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Service Manual
(20
Wheel Loader
(10 points)
L524 / L534 / L538(10
en
Service Manual
(20
Wheel Loader
(10 points)
L524 / L534 / L538
(10
Address
LIEBHERR-WERK BISCHOFSHOFEN GMBH
Product ID
Manufacturer: LIEBHERR-WERK BISCHOFSHOFEN GMBH
Product group: Wheel loader
Type: L524 L534 L538
Production number: 438 434 432
Serial number: from 0101 from 0101 from 0101
Document ID
Order number: 8450818
Author: LBH / T-DOK department
Document version: 02
Manual number:
Owner:
Preface
Target group This service manual is addressed to anyone whose task it is to ensure that
the machines are ready for everyday use. This especially includes mecha-
nics 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, descrip-
tion of maintenance tasks, testing and adjustment tasks and specifications of
fuel and lubricants.
The technical description of the machine is in the following chapters,
structured according to fifteen function groups. The layout, function and
technical data of the groups, components and parts are explained.
Instructions on use This manual describes several types and versions of machines. The
information generally applies to the types and serial numbers stated at the
bottom of the page. The exception to this is information which only applies to
specific types and serial numbers, which are stated at the beginning of the
section concerned (for example technical data of parts).
Where possible, the ID numbers of parts and components are stated in
the heading.
This manual is available in German, English and French.
Working instructions Always follow the safety regulations whenever you work on the machine.
You will find a reference to this in the “General Information” section.
In order to perform these tasks you need a complete set of basic tools
and certain special tools, all in perfect working order. All tasks require
absolute cleanliness.
Replace seals such as O-rings and surface seals during repairs.
DVD edition Please note that this manual is not only available in printed form, but is also
available as electronic documentation on DVD (Lidos).
General information 1
Product description 2
Maintenance 3
Diesel engine 4
Cooling system 5
Travel hydraulics 6
Working hydraulics 7
Steering system 8
Brake system 9
Electrical system 10
Transfer gear 11
Axles and cardan shaft 12
Machine frame and ballast weight 13
Central lubrication system 14
Coverings and access 15
Cab, heating and air-conditioning 16
Lift arms and quick-change device 17
Equipment and accessories 18
Repairs and troubleshooting 19
Options 20
1 General Information
1.0
Chapter contents
1 General Information ............................................................ 1.0-1
1.1.1 Introduction
1. The symbols below have the following meanings:
Danger Danger
Warning that without appropriate precautions, certain procedures could
result in fatal accidents.
Warning
Warning
Warning that without appropriate precautions, certain procedures could
result in severe physical injuries.
Caution
Caution
Warning that without appropriate precautions, certain procedures could
result in minor physical injuries or damage to the machine.
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
Chapter contents
2 Product Description............................................................. 2.0-1
Wheel loader with P lift arms Valid for: L524 - 438 / from 0101
Wheel loader with Z lift arms Valid for: L534 - 434 / from 0101
The values stated refer to the standard version of the machine:
With Z lift arms (2500 mm), without hydraulic quick-change device.
With 20.5 R25 Goodyear GP-2B tyres.
Tipping loads and weights include all lubricants, full fuel tank,
ROPS/FOPS cab and driver.
Tyre sizes and additional attachments affect the operating weight and
tipping load.
Wheel loader with P lift arms Valid for: L534 - 434 / from 0101
The values stated refer to the standard version of the machine:
With P lift arms (2600 mm) and hydraulic quick-change device.
With 20.5 R25 Goodyear GP-2B tyres.
Tipping loads and weights include all lubricants, full fuel tank,
ROPS/FOPS cab and driver.
Tyre sizes and additional attachments affect the operating weight and
tipping load.
Wheel loader with Z lift arms Valid for: L538 - 432 / from 0101
The values stated refer to the standard version of the machine:
With Z lift arms (2500 mm), without hydraulic quick-change device.
With 20.5 R25 Goodyear GP-2B tyres.
Tipping loads and weights include all lubricants, full fuel tank,
ROPS/FOPS cab and driver.
Tyre sizes and additional attachments affect the operating weight and
tipping load.
Wheel loader with P lift arms Valid for: L538 - 432 / from 0101
The values stated refer to the standard version of the machine:
With P lift arms (2600 mm) and hydraulic quick-change device.
With 20.5 R25 Goodyear GP-2B tyres.
Tipping loads and weights include all lubricants, full fuel tank,
ROPS/FOPS cab and driver.
Tyre sizes and additional attachments affect the operating weight and
tipping load.
Diesel engine
Valid for: L524 - 438 / 0101 - 8795; ID no. 9739010
Description Value Unit
Engine model D 504 T
Number of cylinders 4
Capacity 4500 cm³
Rated power as per ISO 9249 81 / 110 kW / PS
Rated speed 2400 min-1
Maximum torque at 1400 min-1 424 Nm
Lower idle speed 850 50
min-1
Upper idle speed 2500 +80 min-1
Inlet valve play (cold) 0.35 mm
Outlet valve play (cold) 0.45 mm
Control thermostat opening temperature 82 °C
Fuel tank
Valid for: L524 - 438 / from 0101; L534 - 434 / from 0101; L538 - 432 / from 0101;
ID no. 7622943
Description Value Unit
Tank capacity, FULL 160 l
Tank capacity, RESERVE 30 l
Vacuum switch
Valid for: L524 - 438 / from 0101; L534 -434 / from 0101; L538 - 432 / from 0101;
ID no. 6906001
Description Value Unit
Air filter contamination vacuum switch 50 mbar
activation point
Coupling
Valid for: L524 - 438 / from 0101; L534 - 434 / from 0101; ID no. 5717325, 10010559
Description Value Unit
Glue for torsion 8 absorber bolts 241 Loctite
Tightening torque for 8 torsion 49 Nm
absorber bolts
Hub star fastening screw tightening torque 50 Nm
Cooling system
Gear pump
Valid for: L524 - 438 / 0101 -6316; ID no. 5717137
Description Value Unit
Capacity 14 cm³
Valid for: L524 - 438 / from 6317; L534 - 434 / from 0101; ID no. 5717323
Description Value Unit
Capacity 16 cm³
Gear motor
Valid for: L524 - 438 / from 0101; L534 - 434 / from 0101;
L538 - 432 / from 0101; ID no. 5717099
Description Value Unit
Gear motor displacement 16 cm³
5
Pressure relief valve 175 bar
Temperature sensor
Valid for: L524 - 438 / from 0101; L534 - 434 / from 0101;
L538 - 432 / from 0101; ID no. 5717099
Description Value Unit
Measuring range -30 to +30 °C
Resistance at 20°C 1112
Control block
Valid for: L524 - 438 / from 0101
Description Value Unit
Piston diameter 14.3 mm
5
LS working hydraulics pressure cut-off 305 bar
5
LS steering pressure cut-off 210 bar
Valid for: L534 - 434 / from 0101; L538 - 432 / from 0101
Description Value Unit
Piston diameter 18 mm
5
LS pressure relief valve 305 bar
Stabilisation module
Description Value Unit
2
Cut-off valve 150 cm³
Lift cylinder
Valid for: L524 - 438 / from 0101
Description Value Unit
Piston diameter 110 mm
Rod diameter 60 mm
Stroke length 735 mm
Valid for: L534 - 434 / from 0101; L538 - 432 / from 0101
Description Value Unit
Piston diameter 140 mm
Rod diameter 80 mm
Stroke length 440 mm
Valid for: L534 - 434 / from 0101; L538 - 432 / from 0101
Description Value Unit
Piston diameter 90 mm
Rod diameter 50 mm
Stroke length 970 mm
Return strainer
Description Value Unit
Filtration grade 40 µm
Bleeder filter
Description Value Unit
Filtration grade 10 µm
Inlet opening pressure 0.03 bar
Outlet opening pressure 0.5 bar
Servostat
Description Value Unit
Displacement 462 cm³
Secondary pressure relief 285 ±10 bar
Volume flow boost 1 : 1.6
Steering cylinder
Description Value Unit
Piston diameter 90 mm
Rod diameter 40 mm
Stroke length 500 mm
Valid for: L524 - 438 / from 6317; L534 - 434 / from 0101
Description Value Unit
Flow rate at rated speed 37.2 l/min
Speed at rated speed 2322 min -1
Disc brake
Description Value Unit
Brake pad gap 1.0 ±0.5 mm
Brake lining thickness, new 4.5 mm
Minimum brake lining thickness 1.0 mm
Battery
Valid for: L524 - 438 / from 0101; L534 - 434 / from 0101
Description Value Unit
Battery voltage 12 V
Battery capacity 100 Ah
Acid density of charged battery 1.26 - 1.28 kg/l
Transfer gear
Valid for: L524 - 438 / from 0101
Description Value Unit
Variable displacement motor 1 transmission 1.829 -
Variable displacement motor 2 transmission 1.641 -
Cardan speed at 34 km/h 2640 min-1
Speed sensor Inductive
Valid for: L534 - 434 / from 0101; L538 - 432 / from 0101
Description Value Unit
Variable displacement motor 1 transmission 1.641 -
Variable displacement motor 2 transmission 1.641 -
Speed sensor
Description Value Unit
Type Inductive sensor -
Distance to spur gear A min. 1.2 mm
max. 1.8 mm
Front axle
Valid for: L524 - 438 / from 0101
Description Value Unit
Self-locking differential level 45 %
Width 1900 mm
Wheel lug tightening torque 650 Nm
Wheel lug spanner size 30 mm
Weight 490 kg
Valid for: L534 - 434 / from 0101; L538 - 432 / from 0101
Description Value Unit
Self-locking differential level 45 %
Width 1900 mm
Wheel lug tightening torque 650 Nm
Wheel lug spanner size 30 mm
Weight 600 kg
Rear axle
Valid for: L524 - 438 / from 0101
Description Value Unit
Self-locking differential level 45 %
Swing angle (to each side) 6 °
Width 1900 mm
Wheel lug tightening torque 650 Nm
Wheel lug spanner size 30 mm
Weight 600 kg
Valid for: L534 - 434 / from 0101; L538 - 432 / from 0101
Description Value Unit
Self-locking differential level 45 %
Swing angle (to each side) 6 °
Width 1900 mm
Ballast weight
Valid for: L524 - 438 / from 0101
Description Value Unit
Left ballast weight 570 kg
Right ballast weight 650 kg
Blower
Description Value Unit
Air flow 630 m³/h
Blower speeds 3
Voltage 24 V
Current consumption (max) free blowing 10.5 A
Power consumption (min) free blowing 245 W
Air filter
Description Value Unit
Filter class EU3
Filtration grade 10 µ
Filter surface (effective) 1.8 m²
Air-conditioning system
Description Value Unit
Coolant oil ZXL 100PG
Cooling power 4.8 kW
Coolant filling quantities 1,4 kg
Temperature switch activation temperature 4 ±1 °C
Temperature switch deactivation temperature 1 ±1 °C
Low pressure switch OFF 1.5 bar
Low pressure switch ON 2.9 bar
High pressure switch OFF 25.0 bar
High pressure switch ON 19.0 bar
Valid for: L534 - 434 / from 0101; L538 - 432 / from 0101
Description Value Unit
L - length 2500 mm
Valid for: L534 -434 / from 0101; L538 - 432 / from 0101
Description Value Unit
L - length 2600 mm
Bucket
Valid for: L524 - 438 / from 0101
Description Value Unit
B bucket width 2500 mm
Specific material weight 1.8 t/m³
Heaped bucket capacity (ISO 7546) 2.0 m³
Forklift
Description Value Unit
Fork carrier prong size FEM III
Prong length 1200 mm
Chapter contents
3 Maintenance........................................................................ 3.0-1