

Description Piston diameter Rod diameter Stroke length

Value 80 40 405

Description Displacement Pressure relief valve

Value Unit 11 cm続 55 5 bar

Description

Value Unit

Switch type Switching point Emergency steering check pressure switch

Description Switch type Switching point

2.1.7 Brake system gear pump

Compact brake valve

Description Displacement RPM at rated engine speed Valid for:

Valid for:

N/O switch 5 1 bar

Valid for:

Value Unit 4 cm続 2550 min -1

Value Unit 185 5 155 5 bar 73 5 bar

L554 - 453 / 0501 - 7476

Value Unit 185 5 155 5 bar 65 5 bar

L544 - 443 / 6190 - 7477

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

2.1 - 8 of 12!

Value Unit

L544 - 443 / 6190 - 7476

Description Cut-off pressure for accumulator charging Cut-in pressure for accumulator charging Max. brake pressure at pedal stop Brake hydro accumulator

N/O switch 18 1 bar

Brake system

Description Cut-off pressure for accumulator charging Cut-in pressure for accumulator charging Max. brake pressure at pedal stop Compact brake valve

Unit mm mm mm

! MJFCIFSS

Value 4 1000 50

Unit Units cm続 bar

L544 - 443 / 6190 - 7476 L554 - 453 / 0501 - 7476


Service Manual

Product description Technical data

Brake hydro accumulator

Parking brake hydro accumulator

Valid for:

L554 - 453 / 0501 - 7476

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

Value 2 1000 50

Description Hydro accumulator volume Preload pressure (nitrogen filling)

Value Unit 160 cmÂł 50 bar

2.1.8

Electrical system

Electrical system

Description Power supply voltage Battery voltage Battery capacity

2.1.9

Transfer gear

Transfer gear

Description Number of gears 1st gear ratio 2nd gear ratio 3rd gear ratio Weight

2.1.10 Front axle

Valid for:

Value Unit 3 6.103 3.033 1.342 285 kg

L544 - 443 / 6190 - 7476

Valid for:

Value 3.89 6.0 23.33 45 2000 650 30 816

Unit

% mm Nm mm kg

L554 - 453 / 0501 - 7476

Description Differential ratio Wheel hub ratio Total gear ratio Locking value of self-locking differential Wheel base Wheel lug tightening torque Wheel lug spanner size Weight L544 - 443 / 6190 - 7476 L554 - 453 / 0501 - 7476

Unit V V Ah

Axles, tyres Description Differential ratio Wheel hub ratio Total gear ratio Locking value of self-locking differential Wheel base Wheel lug tightening torque Wheel lug spanner size Weight

Front axle

Value 24 12 143

Unit units cmÂł bar

! MJFCIFSS

Value 3.7 6.35 23.495 45 2000 650 30 1054

Unit

% mm Nm mm kg

2.0 - 9 of 12


Product description

Service Manual

Technical data

Rear axle

Valid for:

L544 - 443 / 6190 - 7476

Description Differential ratio Wheel hub ratio Total gear ratio Locking value of self-locking differential Angle of swing Wheel base Wheel lug tightening torque Wheel lug spanner size Weight Rear axle

Valid for:

Valid for:

Rear drive shaft

2.1.11 Counterweight

Valid for:

Unit

% ° mm Nm mm kg

Value Unit 125 Nm

Description Flange tightening torque

Value Unit 285 Nm

Description Flange tightening torque

Value Unit 125 Nm

Machine frame, counterweight Valid for:

L544 - 443 / 6190 - 7476

Valid for:

Value Unit 400 kg 960 Nm

L554 - 453 / 0501 - 7476

Description Mass per counterweight Tightening torque for M24/10.9 bolts

2.1 - 10 of 12!

Value 3.7 6.35 23.495 45 13 2000 650 30 700

L554 - 453 / 0501 - 7476

Description Mass per counterweight Tightening torque for M24/10.9 bolts Counterweight

% ° mm Nm mm kg

L544 - 443 / 6190 - 7476

Description Flange tightening torque Front drive shaft

Unit

L554 - 453 / 0501 - 7476

Description Differential ratio Wheel hub ratio Total gear ratio Locking value of self-locking differential Angle of swing Wheel base Wheel lug tightening torque Wheel lug spanner size Weight Front drive shaft

Value 3.89 6.0 23.33 45 13 2000 650 30 816

! MJFCIFSS

Value Unit 800 kg 960 Nm

L544 - 443 / 6190 - 7476 L554 - 453 / 0501 - 7476


Service Manual

Product description Technical data

2.1.12 Heating, ventilation

Cab, heating, air-conditioning system Description Number of blower speeds Heat output

Air-conditioning system

2.1.13 Z-bar kinematics lift arm

Description Refrigerant Filling quantity Cooling output

4 11.3 kW Value Unit R134a 1800 g 5.6 10% kW

Lift arm, quick-change device Valid for:

L544 - 443 / 6190 - 7476

Description L – Length Z-bar kinematics lift arm

Value Unit

Valid for:

Value Unit 2600 mm

L554 - 453 / 0501 - 7476

Description L – Length

Value Unit 2750 mm

Description A – System connected dimensions Weight

Value Unit 1000 mm 450 kg

Quick-change device

L544 - 443 / 6190 - 7476 L554 - 453 / 0501 - 7476

! MJFCIFSS

2.0 - 11 of 12


3 Maintenance Chapter contents 3 Maintenance 3.1

Maintenance and inspection schedule

3.1 - 1

3.2

Testing and adjustment schedule

3.2 - 1

3.3

Testing and adjustment protocol

3.3 - 1

3.4

Lubricant chart, filling quantities

3.4 - 1

3.5

L544 - 443 / 6190 - 7476! L554 - 453 / 0501 - 7476

3.0 - 1

3.4.1

Table of filling quantities

3.4 - 1

3.4.2

Table of filling quantities

3.4 - 2

3.4.3

Table of filling quantities

3.4 - 3

3.4.4

Table of filling quantities

3.4 - 4

3.4.5

Lubrication chart

3.4 - 5

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 - 7

3.5.3

Checking that all screw connections are tight

3.5 - 7

3.5.4

Sealing any leaks

3.5 - 7

3.5.5

Checking the oil level in the diesel engine

3.5 - 8

3.5.6

Changing the engine oil

3.5 - 9

3.5.7

Replacing the oil filters

3.5 - 9

3.5.8

Checking the V-ribbed belt

3.5 - 10

3.5.9

Checking the valve play

3.5 - 11

3.5.10

Lightly greasing the ring gear on the flywheel

3.5 - 12

3.5.11

Replacing the oil separator

3.5 - 12

3.5.12

Checking the flame glow system

3.5 - 12

3.5.13

Draining off water and sediment from the fuel tank

3.5 - 13

3.5.14

Changing the fine fuel filter

3.5 - 13

3.5.15

Draining off condensate from the fuel separator

3.5 - 14

3.5.16

Draining off condensate from the fine fuel filter

3.5 - 14

3.5.17

Replacing the filter insert in the fuel separator

3.5 - 14

! MJFCIFSS

3.0 - 1 of 4


Service Manual

Maintenance 3.5.18

Cleaning the service cap and dust extraction valve on the air filter

3.5 - 15

3.5.19

Cleaning or replacing the air filter main element

3.5 - 16

3.5.20

Checking the air suction hoses for leaks and tight fitting

3.5 - 17

3.5.21

Checking the oil level in the pump distributor gear

3.5 - 18

3.5.22

Changing the gear oil in the pump distributor gear

3.5 - 18

3.5.23

Checking the exhaust lines for leaks and tight fitting

3.5 - 19

3.5.24

Checking the coolant level

3.5 - 19

3.5.25

Replacing the coolant filter

3.5 - 20

3.5.26

Checking the anti-freeze and DCA-4 concentration in the coolant

3.5 - 21

3.5.27

Cleaning the cooling system

3.5 - 23

3.5.28

Replacing the coolant with anti-freeze and DCA-4

3.5 - 23

3.5.29

Lubricating the pilot control unit, cleaning the magnets and lubricating the universal joints

3.5 - 24

3.5.30

Checking the oil level in the hydraulic tank

3.5 - 25

3.5.31

Draining water and sediment from the hydraulic tank

3.5 - 25

3.5.32

Changing the hydraulic oil and checking the return strainer

3.5 - 25

3.5.33

Checking and cleaning the magnetic rod on the hydraulic tank

3.5 - 26

3.5.34

Changing the return suction filter

3.5 - 27

3.5.35

Replacing the bleeder filter on the hydraulic tank

3.5 - 27

3.5.36

Checking the steering

3.5 - 28

3.5.37

Lubricating the bearing points on the steering cylinders

3.5 - 28

3.5.38

Checking the service brake and parking brake

3.5 - 28

3.5.39

Checking the play and wear on the parking brake

3.5 - 29

3.5.40

Checking the indicator lamps and lighting

3.5 - 30

3.5.41

Checking the batteries, fluid level and terminals

3.5 - 30

3.5.42

Checking the oil level in the transfer gear

3.5 - 31

3.5.43

Changing the gear oil in the transfer gear

3.5 - 32

3.5.44

Changing the gear oil filter

3.5 - 32

3.5.45

Checking the tightness of the wheel lugs (once after 50, 100 and 250 h)

3.5 - 32

3.5.46

Checking the oil level and the axles

3.5 - 33

3.5.47

Checking the axle oil levels

3.5 - 33

3.0 - 2 of 4 MJFCIFSS

L 544 - 443 / 6190 - 7476 L 554 - 453 / 0501 - 7476


Maintenance

Service Manual 3.5.48

Changing the gear oil in the axles L544

3.5 - 34

3.5.49

Changing the gear oil in the axles L554

3.5 - 34

3.5.50

Checking and lubricating the front drive shaft

3.5 - 35

3.5.51

Checking and lubricating the rear drive shaft

3.5 - 35

3.5.52

Setting the correct tyre pressure for the machine's use and attachments

3.5 - 35

3.5.53

Lubricating the oscillating axle frame and articulation bearing

3.5 - 36

3.5.54

Checking whether metered quantities (grease collars) are adequate at the bearing points of the central lubrication system

3.5 - 36

Checking the hose lines of the central lubrication system (lubrication points, detached hoses, external leakage)

3.5 - 37

3.5.56

Lubricating the door hinges

3.5 - 37

3.5.57

Cleaning or replacing the fresh air and re-circulated air filter 3.5 - 37

3.5.58

Checking the indicator beads in the dryer-collector unit

3.5 - 37

3.5.59

Lubricating the lift arms and attachment

3.5 - 38

3.5.60

Check the bucket bearing seals and the bearing bushings on the lift arms

3.5 - 39

3.5.61

Checking the lift arms and bucket stops

3.5 - 40

3.5.55

3.6

L544 - 443 / 6190 - 7476! L554 - 453 / 0501 - 7476

Testing and adjustment tasks

3.6 - 1

3.6.1

Preparatory tasks before checking and adjusting

3.6 - 1

3.6.2

Safety precautions before checking and adjusting

3.6 - 1

3.6.3

Warming up the machine to operating temperature

3.6 - 2

3.6.4

Checking the engine RPM

3.6 - 2

3.6.5

Checking the pressure relief valve of the fan motor and the fan control

3.6 - 3

3.6.6

Calibrating the traction force potentiometer

3.6 - 5

3.6.7

Calibrating the inching pedal angle sensor

3.6 - 5

3.6.8

Calibrating the accelerator pedal angle sensor

3.6 - 6

3.6.9

Calibrating the engine characteristics

3.6 - 7

3.6.10

Checking the replenishing pressure of the variable displacement pump

3.6 - 8

3.6.11

Calibrating the block curve

3.6 - 8

3.6.12

Checking the pressure relief/replenishing valves of the variable displacement pump

3.6 - 9

! MJFCIFSS

3.0 - 3 of 4


Service Manual

Maintenance

3.7

3.6.13

Checking the pressure cut-off of the variable displacement pump

3.6.14

Checking the Q max of the variable displacement motors

3.6 - 10

3.6.15

Checking the Q min of the variable displacement motors

3.6 - 11

3.6.16

Check the power of the diesel engine

3.6 - 12

3.6.17

Checking the LS regulation (delta p) of the working hydraulics pump

3.6 - 13

3.6.18

Checking the load-limit (regulation begin) of the working hydraulics pump

3.6 - 14

3.6.19

Checking the secondary pressure relief valves of the control valve block

3.6 - 14

3.6.20

Checking the primary pressure relief valve of the control valve block

3.6 - 15

3.6.21

Checking the pressure cut-off of the working hydraulics pump

3.6 - 16

3.6.22

Depressurising ride control and hydro accumulator

3.6 - 16

3.6.23

Checking the cut-off valve of the stabilisation module

3.6 - 17

3.6.24

Checking the nitrogen in the ride control hydro accumulators

3.6 - 18

3.6.25

Check the pressure cut-off of the steering pump

3.6 - 18

3.6.26

Checking the flow controller (delta P) of the steering pump

3.6 - 18

3.6.27

Checking the cut-off pressure at the compact brake valve 3.6 - 19

3.6.28

Checking the braking pressure at the axles

3.6 - 19

3.6.29

Checking the brake accumulator capacity

3.6 - 20

3.6.30

Checking the brake accumulator capacity

3.6 - 21

3.6.31

Checking the charged accumulator switching pressure 3.6 - 21

3.6.32

Checking the brake lights and brake light pressure switch 3.6 - 22

3.6.33

Checking the operating pressure of the transmission

3.6 - 22

3.6.34

Checking the nitrogen in the transmission hydro accumulator

3.6 - 22

Lubricants and fuels

3.6 - 9

3.7 - 1

3.7.1

Handling lubricants and fuels

3.7 - 1

3.7.2

Lubricant and fuel specifications

3.7 - 2

3.0 - 4 of 4 MJFCIFSS

L 544 - 443 / 6190 - 7476 L 554 - 453 / 0501 - 7476


Service Manual

Maintenance Maintenance and inspection schedule

3.1

Maintenance and inspection schedule Various symbols (solid or empty circles, boxes and stars) are used to indicate the maintenance tasks, which fall into two main types. The symbols have the following meanings: Table with solid circle, box or star –

Here, the machine operator or his maintenance personnel are responsible for carrying out maintenance tasks.

–

This affects the maintenance intervals every 10 and 50 service hours (h) and non-scheduled intervals.

The symbols have the following meanings: Table with blank circle, box or star, or service hours (h) –

Here, authorised specialist technicians from LIEBHERR or its authorised dealers must perform or direct maintenance and inspection work.

–

This affects the maintenance intervals on delivery, every 500, 1000, 2000 service hours (h), and at unscheduled times.

You will find a list of the spare parts needed for maintenance and inspection work in the SERVICE PACKAGE of the spare parts list.

L544 - 443 / 6190 - 7476! L554 - 453 / 0501 - 7476

! MJFCIFSS

3.1 - 1 of 4


Maintenance

Service Manual

Maintenance and inspection schedule Customer: .............................................. Machine type: .................... Ser. no.: ............................. Oper. hours: .............. Date: ...................... Maintenance/inspection at operating hours

WORK TO BE PERFORMED By maintenance personnel By authorised qualified personnel One-off activity One-off activity Repetition interval Repetition interval If necessary If necessary Annually at the start of the cold season Have the operator lubricate the machine in accordance with the lubrication chart and instruct him on proper maintenance Instruct the operator in the operation of all functions Check the machine for external damage Check that all nuts and bolts are tight Seal any leaks Check the hydraulic pressure according to the testing and adjustment schedule Diesel engine, pump distributor gear Check the oil level in the diesel engine

250h

Change the engine oil (once after 500 h, then every 250 h or 500 h, depending on oil specifications) Replace the oil filters Check and replace the ribbed V- belt Check the valve play Lightly grease the ring gear on the flywheel

3000h Replace the oil separator (minimum of every 2 years) Check the flame glow system Drain off water and sediment from the fuel tank Replace the fuel fine filter Drain off condensate from the fuel separator Replace the filter insert in the fuel separator Clean the service cap and dust extraction valve on the air filter Clean or replace the air filter main element (replace the safety element after having replaced the main element 3 times) Check the air suction hoses for leaks and tight fitting Check the oil level in the pump distributor gear Change the oil in the pump distributor gear Check the exhaust lines for leaks and tight fitting Cooling system Check the coolant level Replace the coolant filter Check the anti-freeze protection and DCA-4 concentration in the coolant Clean the cooling system 3000h Replace the coolant with anti-freeze protection and DCA-4 (at least every 2 years)

3.1 - 2 of 4 MJFCIFSS

L 544 - 443 / 6190 - 7476 L 554 - 453 / 0501 - 7476


Service Manual

Maintenance Maintenance and inspection schedule

Customer: .............................................. Machine type: .................... Ser. no.: ............................. Oper. hours: .............. Date: ...................... Maintenance/inspection at operating hours

WORK TO BE PERFORMED By maintenance personnel One-off activity Repetition interval If necessary Annually at the start of the cold season

By authorised qualified personnel One-off activity Repetition interval If necessary

Working hydraulics Lubricate the pilot control unit, clean the magnets and lubricate the universal joints Check the oil level in the hydraulic tank Drain water and sediment from the hydraulic tank Change the hydraulic oil and check the return strainer 250h

Check and clean the magnetic rod on the hydraulic tank Change the return suction filter Replace the breather filter on the hydraulic tank Steering system Check the steering Lubricate the bearing points on the steering cylinders Brake system Check the service brake and parking brake Check the play and wear on the parking brake Electrical system Check the indicator lamps and lighting Check the batteries, fluid level and terminals Transmission Check the oil level in the transmission Change the oil in the transmission Change the oil filter Axles, tyres Check the tightness of the wheel lugs (once after 50, 100 and 250 h) Check the axle oil levels Change the axle gear oil Check and lubricate the front drive shaft Check and lubricate the rear drive shaft Set the correct tyre pressure for the machine's use and attachments Machine frame, counterweight Lubricate the oscillating axle frame and articulation bearing

L544 - 443 / 6190 - 7476! L554 - 453 / 0501 - 7476

! MJFCIFSS

3.1 - 3 of 4


Maintenance

Service Manual

Maintenance and inspection schedule

Customer: .............................................. Machine type: .................... Ser. no.: ............................. Oper. hours: .............. Date: ...................... Maintenance/inspection at operating hours

WORK TO BE PERFORMED By maintenance personnel One-off activity Repetition interval If necessary Annually at the start of the cold season Central lubrication system

By authorised qualified personnel One-off activity Repetition interval If necessary

Check whether the metered quantities from the central lubrication system are adequate for all bearing points Check the hose lines of the central lubrication system (lubrication points, detached hoses, external leakage) Cab, heating, air-conditioning system Lubricate the door hinges Clean or replace the fresh air and re-circulating air filters Check the indicator beads in the dryer unit Lift arm, quick-change device Lubricate the lift arms and attachment Check the bucket bearing seals and the bearing bushings on the lift arms Check the lift arms and bucket stops

3.1 - 4 of 4 MJFCIFSS

L 544 - 443 / 6190 - 7476 L 554 - 453 / 0501 - 7476


Service Manual

Maintenance Testing and adjustment schedule

3.2

Testing and adjustment schedule Only LIEBHERR trained, personnel may perform the tasks listed in the testing and adjustment schedule. For a short description of how to perform the adjustments and inspection tasks, see the testing and adjustment protocol section. For a detailed description of how to perform these tasks, see the section on testing and adjustment tasks.

L544 - 443 / 6190 - 7476! L554 - 453 / 0501 - 7476

! MJFCIFSS

3.2 - 1 of 2


Maintenance

Service Manual

Testing and adjustment schedule Customer: .............................................. Machine type: .................... Ser. no.: ............................. Oper. hours: .............. Date: ...................... Maintenance/inspection at operating hours

WORK TO BE PERFORMED By authorised qualified personnel One-off activity Repetition interval If necessary Diesel engine Check the speed on the diesel engine Cooling system Check the pressure relief valve of the fan motor and the fan control Travel hydraulics Calibrate the tractive force rotary switch Calibrate the inching pedal angle sensor Calibrate the accelerator pedal angle sensor Record the engine characteristics Check the replenishing pressure of the variable displacement pump Check the pressure relief / replenishing valves of the variable displacement pump Check the pressure cut-off of the variable displacement pump Calibrate the block curve Check the Q max of the variable displacement motors Check the Q min of the variable displacement motors Check the power of the diesel engine Working hydraulics Check the flow controller ( P) on the working hydraulics pump Check the power controller (regulation begin) of the working hydraulics pump Check the secondary pressure relief valves on the control valve block Check the primary pressure relief valve on the control valve block Check the pressure cut-off of working hydraulics pump Check the cut-off valve on the stabilisation module Check the nitrogen in the ride control hydro accumulator Steering system Check the pressure cut-off of the steering pump Check the flow controller ( P) of the steering pump Brake system Check the cut-in and cut-off pressure at the compact brake valve Check the brake pressure at the axles Check the brake accumulator capacity Check the charged accumulator switching pressure Check the brake lights and brake light pressure switch Transmission Check the operating pressure of the transmission Check the nitrogen in the transmission hydro accumulator

3.2 - 2 of 2 MJFCIFSS

L 544 - 443 / 6190 - 7476 L 554 - 453 / 0501 - 7476


Service Manual

Maintenance Testing and adjustment protocol

3.3

Testing and adjustment protocol The testing and adjustment protocol lists all the activities to be performed during testing and adjustment. You will find information that is more detailed in the section testing and adjustment tasks.

L544 - 443 / 6190 - 7476! L554 - 453 / 0501 - 7476

! MJFCIFSS

3.3 - 1 of 6


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Liebherr l544 443 wheel loader service repair manual sn:6190 to 7476  
Liebherr l544 443 wheel loader service repair manual sn:6190 to 7476  
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