Liebherr L524-659 Wheel Loader Service Repair Manual SN FROM 17890 PDF

en
Service Manual
(20
Wheel loader
(10 points)
L524 – L542 2plus1
en
Service Manual
(20
Wheel loader
(10 points)
L524 – L542 2plus1
(10
Address
Address: LIEBHERR-WERK BISCHOFSHOFEN GMBH
Dr. Hans Liebherr – Straße 4

A – 5500 BISCHOFSHOFEN
Product ID
Manufacturer: LIEBHERR-WERK BISCHOFSHOFEN GMBH
Product group: Wheel loader
Type: L524 L528 L538 L542
Production number: 659 660 433 435
Serial number: 17890 17891 17893 17895
Document ID
Order number: 10411314
Author: LBH / Technical Documentation Department
Document version: 01
Manual number:
Owner:
Preface
Intended readership 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.
Chapter 19 contains information on troubleshooting, the service code table
and a description of the “SCULI” service software.
Chapter 20 will be gradually updated with the latest options.
Instructions on use This manual describes several types and versions of machines. The
information generally applies to the types and serial numbers stated at the
bottom of the page. The exception to this is information which only applies to
specific types and serial numbers, which are stated at the beginning of the
section concerned (for example technical data of parts).
Where possible, the ID numbers of parts and components are stated in
the heading.
This manual is available in German, English, French, Spanish, Italian and
Russian.
Working instructions Always follow the safety regulations whenever you work on the machine.
You will find a reference to this in the “General Information” section.
In order to perform these tasks you need a complete set of basic tools
andcertain special tools, all in perfect working order. All tasks require
absolute cleanliness.
Replace seals such as O-rings and surface seals during repairs.
DVD edition Please note that this manual is not only available in printed form, but is also
available as electronic documentation on DVD (Lidos).
General information 1
Product description 2
Maintenance 3
Diesel engine and pump distributor gear 4
Cooling system 5
Travel hydraulics 6
Working hydraulics 7
Steering system 8
Brake system 9
Electrical system 10
Transfer gear 11
Axles 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
Service codes and diagnosis 19
Options 20
1 General informations
1.0
Chapter contents
1 General informations........................................................... 1.0-1
1.1 Safety regulations ...........................................................................1.1-1

1.1.1 Introduction...........................................................................1.1-1
1.1.2 Overview of the safety regulations .......................................1.1-2
1.2 Special tools for maintenance and repair work...............................1.2-1

1.2.1 Special tools in general ........................................................1.2-1
1.2.2 Special tools for Liebherr diesel engines..............................1.2-1
1.2.3 Special tools for hydraulic cylinders .....................................1.2-2
1.2.4 Special tools for electronics..................................................1.2-3
1.2.5 Special tools for axles...........................................................1.2-3
1.2.6 Central lubrication system ....................................................1.2-4
1.2.7 Special tools for the air conditioning system ........................1.2-4
1.3 Standard .........................................................................................1.3-1

1.3.1 Anziehmomente für SchraubenFehler! Textmarke nicht definiert.
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Service manual General informations
Safety regulations
1.1 Safety regulations

Working on the machine poses safety risks to the operator, driver or
maintenance engineers. You can prevent risks and accidents by regularly
reading and observing the various safety instructions.
This is especially important for personnel who only occasionally work on the
machine, for example, carrying out rigging or maintenance work. The safety
regulations listed below, if conscientiously followed, will ensure your own
safety and that of others, and will prevent the machine from being damaged.
Whenever tasks which could cause danger to personnel or damage to the
machine are described, the necessary safety precautions are explained in
this manual.
T These are indicated by the headings Danger, Warning, Caution or
Notice.
1.1.1 Introduction
1. The symbols below have the following meanings:
DANGER
Denotes an urgent, dangerous situation.
Will result in death or serious injury.
Actions to avert the danger.
WARNING
Denotes a dangerous situation.
Can result in death or serious injury.
CAUTION
Risk of personal injury.
Denotes a potentially dangerous situation which can lead to slight injury if
not avoided.
NOTICE
Risk of damage to the machine.
Denotes actions or circumstances which may result in damage to the machine.
Note
Useful information
Denotes information on correctly handling the machine and the lubricants
and fuels used.
Actions to implement.

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General informations Service manual
Safety regulations
2. Observance of these instructions does not exempt you from

following any additional rules and guidelines that may apply
The following should also be observed:
– The safety rules in force at the operating site
– Legally enforceable road traffic regulations
– Guidelines issued by trade associations
1.1.2 Overview of the safety regulations

A detailed description of these can be read in the relevant section of the
safety regulations chapter in the operating manual.
The following sections are included in the operating manual:
1 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
21 Protection against vibrations
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MJFCIFSS L538 - 433 / from 17890
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Safety regulations
1.2 Special tools for maintenance and

repair work
1.2.1 Special tools in general
Description ID no. Use Remarks
For checking the acid concentration
Anti-freeze and battery tester 7408922 All wheel loaders
(battery charging state) and anti-freeze
24 volt vacuum pump 7408148 All wheel loaders For preventing oil loss
Filling and testing device with case 8145359 All wheel loaders For checking the hydro accumulator
Manometer 0 - 40 bar 7361288 All wheel loaders For checking the hydraulic pressure
Manometer connection 7002436 All wheel loaders Connection for the manometer
High pressure hose 1500 mm 7002475 All wheel loaders High pressure hose for manometer
High pressure hose 4000 mm 7009134 All wheel loaders High pressure hose for manometer
Draining hose 7005660 All wheel loaders For draining oil via a drain valve
Drain piece 7402657 All wheel loaders For the drain hose
For securing the valves on the variable
Safety cap 10 mm 7009315 All wheel loaders
adjustment motor
Safety cap 13 mm 7615515 All wheel loaders For securing the valves on the pumps
For securing the valves on the control
Safety cap 17 mm 7622068 All wheel loaders
block
USB dongle 10333608 L524 - L586 With SERVICE authorisation
For adjusting the travel hydraulics, and
Diagnostic data cable 9067426 L524 - L586
testing the electrical system and options
For communicating with the wheel loader
Adapter cable RS232<>USB 693190714 All wheel loaders electronics if there is an error with the
RS232 interface on the notebook.
1.2.2 Special tools for Liebherr diesel engines

Compression tester 8008782 Engine For checking the compression
Nozzle tester 7361236 L538, L542 engine For checking the injection valves
Adapter for compression tester 0524044 L538, L542 engine Instead of the injection valve
Injection valve extraction tool 0524072 L538, L542 engine For removing the injection valves
Extraction tool adapter 0524029 L538, L542 engine For use with the extraction tool
For pushing the piston rings together
Piston ring tensioning belt 8000952 All wheel loaders
during installation of the pistons
Krikit 2 V-belt tester 8042829 L524 - L542 engine For testing the V-belt tension
Flywheel cranking device 0524045 L538, L542 engine For cranking the engine via the flywheel
Shaft seal ring installation tool 7090373 L524, L528 engine For installing the front crankshaft oil seal
Extractor tool 7090377 L524, L528 engine For removing the front wear ring
Extractor tool 7090395 L524, L528 engine For removing the front wear ring
Seal remover 7090372 L524, L528 engine For removing the front crankshaft oil seal
For installing the rear oil seal ring and
Installation set 7090378 L524, L528 engine
wear ring

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Special tools for maintenance and repair work

For measuring the valve depth in the
Depth gauge 7090370 L524 - L542 engine cylinder head and for measuring the
piston and bushing height
For removing the rear crankshaft oil
Extractor tool 7090376 L524, L528 engine
seal ring and wear ring
For installing and removing the
Extractor tool 7090363 L524, L528 engine
cylinder bushings
For screws on cylinder head, main
Angle wrench 0524062 L538, L542 engine
bearing and big end bearing
1.2.3 Special tools for hydraulic cylinders

L524, L528 P kinematics tilt
Assembly sleeve 80 mm 9227165 For fitting the seals
cylinder
L524 - L542 steering cylinder
Assembly sleeve 90 mm 9227161 L538, L542 P kinematics tilt For fitting the seals
cylinder
Assembly sleeve 100 mm 9998626 L524, L528 lift cylinder For fitting the seals
Assembly sleeve 110 mm 9170509 L538, L542 lift cylinder For fitting the seals
L524, L528 Z kinematics tilt
cylinder
cylinder
Expansion sleeve 80 mm 9227166 For fitting the seals
cylinder
Expansion sleeve 90 mm 9227162 L538, L542 P kinematics tilt For fitting the seals
cylinder
Expansion sleeve 100 mm 9110405 L524, L528 lift cylinder For fitting the seals
Expansion sleeve 110 mm 9170511 L538, L542 lift cylinder For fitting the seals
cylinder
cylinder
Piston spanner 80/12 mm 8007364 L524 - L542 lift cylinder For fitting the piston
Piston spanner 88/12 mm 8007365 For fitting the piston
cylinder
cylinder
Piston nut spanner 9921123 L524 - L542 lift cylinder For fitting the piston nut
L524 - L542 P Z kinematics
Piston nut spanner 9921124 For fitting the piston nut
tilt cylinder
cylinder
Piston rod bearing spanner 9210219 For fitting the piston rod bearing
cylinder
Piston spanner 60/14 mm 9131362 cylinder For fitting the piston
Piston rod bearing
0541665 cylinder For fitting the piston rod bearing
spanner 76/9 mm

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Safety regulations
1.2.4 Special tools for electronics

For measuring voltage, current,
Digital multimeter 8502956 All wheel loaders
resistance and frequency
Test probe, red 884191214 All wheel loaders For testing DEUTSCH connectors
Test probe, black 884191114 All wheel loaders For testing DEUTSCH connectors
Magnet tester 8145743 All wheel loaders For checking solenoid valves
Stripping and crimping pliers
8460263 All wheel loaders For MATE-N-LOK connectors
0.5 - 6.0 mm2
Crimping pliers 8503647 All wheel loaders For DEUTSCH connectors
Wedge extractor tool 7026267 All wheel loaders For DEUTSCH connectors
Extraction tool size 12 for pin
8145674 All wheel loaders For DEUTSCH connectors
and bushing
and bushing
and bushing
Plug-in fuse tester 8145834 All wheel loaders For checking the fuses
Wide METRI-PACK For removing terminals on the main
7091022 L524, L528
extractor tool connector of the ECU engine controller
Narrow METRI-PACK For removing terminals on the main
7091023 L524, L528
extractor tool connector of the ECU engine controller
1.2.5 Special tools for axles

L524 - L542 axles For relieving the disc springs and for
Hand pump 8145835
testing the tightness of the disc brakes
L524 - L542 axles For inspecting the wear on the wet disc
Feeler gauge 8145535
brake (T1-2313)
L524 - L542 axles For gripping whilst installing or removing
Set of 5 spanners 10220617
the bevel gear shaft (T5-2386)
L524 - L542 axles For installing the shaft seal ring in the hub
Driver, Øa=185 mm 10220623
(T10-3502)
L524 - L542 axles For removing and fitting the differential
Slotted nut spanner 10220633
gear (T13-3333)
L524 - L542 axles
Handle for driver 10220624 Required for holding the driver
Slotted nut spanner with L524 - L542 axles For removing and fitting the bevel gear
10220626
adapter shaft (T22-3317/A)
L524 - L542 axles For installing the shaft seal ring in the axle
Driver, Øa=62.5 mm 10220631
casing (T34-2322)
L524 - L542 axles For installing the shaft seal ring in the
Driver, Øa=90 mm 10220632
bearing bushing of the axle (T5-3342)

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Special tools for maintenance and repair work
1.2.6 Central lubrication system

BEKA MAX filling press 10009239 All wheel loaders For quickly filling the
BEKA MAX filling port 7029283 All wheel loaders For filling the reservoir
Groeneveld filling press 10333342 All wheel loaders For quickly filling the reservoir
Groeneveld central lubrication
For inspecting the
data cable 7624289 All wheel loaders
central lubrication system
For inspecting the
plug adapter 7624290 All wheel loaders
For inspecting the
software As below All wheel loaders
1.2.7 Special tools for the air conditioning system

For evacuating the air
Vacuum pump 7027552 All wheel loaders
conditioning system
For testing, evacuating and filling the air
4-valve test fitting 7027558 All wheel loaders
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

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Mjfcifss - Standard
1.3 Standard
1.3.1 Tightening torques for screws
Pre-loading forces and tightening torques for screws with standard and fine
metric threads.
Standard and fine metric threads
Standard and fine metric threads. All figures are for bolted connections
All figures are for bolted connections with at least one Dacromet
without any Dacromet 500 coated elements (screws, washers, nuts…)
500 coated element (screws, washers, nuts…)
Surface: Surface:
- DACROMET 500 - black finish or phosphated
- zinc-plated
Assembly pre- Tightening Assembly pre- Tightening
Thread Class loading forces torques Thread Class loading forces torques MA in
FM in N MA in Nm FM in N Nm
for avg. coefficient of friction µG= 0.10 for avg. coefficient of friction µG= 0.12
8.8 4 200 2,5 8.8 4 050 2,8
M4 10.9 6 200 3,7 M4 10.9 6 000 4,1
12.9 7 300 4,3 12.9 7 000 4,8
8.8 6 900 4,9 8.8 6 600 5,5
M5 10.9 10 100 7,3 M5 10.9 9 700 8,1
12.9 11 900 8,5 12.9 11 400 9,5
8.8 9 700 8,5 8.8 9 400 9,5
M6 10.9 14 300 12,5 M6 10.9 13 700 14,0
12.9 16 700 14,5 12.9 16 100 16,5
8.8 14 200 14,0 8.8 13 700 15,5
M7 10.9 20 900 20,5 M7 10.9 20 100 23,0
12.9 24 500 24,0 12.9 23 500 27
8.8 17 900 20,5 8.8 17 200 23
M8 10.9 26 000 30 M8 10.9 25 000 34
12.9 30 500 35 12.9 29 500 40
8.8 19 600 22 8.8 18 800 24,5
M8x1 10.9 28 500 32 M8x1 10.9 27 500 36
12.9 33 500 38 12.9 32 500 43
8.8 25 500 32 8.8 24 800 36
M9x1 10.9 38 000 46 M9x1 10.9 36 500 53
12.9 44 000 54 12.9 42 500 62
8.8 28 500 41 8.8 27 500 46
M10 10.9 42 000 60 M10 10.9 40 000 68
12.9 49 000 71 12.9 47 000 79
8.8 32 500 45 8.8 31 500 52
M10x1 10.9 48 000 67 M10x1 10.9 46 500 76
12.9 56 000 78 12.9 54 000 89
8.8 30 500 43 8.8 29 500 49
M10x1,25 10.9 45 000 64 M10x1,25 10.9 43 000 72
12.9 53 000 74 12.9 51 000 84
8.8 41 500 71 8.8 40 000 79
M12 10.9 61 000 104 M12 10.9 59 000 117
12.9 71 000 121 12.9 69 000 135
8.8 46 500 77 8.8 45 000 87
M12x1,25 10.9 68 000 112 M12x1,25 10.9 66 000 125
12.9 80 000 130 12.9 77 000 150
8.8 44 000 74 8.8 42 500 83
M12x1,5 10.9 65 000 108 M12x1,5 10.9 62 000 122
12.9 76 000 125 12.9 73 000 145
8.8 57 000 113 8.8 55 000 125
M14 10.9 84 000 165 M14 10.9 80 000 185
12.9 98 000 195 12.9 94 000 215
8.8 63 000 121 8.8 61 000 135
M14x1,5 10.9 92 000 175 M14x1,5 10.9 89 000 200
12.9 108 000 205 12.9 104 000 235
This document must not be copied or reproduced without prior permission. This Liebherr-Norm_DE_V001.dot
document has been electronically prepared and is valid without requiring a signature.
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Mjfcifss - Standard

8.8 78 000 170 8.8 75 000 195
M16 10.9 115 000 250 M16 10.9 111 000 280
12.9 134 000 300 12.9 130 000 330
8.8 85 000 180 8.8 82 000 205
M16x1,5 10.9 125 000 270 M16x1,5 10.9 121 000 300
12.9 147 000 310 12.9 141 000 360
8.8 98 000 245 8.8 94 000 280
M18 10.9 140 000 350 M18 10.9 135 000 390
12.9 164 000 410 12.9 157 000 460
8.8 114 000 270 8.8 110 000 310
M18x1,5 10.9 163 000 390 M18x1,5 10.9 157 000 440
12.9 191 000 450 12.9 184 000 520
8.8 106 000 260 8.8 102 000 290
M18x2 10.9 151 000 370 M18x2 10.9 146 000 420
12.9 177 000 430 12.9 170 000 490
8.8 126 000 350 8.8 121 000 390
M20 10.9 180 000 490 M20 10.9 173 000 560
12.9 210 000 580 12.9 202 000 650
8.8 144 000 380 8.8 139 000 430
M20x1,5 10.9 206 000 540 M20x1,5 10.9 199 000 620
12.9 240 000 630 12.9 232 000 720
8.8 157 000 470 8.8 152 000 530
M22 10.9 224 000 670 M22 10.9 216 000 750
12.9 260 000 780 12.9 250 000 880
8.8 177 000 510 8.8 171 000 580
M22x1,5 10.9 255 000 720 M22x1,5 10.9 245 000 820
12.9 295 000 840 12.9 285 000 960
8.8 182 000 600 8.8 175 000 670
M24 10.9 260 000 850 M24 10.9 249 000 960
12.9 305 000 1000 12.9 290 000 1 120
8.8 215 000 700 8.8 207 000 760
M24x1,5 10.9 306 000 990 M24x1,5 10.9 295 000 1 090
12.9 358 000 1170 12.9 346 000 1 270
8.8 203 000 640 8.8 196 000 730
M24x2 10.9 290 000 920 M24x2 10.9 280 000 1 040
12.9 340 000 1070 12.9 325 000 1 220
8.8 239 000 880 8.8 230 000 1 000
M27 10.9 340 000 1250 M27 10.9 330 000 1 400
12.9 400 000 1450 12.9 385 000 1 650
8.8 276 000 1010 8.8 267 000 1 110
M27x1,5 10.9 394 000 1440 M27x1,5 10.9 381 000 1 580
12.9 461 000 1690 12.9 445 000 1 850
8.8 265 000 940 8.8 255 000 1 070
M27x2 10.9 375 000 1350 M27x2 10.9 365 000 1 500
12.9 440 000 1550 12.9 425 000 1 800
8.8 290 000 1190 8.8 280 000 1 350
M30 10.9 415 000 1700 M30 10.9 400 000 1 900
12.9 485 000 2000 12.9 465 000 2250
8.8 346 000 1410 8.8 335 000 1 540
M30x1,5 10.9 493 000 2000 M30x1,5 10.9 477 000 2 190
12.9 576 000 2340 12.9 558 000 2 560
8.8 332 000 1370 8.8 321 000 1 490
M30x2 10.9 472 000 1940 M30x2 10.9 457 000 2 120
12.9 553 000 2270 12.9 534 000 2 480
8.8 360 000 1600 8.8 350 000 1 850
M33 10.9 520 000 2300 M33 10.9 495 000 2 600
12.9 600 000 2700 12.9 580 000 3 000
8.8 423 000 1880 8.8 410 000 2 050
M33x1,5 10.9 603 000 2670 M33x1,5 10.9 584 000 2 920
12.9 705 000 3130 12.9 683 000 3 420
8.8 410 000 1750 8.8 395 000 2 000
M33x2 10.9 580 000 2500 M33x2 10.9 560 000 2 800
12.9 680 000 2900 12.9 660 000 3 300
8.8 425 000 2100 8.8 410 000 2 350
M36 10.9 600 000 3000 M36 10.9 580 000 3 300
12.9 710 000 3500 12.9 680 000 3 900
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Mjfcifss - Standard

8.8 508 000 2450 8.8 492 000 2 680
M36x1,5 10.9 724 000 3490 M36x1,5 10.9 701 000 3 820
12.9 847 000 4090 12.9 820 000 4 470
8.8 455 000 2200 8.8 440 000 2 500
M36x3 10.9 650 000 3100 M36x3 10.9 630 000 3 500
12.9 760 000 3600 12.9 740 000 4 100
8.8 510 000 2700 8.8 490 000 3 000
M39 10.9 730 000 3800 M39 10.9 700 000 4 300
12.9 850 000 4500 12.9 820 000 5 100
8.8 601 000 3140 8.8 582 000 3 430
M39x1,5 10.9 857 000 4470 M39x1,5 10.9 830 000 4 890
12.9 1 002 000 5230 12.9 971 000 5 720
8.8 550 000 2800 8.8 530 000 3 200
M39x3 10.9 780 000 4000 M39x3 10.9 750 000 4 600
12.9 910 000 4700 12.9 880 000 5 300
Comments concerning this standard:

The tightening torques indicated on the drawings supersede the standard
works values.
These must be observed and adhered to.
This standard only applies to Liebherr wheel loaders.
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2 Product description
2.0
Chapter contents
2 Product description ............................................................. 2.0-1
2.1 Technical data ................................................................................ 2.0-1

2.1.1 Complete machine ................................................................ 2.0-1
2.1.2 Engine and splitter box ......................................................... 2.0-6
2.1.3 Cooling system ..................................................................... 2.0-8
2.1.4 Travel hydraulics .................................................................. 2.0-9
2.1.5 Working hydraulics ............................................................. 2.0-11
2.1.6 Steering system .................................................................. 2.0-15
2.1.7 Brake system ...................................................................... 2.0-16
2.1.8 Electrical system................................................................. 2.0-17
2.1.9 Transmission ...................................................................... 2.0-18
2.1.10 Axles and cardan shaft ....................................................... 2.0-18
2.1.11 Machine frame and ballast weight ...................................... 2.0-20
2.1.12 Cab, heating and air-conditioning ....................................... 2.0-20
2.1.13 Lift arms and quick-change device ..................................... 2.0-22
2.1.14 Equipment and accessories ............................................... 2.0-23
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Service manual Product description
Technical data
2.1 Technical data

2.1.1 Complete machine
Valid for: L524 - 659 / from 17890
The values stated refer to the standard version of the machine:
With Z lift arms (2400 mm), without hydraulic quick-change device.
With 17.5 5R25 Goodyear GP-2B tyres
Tipping loads and weights include all lubricants, full fuel tank, ROPS/
FOPS cab and driver.
Tyre sizes and additional attachments affect the operating weight and
tipping load.
Dimensions of machine with Z and P lift arms

Item Description Unit Value
Load geometry Z bar P bar
Bucket capacity as per ISO 7546 m³ 2.0 1.7
Bucket width mm 2500 2500
Specific material weight t/m³ 1.8 1.8
A Dump height at maximum lifting height and 45° tilt-out angle mm 2870 2845
B Dump height mm 3335 3370
C Maximum bucket base height mm 3530 3590
D Maximum bucket pivot point height mm 3775 3830
E Maximum bucket top height mm 4860 4980
F Reach at maximum lifting height and 42° tilt-out angle mm 850 1010
G Digging depth mm 80 61
H Height above the cab mm 3200 3200
I Height above exhaust mm 2860 2860
J Ground clearance mm 460 460

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Product description Service manual
Technical data

K Wheel base mm 2750 2750
L Overall length mm 6720 6965
Turning radius over bucket outer edge mm 5520 5610
Lifting force (SAE) kN 100 71
Breakout force (SAE) kN 91 83
Tipping load when straight kg 8310 7150
Tipping load articulated at 40° kg 7300 6300
Angle of articulation (to each side) ° 40 40
Swing angle (to each side) ° 6 6
Operating weight kg 10300 10525
Tractive force daN 81.48 81.48
Travel speed in travel range 1, forward and reverse km/h 0-6 0-6
Travel speed in travel range 2, forward and reverse km/h 0 - 16 0 - 16
Sound pressure level in cab according to ISO 6396 L pA dB (A) 69 69
Valid for: L528 - 660 / from 17890

With 17.5 R25 Goodyear GP-2B tyres
tipping load.
2.0-2 of 23 Copyright L524 - 659 / from 17890

L528 - 660 / from 17890
L542 - 435 / from 17890
Technical data

Valid for: L538 - 433 / from 17890

tipping load.

L528 - 660 / from 17890
L542 - 435 / from 17890
Technical data


L528 - 660 / from 17890
L542 - 435 / from 17890
Technical data
Valid for: L542 - 435 / from 17890

tipping load.


L528 - 660 / from 17890
L542 - 435 / from 17890
Technical data

2.1.2 Engine and splitter box
Engine
Valid for: L524 - 659 / from 17890; L528 - 660 / from 17890;
Description Value Unit
Engine model Liebherr D 504 TI / John Deere CD 4045
Number of cylinders 4 4
Capacity 4500 4500 cm³
Rated power as per ISO 9249 86 / 117 86 / 117 kW /
hp
Rated speed 2400 2400 min-1
Maximum torque at 1500 min-1 430 430 Nm
Lower idle speed 850 10
850 10
min-1
Upper idle speed 2550 20
2550 20
min-1
Inlet valve play (cold) 0,36 0,36 mm
Outlet valve play (cold) 0,46 0,46 mm
Control thermostat opening temperature 82 82 °C
Longitudinal / traverse inclinability 30 / 30 30 / 30 °
Starter operating voltage 24 24 V
Starter power consumption 7 7 kW
Alternator voltage output 27,8 27,8 V
Alternator current output 55 55 A
Emission thresholds comply with EU RL 97/68 EC Stage IIIa
Engine
Valid for: L538 - 433 / from 17890; L542 - 435 / from 17890; ID 1011 8823
Engine model D 934 S A6
Number of cylinders 4
Firing order 1-3-4-2
Capacity 6360 cm³
Cylinder bore 122 mm
Stroke 136 mm

L528 - 660 / from 17890
L542 - 435 / from 17890
Technical data

Rated power as per ISO 9249 105 / 143 kW / hp
Rated speed 2000 min-1
Maximum torque at 1000 - 1300 min-1 770 Nm
Lower idle speed 900 10
min-1
Upper idle speed 2060 20
min-1
Start of delivery Electronic
Compression ratio 17:1
Combustion pressure 20 - 34 bar
Injection nozzle pressure 300 +8/-3 bar
Inlet valve play (cold) 0.30 mm
Outlet valve play (cold) 0.40 mm
Direction of rotation, looking at flywheel Anticlockwise
Number of teeth on flywheel gear 147 Qty.
Control thermostat opening temperature 79 °C
Longitudinal / traverse inclinability 45 / 45 °
Starter operating voltage 24 V
Starter power consumption 5.4 kW
Alternator voltage output 27,8 V
Alternator current output 80 A
Auxiliary power take-off transmission 1:1.234
Weight 965 kg
Emission levels comply with EU RL 97/68/EC Stage IIIa
Fuel tank
Tank capacity, FULL 180 l
Tank capacity, RESERVE 30 l
Fuel pre-filter
Filtration grade 30 µm
Fuel fine filter


L528 - 660 / from 17890
L542 - 435 / from 17890
Technical data
Vacuum switch
Air filter contamination vacuum switch 50 mbar
activation point
Clutch
Torsion damper screw adhesive 241 Loctite
Torsion damper screw tightening torque 49 Nm
Hub star fastening screw tightening torque 86 Nm
Torsion damper screw adhesive 241 Loctite
Torsion damper screw tightening torque 117 Nm
2.1.3 Cooling system
Gear pump
Capacity 16 cm³
Rotary speed at rated engine speed 2323 min-1
Valid for: L538 - 433 / 17890 - 19018; L542 - 435 / 17890 - 19018; ID 1029 5259
Capacity 14 cm³
-1
Rotary speed at rated engine speed 2468 min
Capacity 16 cm³
Rotary speed at rated engine speed 2468 min-1
Gear motor
Valid for: ID 5717 099
Gear motor displacement 16 cm³
5
Pressure relief valve 175 bar
Coil resistance 4.5 Ohm
41
Screw tightening torque 124 Nm

L528 - 660 / from 17890
L542 - 435 / from 17890
Technical data
Temperature sensor (B8, B21)

Measuring range min. -30 °C
max. 130 °C
Resistance at 0 °C 1000 Ohm
Screw thread M 14 x 1.5 mm
Protection class IP 65
Max. tightening torque 30 Nm
Plug connection Bosch Jet plug,
2-pin (Gold contacts)
2.1.4 Travel hydraulics
Variable displacement pump

Valid for: L524 - 659 / from 17890; L528 - 660 / from 17890
Control type EP
Maximum capacity 90 cm³
Flow rate at rated speed 212 l/min
Power 72 kW
Replenishing pump capacity 19.6 cm³
Replenishing pump flow rate (at rated speed) 43 l/min
Inlet restrictor 1.8 mm
Travel direction solenoid current consumption 1.2 A
Travel direction solenoid resistance 22 Ohm
Control pressure proportional valve resistance 12 Ohm
10
Pressure relief and replenishing valves 470 bar
5
Pressure cut-off 440 bar
Weight 60 kg
Control type EP
Power 90 kW

L528 - 660 / from 17890
L542 - 435 / from 17890
Technical data

Replenishing pump capacity 28.3 cm³
Replenishing pump flow rate (at rated speed) 53 l/min
Inlet restrictor 1.8 mm
Travel direction solenoid current consumption 1.2 A
Travel direction solenoid resistance 22 Ohm
Control pressure proportional valve resistance 12 Ohm
10
Pressure relief and replenishing valves 470 bar
5
Pressure cut-off 440 bar
Weight 75 kg
Variable displacement motor 1

Control type HA1R
Maximum displacement 55 cm³
Minimum displacement 40 cm³
Maximum swivel angel 25 °
Minimum swivel angle 18.1 °
Maximum speed 5220 min-1
Torque ( p 400 bar) 356 Nm
5
Start of regulation 250 bar
Current consumption of travel direction 1,2 A
solenoid valve
Resistance of travel direction solenoid 22 Ohm
valve
Current consumption of travel range 1 1,4 A
solenoid valve
Resistance of travel range 1 solenoid valve 19 Ohm
Weight 26 kg
Control type HA1R
Minimum displacement 52 cm³
Minimum swivel angle 16.3 °
5
Start of regulation 250 bar
Current consumption of travel direction 1,2 A
solenoid valve
Resistance of travel direction solenoid 22 Ohm
valve

L528 - 660 / from 17890
L542 - 435 / from 17890
Technical data

Current consumption of travel range 1 1,4 A
solenoid valve
Resistance of travel range 1 solenoid valve 19 Ohm
Weight 34 kg
Variable displacement motor 2

Control type EP
Minimum swivel angle 0 °
Maximum discharge valve capacity 15 l/min
Discharge valve orifice diameter 2.5 mm
Weight 47 kg
Control type EP
Minimum swivel angle 0 °
Maximum discharge valve capacity 15 l/min
Discharge valve orifice diameter 2.5 mm
Weight 60 kg
2.1.5 Working hydraulics
Working hydraulics pump

Control type DFLR
Power 40 kW
2
Flow regulator (delta p) 32 bar
Weight 21 kg
  

L528 - 660 / from 17890
L542 - 435 / from 17890
Technical data
Control type LRDS
Power 51 kW
Power controller start of regulation 190 bar
2
Flow regulator (delta p) 32 bar
Weight 45 kg
Control block
Piston diameter 18 mm
Lift arm up/down control piston flow 140 / 60 l/min
Tilt in/out control piston
120 / 80 l/min
(Z kinematics) flow rate
Tilt in/out control piston
140 / 90 l/min
(P kinematics) flow rate
5
LS pressure cut-off / L524, L528 315 bar
5
Working hydraulics L538, L542 330 bar
5
LS pressure cut-off / L524, L528 230 bar
5
Steering L538, L542 250 bar
3
Pressure relief valve pre-tension 16 bar
Weight 32 kg
Pilot control valve

Retaining solenoid current consumption 0,4 A
Retaining solenoid resistance 70 Ohm
Weight 5,7 kg
Working hydraulics lockout solenoid valve

Current consumption 0,7 A
Resistance 40 Ohm
Pilot control hydro accumulator

Hydro accumulator volume 320 cm³
Preload pressure (nitrogen filling) 15 bar

L528 - 660 / from 17890
L542 - 435 / from 17890
Technical data
Stabilisation module
Control piston diameter 16 mm
20
Cut-off pressure (LFD off) 120 bar
10
Safety valve 330 bar
Restrictor check valve diameter 2.0 / 0.4 mm
Solenoid valve current consumption 0.7 A
Solenoid valve resistance 40 Ohm
Weight 13 kg
Ride control hydro accumulator

2
Oil filling 350 cm³
Lift cylinder
Rod diameter 60 mm
Stroke length 735 mm
Minimum installation length 1170 mm
Weight 80 kg
Lifting at rated load 6.0 sec
Lowering empty 4.0 sec
Piston rod bearing tightening torque (hex 290 Nm
screws)
Piston tightening torque WN - 4121-091 -
Rod diameter 60 mm
Weight 89 kg
Lifting at rated load 6.0 sec
Lowering empty 4.0 sec
Piston rod bearing tightening torque 290 Nm
(hex screws)

L528 - 660 / from 17890
L542 - 435 / from 17890
Technical data
Z kinematics tilt cylinder

Rod diameter 70 mm
Weight 70 kg
Tilt in/out empty 3.0 sec
(hex screws)
Rod diameter 80 mm
Weight 110 kg
(hex screws)
P kinematics tilt cylinder

Rod diameter 50 mm
Weight 53.5 kg
Rod diameter 50 mm
Weight 57 kg

L528 - 660 / from 17890
L542 - 435 / from 17890
Technical data
Filter unit
Pre-tension valve 0.5 bar
Replenishing valve 0.05 bar
Replenishing strainer 160 µm
Bypass valve 2.5 bar
Return strainer 80 µm
Bleeder filter
Filtration grade 10 m
Inlet opening pressure 0.03 bar
Outlet opening pressure 0.5 bar
Thread 3/4 inch
2.1.6 Steering system
Servostat
Displacement 370 cm³
10
Secondary pressure relief 285 bar
Flow booster 1 : 1.6
Steering cylinder
Rod diameter 45 mm
Weight 26.2 kg
Emergency steering pump

Capacity 11 cm²
Pressure relief valve 55 ±5 bar
Emergency steering pump pressure switch

Type Electronic
pressure switch
Switch type Normally open
2
Switching point 16 bar

L528 - 660 / from 17890
L542 - 435 / from 17890
Technical data

Thread M 12 x 1.5 mm
Emergency steering check pressure switch

Type Electronic
pressure switch
2
Switching point 16 bar
2.1.7 Brake system
Brake system gear pump

Capacity 4 cm³
Flow rate at rated speed 9.3 l/min
Speed at rated speed 2322 min-1
Capacity 4 cm³
Flow rate at rated speed 9.9 l/min
Speed at rated speed 2474 min-1
Compact brake valve

Accumulator charge valve 130 ±5 bar
activation pressure
Accumulator charge valve 160 ±5 bar
deactivation pressure
Maximum service brake pressure 60 ±5 bar
Parking brake solenoid valve current 0.6 A
consumption
Parking brake solenoid valve resistance 40 Ohm
Pedal start angle 42°
Pedal stop angle 15°

L528 - 660 / from 17890
L542 - 435 / from 17890
Technical data
Service brake hydro accumulator

Number of hydro accumulators 2 Qty.
Brake light pressure switch

Switch point, rising 5 ±0.5 bar
Disc brake
Brake pad gap 1.0 ±0.5 mm
Brake lining thickness, new 4.5 mm
Minimum brake lining thickness 1.0 mm
Parking brake hydro accumulator

Accumulator charge pressure switch

Type Electronic
pressure switch
Switching point, falling 90 ±5 bar
2.1.8 Electrical system
Battery
Battery voltage 12 V
Battery capacity 135 Ah
Acid density of charged battery 1.26 - 1.28 kg/l
Cold test current (at -18 °C EN 60095-1) 950 A

L528 - 660 / from 17890
L542 - 435 / from 17890
Technical data
2.1.9 Transmission
Transmission
Type 319
Variable displacement motor 1 1.55 -
transmission
Variable displacement motor 2 3.83 -
transmission
Cardan speed at 40 km/h 3098 min-1
Type 319
Variable displacement motor 1 transmission 1.55 -
Variable displacement motor 2 transmission 3.83 -
Cardan speed at 40 km/h 2795 min-1
Speed sensors
Type Inductive sensor -
Resistance at 20 °C 1050 ±100 Ohm
2.1.10 Axles and cardan shaft
Front axle
Type 123/60
Self-locking differential level 45 %
Width 1960 mm
Overall transmission 18.6
Differential transmission 10/31
Wheel hub transmission 1/6
Wheel lug tightening torque 650 Nm
Wheel lug spanner size 30 mm
Flange size 1920 mm
Weight 570 kg
Type 113/58
Width 1900 mm

L528 - 660 / from 17890
L542 - 435 / from 17890
Technical data

Flange size 1920 mm
Weight 720 kg
Rear axle
Type 123/51
Width 1960 mm
Swing angle (to each side) 6 °
Flange size 1920 mm
Weight 680 kg
Type 113/50
Width 1900 mm
Swing angle (to each side) 6 °
Flange size 1920 mm
Weight 840 kg
Cardan shaft
Minimum length 1875 mm
Width 2020 mm
Weight 27.5 kg

L528 - 660 / from 17890
L542 - 435 / from 17890
Technical data
Minimum length 1967 mm
Width 2122 mm
Weight 30.5 kg
2.1.11 Machine frame and ballast weight
Ballast weight
Left ballast weight 515 kg
Right ballast weight 565 kg
Valid for: L528 - 660 / from 17890

Valid for: L542 - 435 / from 17890

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

Rated voltage 24 V
Number of blower levels 6
Maximum fan current consumption 15.7 A
Maximum air flow 600 m³/h
Heating power 11 kW
Air conditioning system

Refrigerant R134a
Refrigerant oil (PAG oil) ZXL 100 PG
Coolant quantity 1050+50 g
10%
Cooling power 9.7 kW

L528 - 660 / from 17890
L542 - 435 / from 17890
Technical data
Refrigerant R134a
Coolant quantity 1250+50 g
10%
Air conditioning compressor

Type SD7H15
Capacity 154.9 cm³
(SP 10)
Filling quantity 200 cm³
Maximum current consumption 2.63 A
Weight without oil 6.9 kg
Condenser
Maximum air flow 4000 m³/h
Heating power 9.7 ±1 kW
Test pressure 35 bar
Dryer collector unit

Contents 0.70 l
Leak test 30 bar
Dryer water consumption 16 g
Burst pressure 130 bar
Pressure switch
Low pressure OFF 1.5 ±0.5 bar
Low pressure ON 3.5 bar
High pressure OFF 25 ±2 bar
High pressure ON 18 ±1.5 bar
Fan OFF 15 ±1 bar
Fan ON 19 ±1 bar

L528 - 660 / from 17890
L542 - 435 / from 17890
Technical data
Evaporator
±10%
Temperature sensor activation temperature 5.5 °C
±10%
Temperature sensor deactivation temperature 4.5 °C
Temperature sensor B26

Operating temperature -40 - +125 °C
Resistance at -5 °C 42330 Ohm
Protection class IP 68
2.1.13 Lift arms and quick-change device
Lift arms with Z kinematics

L length 2400 mm
Weight 962 kg
L length 2500 mm
Weight 1072 kg
Lift arms with P kinematics

L length 2500 mm
L high lift length 3000 mm
Weight (without QCD) 1165 kg
L length 2500 mm
L high lift length 3000 mm
Weight (without QCD) 1165 kg

L528 - 660 / from 17890
L542 - 435 / from 17890
Technical data
Hydraulic quick-change device for Z lift arms.

A system connection size 1000 mm
Weight 300 kg
Hydraulic quick-change device for P lift arms.

A system connection size 1000 mm
Weight 230 kg
2.1.14 Equipment and accessories
Bucket
Valid for: L524 - 659 / from 17890
B bucket width 2500 mm
Specific material weight 1.8 t/m³
Heaped bucket capacity (ISO 7546) 2 m³
Valid for: L528 - 660 / from 17890

Heaped bucket capacity (ISO 7546) 2.2 m³
Valid for: L538 - 433 / from 17890

Valid for: L542 - 435 / from 17890

Forklift
Fork carrier prong size FEM III
Prong length 1200 mm

L528 - 660 / from 17890
L542 - 435 / from 17890
3 Maintenance
3.0
Chapter contents
3 Maintenance........................................................................ 3.0-1
3.1 Maintenance and inspection schedule ...........................................3.1-1
3.2 Testing and adjustment plan...........................................................3.2-1
3.3 Testing and adjustment checklists..................................................3.3-1
3.4 Lubrication chart and filling quantities ............................................3.4-1

3.4.1 Table of filling quantities L524, L528....................................3.4-1
3.4.2 Table of filling quantities L538, L542....................................3.4-2
3.4.3 Lubrication chart L524, L528................................................3.4-4
3.4.4 Lubrication chart L538, L542................................................3.4-6
3.5 Maintenance tasks..........................................................................3.5-1

3.5.1 Preparatory tasks for maintenance ......................................3.5-1
3.5.2 Removing loose parts, dirt, ice and snow from the
machine ................................................................................3.5-5
3.5.3 Checking the machine for external damage.........................3.5-5
3.5.4 Making sure the bolted connections are tight.......................3.5-5
3.5.5 Sealing leaks ........................................................................3.5-5
3.5.6 Checking the engine oil level L524, L528.............................3.5-6
3.5.7 Checking the engine oil level L538, L542.............................3.5-6
3.5.8 Changing the engine oil L524, L528.....................................3.5-7
3.5.9 Changing the engine oil L538, L542.....................................3.5-8
3.5.10 Changing the engine oil filterL524, L528..............................3.5-9
3.5.11 Changing the engine oil filterL538, L542............................3.5-10
3.5.12 Checking the V-ribbed belt L524, L528 ..............................3.5-11
3.5.13 Checking the V-ribbed belt L538, L542 ..............................3.5-12
3.5.14 Checking the valve play L524, L528 ..................................3.5-14
3.5.15 Checking the valve play L538, L542 ..................................3.5-16
3.5.16 Checking the heating flange L524, L528............................3.5-18
3.5.17 Checking the heating flange L538, L542............................3.5-18
3.5.18 Greasing the ring gear on the flywheel L538, L542 ...........3.5-19
3.5.19 Changing the oil separator filter insert L538, L542 ............3.5-20
3.5.20 Checking the bearings and condition of the engine
control units L524, L528 .....................................................3.5-20

L528 - 660 / from 17890
L542 - 435 / from 17890
Maintenance Service manual
3.5.21 Checking the bearings and condition of the engine

control units L538, L542 .................................................... 3.5-21
3.5.22 Checking the sensors and cable connections L524,
L528 ................................................................................... 3.5-21
3.5.23 Checking the sensors and cable connections L538,
L542 ................................................................................... 3.5-22
3.5.24 Changing the fuel pre-filter L524, L528 ............................. 3.5-23
3.5.25 Changing the fuel pre-filter L538, L542 ............................. 3.5-24
3.5.26 Changing the fuel fine filter L524, L528............................. 3.5-25
3.5.27 Changing the fuel fine filter L538, L542............................. 3.5-26
3.5.28 Draining off condensate from the fuel filter L524,L52........ 3.5-27
3.5.29 Draining off condensate from the fuel filter L538,L542...... 3.5-28
3.5.30 Bleeding the fuel system L524, L528 ................................ 3.5-29
3.5.31 Bleeding the fuel system L538, L542 ................................ 3.5-30
3.5.32 Draining off condensate and sediment from the fuel
tank .................................................................................... 3.5-32
3.5.33 Cleaning the air filter service cap and dust extraction
valve................................................................................... 3.5-32
3.5.34 Test the air filter vacuum switch ........................................ 3.5-33
3.5.35 Changing the air filter main element when indicated by
the vacuum switch ............................................................. 3.5-33
3.5.36 Changing the air filter secondary element ......................... 3.5-34
3.5.37 Checking the air suction hoses for leaks and tight fitting .. 3.5-35
3.5.38 Checking the exhaust lines for leaks and tight fitting ........ 3.5-36
3.5.39 Checking the coolant antifreeze and corrosion inhibitor
concentration ..................................................................... 3.5-36
3.5.40 Cleaning the cooling system.............................................. 3.5-40
3.5.41 Changing the coolant L524, L528...................................... 3.5-41
3.5.42 Changing the coolant L538, L542...................................... 3.5-42
3.5.43 Checking the oil level in the hydraulic tank........................ 3.5-43
3.5.44 Draining off condensate and sediment from the
hydraulic tank..................................................................... 3.5-43
3.5.45 Changing the oil in the hydraulic tank................................ 3.5-44
3.5.46 Checking and cleaning the magnetic rod on the
hydraulic tank..................................................................... 3.5-46
3.5.47 Changing the hydraulic tank return suction filter ............... 3.5-46
3.5.48 Changing the hydraulic tank bleeder filter ......................... 3.5-47
3.5.49 Lubricating the pilot control device solenoids, universal
joints and tappets............................................................... 3.5-47
3.5.50 Testing the steering ........................................................... 3.5-48
3.5.51 Lubricating the bearing points on the steering cylinders ... 3.5-48
3.5.52 Testing the service brake and parking brake..................... 3.5-48
3.5.53 Checking the gap and wear on the parking brake linings.. 3.5-49
3.5.54 Checking the indicator lamps and lighting ......................... 3.5-50

L528 - 660 / from 17890
L542 - 435 / from 17890
Service manual Maintenance
3.5.55 Checking the batteries, fluid level and terminals................3.5-51

3.5.56 Checking the transfer gear oil level ....................................3.5-52
3.5.57 Changing the transmission oil ............................................3.5-52
3.5.58 Checking the wheel tightness.............................................3.5-53
3.5.59 Checking the axle oil levels ................................................3.5-53
3.5.60 Changing the axle oil ..........................................................3.5-55
3.5.61 Checking the tyre pressure ................................................3.5-56
3.5.62 Lubricating the articulation bearing and rear oscillating
bearing................................................................................3.5-57
3.5.63 Greasing the cab door hinges ............................................3.5-57
3.5.64 Checking / topping up the windscreen washer reservoir....3.5-58
3.5.65 Cleaning the fresh air and recirculated air filter..................3.5-58
3.5.66 Changing the fresh air and recirculated air filter ................3.5-59
3.5.67 Checking the indicator and filling level beads in the
dryer-collector unit (optional) of the air conditioner ............3.5-60
3.5.68 Lubricating the lift arms and attachment (Z kinematics).....3.5-61
3.5.69 Lubricating the lift arms and attachment (P kinematics) ....3.5-61
3.5.70 Checking the lift arm bearing bushings ..............................3.5-62
3.5.71 Checking the lift arm bucket stops (Z kinematics)..............3.5-63
3.5.72 Lubricating and testing the quick-change device ...............3.5-64
3.6 Testing and adjustment tasks .........................................................3.6-1

3.6.1 Preparing for testing and adjustment ...................................3.6-1
3.6.2 Bringing the machine up to operating temperature ..............3.6-2
3.6.3 Checking the fan motor and fan control pressure
relief valve ............................................................................3.6-2
3.6.4 Calibrating the pedals...........................................................3.6-4
3.6.5 Checking the engine speed..................................................3.6-4
3.6.6 Checking the replenishing pressure of the variable
displacement pump L524, L528 ...........................................3.6-5
3.6.7 Checking the replenishing pressure of the variable
3.6.8 Checking the pressure relief and replenishing valve of
the variable displacement pump...........................................3.6-5
3.6.9 Checking the pressure cut-off of the variable
3.6.10 Checking the pressure cut-off of the variable
3.6.11 Calibrating the block curve L524, L528 ................................3.6-8
3.6.12 Calibrating the block curve L538, L542 ................................3.6-9
3.6.13 Checking the start of regulation for variable
displacement motor 1 L524, L528 ......................................3.6-10
3.6.14 Checking the start of regulation for variable
displacement motor 1 L538, L542 ......................................3.6-10

L528 - 660 / from 17890
L542 - 435 / from 17890
Maintenance Service manual
3.6.15 Calibrating variable displacement motor 2 ........................ 3.6-11

3.6.16 Checking the engine output ............................................... 3.6-12
3.6.17 Checking the secondary pressure relief valves on the
control block L524, L528.................................................... 3.6-13
3.6.18 Checking the secondary pressure relief valves on the
control block L538, L542.................................................... 3.6-14
3.6.19 Checking the LS pressure cut-off on the control block
L524, L528 ......................................................................... 3.6-14
3.6.20 Checking the LS pressure cut-off on the control block
L538, L542 ......................................................................... 3.6-15
3.6.21 Checking the flow controller of the working
hydraulics pump L524, L528.............................................. 3.6-15
3.6.22 Checking the flow controller of the working
hydraulics pumpL538, L542............................................... 3.6-16
3.6.23 Depressurising ride control and the hydro accumulators .. 3.6-16
3.6.24 Checking the cut-off pressure in the stabilisation
module ............................................................................... 3.6-16
3.6.25 Checking the nitrogen in the ride control hydro
accumulator........................................................................ 3.6-17
3.6.26 Checking the opening and closing pressure of the
compact brake valve.......................................................... 3.6-18
3.6.27 Checking the brake pressure at the axles ......................... 3.6-18
3.6.28 Checking the capacity of the brake accumulators ............. 3.6-19
3.6.29 Check the accumulator charge pressure........................... 3.6-19
3.6.30 Check the brake light pressure switch and brake lights .... 3.6-20
3.7 Lubricants and fuels....................................................................... 3.7-1

3.7.1 Diesel fuels .......................................................................... 3.7-2
3.7.2 Lubricating oils for diesel engines ....................................... 3.7-3
3.7.3 Coolant for the engine ......................................................... 3.7-5
3.7.4 Hydraulic fluid ...................................................................... 3.7-8
3.7.5 Lubricating oils for the transmission .................................. 3.7-11
3.7.6 Grease for general lubrication points................................. 3.7-12

L528 - 660 / from 17890
L542 - 435 / from 17890
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Dr. Hans Liebherr – Straße 4

1.1 Safety regulations ...........................................................................1.1-1

1.2 Special tools for maintenance and repair work...............................1.2-1

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

L524 - 659 / from 17890 copyright 1.0-1 of 2

1.1 Safety regulations

L524 - 659 / from 17890 copyright 1.1-1 of 2

2. Observance of these instructions does not exempt you from

1.1.2 Overview of the safety regulations

1.1-2 of 2 copyright L524 - 659 / from 17890

1.2 Special tools for maintenance and

1.2.2 Special tools for Liebherr diesel engines

L524 - 659 / from 17890 copyright 1.2-1 of 4

Description ID no. Use Remarks

1.2.3 Special tools for hydraulic cylinders

1.2-2 of 4 copyright L524 - 659 / from 17890

1.2.4 Special tools for electronics

1.2.5 Special tools for axles

L524 - 659 / from 17890 copyright 1.2-3 of 4

1.2.6 Central lubrication system

1.2.7 Special tools for the air conditioning system

1.2-4 of 4 copyright L524 - 659 / from 17890

Assembly pre- Tightening Assembly pre- Tightening

Assembly pre- Tightening Assembly pre- Tightening

Comments concerning this standard:

2.1 Technical data ................................................................................ 2.0-1

L524 - 659 / from 17890 Copyright 2.0-1 of 2

2.1 Technical data

Dimensions of machine with Z and P lift arms

L524 - 659 / from 17890 Copyright 2.0-1 of 23

Item Description Unit Value

Valid for: L528 - 660 / from 17890

Dimensions of machine with Z and P lift arms

2.0-2 of 23 Copyright L524 - 659 / from 17890

Item Description Unit Value

Valid for: L538 - 433 / from 17890

L524 - 659 / from 17890 Copyright 2.0-3 of 23

Dimensions of machine with Z and P lift arms

2.0-4 of 23 Copyright L524 - 659 / from 17890

Valid for: L542 - 435 / from 17890

Dimensions of machine with Z and P lift arms

L524 - 659 / from 17890 Copyright 2.0-5 of 23

Item Description Unit Value

2.1.2 Engine and splitter box

2.0-6 of 23 Copyright L524 - 659 / from 17890

Description Value Unit

Fuel fine filter

L524 - 659 / from 17890 Copyright 2.0-7 of 23

2.1.3 Cooling system

2.0-8 of 23 Copyright L524 - 659 / from 17890

Temperature sensor (B8, B21)

2.1.4 Travel hydraulics

Variable displacement pump

L524 - 659 / from 17890 Copyright 2.0-9 of 23

Description Value Unit

Variable displacement motor 1

2.0-10 of 23 Copyright L524 - 659 / from 17890

Description Value Unit

Variable displacement motor 2

2.1.5 Working hydraulics

Working hydraulics pump

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