Service Manual Service Manual Wheel Loader Wheel Loader L524 / L534 / L538 L524 / L534 / L538 [PDF]

Zitiervorschau

 

en

Service Manual Wheel Loader

(20 (10 points) 

L524 / L534 / L538(10

 

en

Service Manual (20

Wheel Loader (10 points) 

L524 / L534 / L538 (10

 

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

Product ID  ID  Manufacturer:  Manufacturer:  Product group:  group:  Type:   Type: Production number:  number:  Serial number: 

LIEBHERR-WERK BISCHOFSHOFEN GMBH Wheel loader L524 L534 L538  438 434 432  from 0101 from 0101 from 0101 

Document ID  ID  Order number:  number:  8450818 Author:   LBH / T-DOK department Author: Document version:  version:  02 Manual number: Owner:

 

Preface

  Target group  group  This service manual manual is addressed to anyone who whose se task it is to ensure that the machines are ready for everyday use. This especially includes mechanics and workshop staff of Liebherr dealers and branch branches. es. Contents   The first chapter contains information on safety regulations and on the Contents 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 maintenance tasks, testing and adjustment 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  use 

This manual manual de describes scribes sev several eral types and and versions versions of machines. 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  instructions 

Always follow follow the the safety safety regulations regulations whenever you work work on the machine. 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  edition 

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

 

General information

1 

Product descriptio description n

2

Maintenance

3

Diesel engine

4

Cooling system Travel hydraulics

5 6

Working hydraulics

7

Steering system

8

Brake system

9

Electrical system Transfer gear

10 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 troublesho oting

19

Options

20

 

1 General Information 1.0

Chapter contents 1

Ge Gene nera rall In Info form rmat atio ion n .. .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .. 1. 1.00-1 1 1.1 1.1

Sa Safe fety ty regu regula lati tion ons s .. .... .... ..... ..... .... .... .... ..... ..... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... ..... ..... .... .... .... ....1. ..1.11-1 1 1.1. 1.1.1 1

Intr Introd oduc ucti tion.. on.... .... .... .... ..... ..... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... ..... ..... .... .... .... .... .... .... .... .... .... .... .... ...1. .1.11-1 1

1.1. 1.1.2 2

Ov Over ervi view ew of th the e safe safety ty re regu gula lati tion ons s .. .... .... .... .... .... .... .... .... .... .... .... ..... ..... .... .... .... .... ....1 ..1.1 .1-2 -2

1.2 1.2

Sp Spec ecia iall tool tools s for for main mainte tena nance nce an and d re repa pair ir work. work... .... .... .... .... .... .... .... .... .... ..... ..... .... .... ...1. .1.22-1 1 1.2. 1.2.1 1

Sp Spec ecia iall too tools ls in ge gene nera rall .. .... .... .... .... ..... ..... .... .... .... ..... ..... .... .... .... .... .... .... .... ..... ..... .... .... .... .... .... ...1. .1.22-1 1

1.2. 1.2.2 2

Sp Spec ecia iall to tool ols s fo forr L Lie iebh bher errr die diese sell en engi gine nes. s... .... .... .... .... ..... ...... ..... .... .... .... .... .... ...1. .1.22-1 1

1.2. 1.2.3 3

Sp Spec ecia iall to tool ols s fo forr hy hydr drau auli lic c cy cyli lind nder ers s .. .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... ...1. .1.22-3 3

1.2. 1.2.4 4

Sp Spec ecia iall to tool ols s for for elec electr tron onic ics.. s.... .... .... .... .... .... .... .... ..... ..... .... .... .... .... .... .... .... .... .... .... .... .... .... ...1. .1.22-3 3

1.2. 1.2.5 5

Sp Spec ecia iall too tools ls fo forr axles axles.. ..... ..... .... .... .... .... .... .... .... ..... ..... .... .... .... .... .... .... .... ..... ..... .... .... .... .... .... .... ....1 ..1.2 .2-4 -4

1.2. 1.2.6 6

Ce Cent ntra rall lub lubri rica cati tion on sy syst stem.... em...... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... ....1 ..1.2 .2-4 -4

1.2. 1.2.7 7

Spec Specia iall to tool ols s for for the the air air condi conditi tion onin ing g syst system.. em.... .... .... .... .... .... .... .... .... .... ....1 ..1.2 .2-4 -4

 

 

Service Manual

General Information Safety regulations  

1.1 Safety regulations Working on the machine poses safety risks to the operator, driver or maintenance engineers. You can prevent risks and accidents by regularly reading and observing the various safety instructions. This is especially important for personnel who only occasionally work on the machine, for example, carrying out rigging or maintenance work. The safety regulations listed below, if conscientiously followed, will ensure your own

safety and that of others, and will prevent the machine from being damaged. Whenever tasks which could cause danger to personnel or damage to the machine are described, the necessary safety precautions are explained in this manual. These are indicated by the headings Danger, Warning or Caution.

1.1.1

Introduction

1. The symbols below have the following meanings: Danger  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.

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 rule rules s in force at the operating site  – Legally enfo enforceable rceable roa road d traffic regulations regulations  – Guideline Guidelines s issued by trade associations

 

General Information

Service Manual

Safety regulations

1.1.2

Overview of the safety regulations  A detailed description of these can be read in the relevant section of the safety regulations chapter in the operating manual. The following sections are included in the operating manual: 1

Introduction

2

General safety regulations

3

Proper use

4

Decals on the machine

5

Instructions Instruct ions 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 Transporti ng the machine safely

13

Towing the machine safely

14

Measures for ensuring safe maintenance

15

Safety instructions for working on machines with hydro accumulators accumulators

16

Safety instructions for welding work on the machine

17

Instructions for working safely on the working attachment attachment

18

Safety instructions for transporting the machine by crane

19

Safe maintenance of hydraulic hoses and hose lines

20

Attachments and accessories

 

Service Manual

General Information Special tools for maintenance and repair work  

1.2 Special tools for maintenance and repair work 1.2.1 Description   Description

Special tools in general ID no.  no. 

Use   Use

Digital thermometer

7020372

All wheel loaders

DCA 4 water testing kit

5608459

All wheel loaders

 Anti-freeze and and battery tester

7408922

All wheel loa loaders ders

24 volt vacuum pump Filling and testing device

7408148

All wheel loaders

Remarks  Remarks  For measuring temperature during adjustments For testing the DCA4 and antifreeze content For checking the acid concentration (battery charging state) and anti-freeze For preventing oil loss

with case Manometer 0-40 bar Manometer 0-250 bar Manometer 0-600 bar Manometer connection High pressure hose 1500 mm High pressure hose 4000 mm Screw connection M 10 x 1 Draining hose Drain piece

8145359

All wheel loaders

For checking the hydro accumulator

7361288 5002932 5002866 7002436 7002475 7009134 5005180 7005660 7402657

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

Safety cap SW 10

7009315

All wheel loaders

For checking the hydraulic pressure For checking the hydraulic pressure For checking the hydraulic pressure Connection for the manometer High pressure hose for manometer High pressure hose for manometer For checking the hydraulic pressure For draining oil via a drain valve For the drain hose For securing the valves on the variable adjustmentt motor adjustmen

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

7615515 7615589 7009317

All wheel loaders All wheel loaders All wheel loaders

Safety cap SW 17

7622068

All wheel loaders

1.2.2

For securing the valves on the pumps For securing the valves on the pumps For securing the valves on the pumps For securing the valves on the control block

Special tools for Liebherr diesel engines

Description  Description  Compression tester Nozzle tester  Adapter  Adap ter for for compressio compression n tester tester  Adapter  Adap ter for for compressio compression n tester tester Injection valve extraction tool

ID no.  no.  8008782 7361236 0524044 7090397 0524072

Use  Use  L524 - L538 engine L524 - L538 engine L538 engine engine L524 - L534 L534 engine L538 engine

Remarks  Remarks  For checking the compression compressi on For checking the injection injecti on valves Instead of the injection valve valve Instead of the injection valve valve For removing the injection valves

Extraction Extract ion tool adapter

0524029

L538 engine

Piston ring tensioning belt

8000952

All wheel loaders

Krikit 2 V-belt tester Flywheel cranking device

8042829 0524045

L524 - L538 engine L538 engine

Stopwatch

7022418

L538 engine

Measuring device

7022420

L538 engine

 Adapter

7022419

L538 engine engine

For use with the extraction extract ion tool For pushing the piston rings together during installation of the pistons For testing the V-belt tension For cranking the engine via the flywheel For adjusting the start of delivery of the distributor injection pump For adjusting the start of delivery of the distributor injection pump For adjusting the start of delivery of the distributor injection pump

 

General Information

Service Manual

Special tools for maintenance and repair work

Description   Description

ID no.  no. 

Use   Use

Crankshaft turning device

0541887

L524, L534 engine

Crankshaftt turning device Crankshaf

9183785

L538 engine

Install ation pin Installation  Adjusting pin for injection pump DE10

7090360

L524, L534 engine L524, L534 engine with electronic injection

Extractor

7090374

L524, L534 engine

Shaft seal ring installation tool

7090373

L524, L534 engine

Extract or tool Extractor Extractor Extract or tool Seal remover

7090377 7090395 7090372

L524, L534 engine L524, L534 engine L524, L534 engine

 Adjusting device device

7090384

L524, L534 engine

Extractor tool

7090364

L524, L534 engine

7090592

Remarks   Remarks For cranking the engine via the V-belt pulley For cranking the engine via the crankshaft For fixing the engine at UDC For static adjustment adjustment when installing the injection pump For removing the drive gearwheel of the Stanadyne injection pump For installing the front crankshaft oil seal For removing the front wear ring For removing the front wear ring For removing the front crankshaft oil seal For dynamically adjusting the start of delivery of the distributor injection pump For removing Stanadyne injection nozzles

Installation tool

7090382

L524, L534 engine

Cleaning tool

7090375

L524, L534 engine

Installation set

7090378

L524, L534 engine

Depth gauge

7090370

L524, L534 engine

Extractor Extract or tool

7090376

L524, L534 engine

Extractor tool

7090363

L524, L534 engine

 Angle wrench

0524062

L538 eng engine ine

MURPHY GAGE diagnostic tool with cable

10030461

 Adapter cable

9067863

L524, L534 engine with electronic injection L524, L534 engine with electronic injection

For inserting the carbon seal in the injection nozzle groove For cleaning the injection nozzle bore hole in the cylinder head For installing the rear oil seal ring and wear ring For measuring the valve depth in the cylinder head and the piston and bushing height For removing the rear crankshaft oil seal ring and wear ring For installing and removing the cylinder bushings For screws on cylinder head, main bearing and big end bearing For diagnosing controls and ECU (A14) engine controller For diagnosis with the MURPHY GAGE

 

Service Manual

General Information Special tools for maintenance and repair work  

1.2.3 Description   Description

Special tools for hydraulic cylinders ID no.  no. 

 Assembly sleeve sleeve 80 mm

9227165

 Assembly sleeve sleeve 90 mm

9227161

 Assembly sleeve sleeve 100 mm  Assembly sleeve sleeve 110 mm

9998626 9170509

 Assembly sleeve sleeve 120 mm

9998778

 Assembly sleeve sleeve 140 mm

9998623

Expansion sleeve 80 mm

9227166

Expansion sleeve 90 mm

9227162

Expansion sleeve 100 mm Expansion sleeve 110 mm

9110405 9170511

Use  Use  L524 P kinematics tilt cylinder L524 - L538 steering cylinder L534, L538 P kinematics tilt cylinder L524 lift cylind cylinder er L534, L53 L538 8 lift cylinder L524 Z kinematics tilt cylinder L534, L538 P Z kinematics tilt cylinder L524 P kinematics tilt cylinder L524 - L538 steering cylinder L534, L538 P kinematics tilt cylinder L524 lift cylinder L534, L538 lift cylinder

Remarks   Remarks For fitting the seals

For fitting the seals For fitting the seals seals For fitting the seals 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

Expansion sleeve 120 mm

9110407

Expansion sleeve 140 mm

9110409

Piston spanner

9211967

Piston spanner 80/12 mm

8007364

Piston spanner

4002681

Piston spanner 88/12 mm

8007365

Piston spanner 100/14 mm

8007366

1.2.4 Description   Description

L524 Z kinematics tilt cylinder L534, L538 P Z kinematics tilt cylinder L524 - L538 steering cylinder L524 - L538 lift cylinder L524 - L538 P kinematics tilt cylinder L524 Z kinematics tilt cylinder L534, L538 Z kinematics tilt cylinder

For fitting the seals For fitting the seals For fitting the piston For fitting the piston For fitting the piston For fitting the piston For fitting the piston

Special tools for electronics ID no.  no. 

8502956

All wheel loaders

Test probe, red Test probe, black Magnet tester Stripping and crimping pliers 0.5 - 6.0 mm2  Insertion tool Extractor tool Crimping pliers Wedge extractor tool Extraction tool size 12 for pin and bushing Extraction tool size 16 for pin and bushing

88419121 884191214 4 88419111 884191114 4 8145743

All wheel loaders All wheel loaders All wheel loaders

Remarks  Remarks  For measuring voltage, current, resistance and frequency For testing DEUTSCH connectors For testing DEUTSCH connectors For checking solenoid valves

8460263 8145432 7366655 8503647 7026267

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

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

8145674

All wheel loaders

For DEUTSCH connectors

8145673

All wheel loaders

For DEUTSCH connectors

Extraction tool size 20 for pin

8503630

All wheel loaders

For DEUTSCH connectors

Digital multimeter

Use   Use

 

General Information

Service Manual

Special tools for maintenance and repair work

Description   Description

ID no.  no. 

and bushing Plug-in fuse tester Wide METRI-PACK extractor tool Narrow METRI-PACK extractor tool

Use   Use

Remarks   Remarks

8145834 8145834

All wheel loaders

7091022

L524, L534

7091023

L524, L534

For checking the fuses For removing terminals on the main connector of the ECU engine controller For removing terminals on the main connector of the ECU engine controller

1.2.5 Description   Description

Special tools for axles ID no.  no. 

Measuring tool

8145535

1.2.6

ID no.  no. 

Filling press Filling connection

Gröneveld central lubrication 

data cable Gröneveld central lubrication 

plug adapter

Remarks   Remarks  For measuring wear on the service brake discs

Central lubrication system

Description

BEKA MAX central lubrication  data cable + software

Use  Use  L524 - L538 front axle L524 - L538 rear axle

Use   Use

Remarks   Remarks

100092 10009239 39

All wheel loaders

For quickly filling the

7029283 7029283

All wheel loaders

reservoir

10008427

All wheel loaders

For inspecting the central lubrication system

7624289

All wheel loaders

For inspecting the central lubrication system

7624290

All wheel loaders

For inspecting the central lubrication system

Gröneveld central lubrication 

 As below

software

For inspecting the central lubrication system

All wheel loaders loaders

The software for the Gröneveld central lubrication system must be purchased from Gröneveld and enabled with a registration code. Procedure and necessary data:  – Company n name ame and department department  – A six-digit num number ber of your choice choice This data must be e-mailed to the following address: [email protected]  

1.2.7 Description   Description

Special tools for the air conditioning system ID no.  no. 

Use   Use

Remarks   Remarks

Vacuum pump

7027552

All wheel loaders

For evacuating the air conditioning conditioning system

4-valve test fitting

7027558

All wheel loaders

For testing, evacuating and filling the air conditioning conditionin g 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

 

2 Product Description 2.0 Chapter contents 2

Prod Produc uctt De Desc scri ript ptio ion... n..... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .. 2. 2.00-1 1 2.1 2.1

Te Tech chni nica call da data ta .. .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... ..... ..... .... .... .... .... .... .... .... .... .... .... .... .... .... .... ...2. .2.00-1 1 2.1. 2.1.1 1

Co Comp mple lete te ma mach chin ine. e... .... .... .... .... .... ..... ..... .... .... .... .... .... .... .... .... .... .... .... .... .... ..... ..... .... .... .... ..... ..... .... ....2 ..2.0 .0-1 -1

2.1. 2.1.2 2

Dies Diesel el en engi gine ne and and pu pump mp di dist stri ribu buto torr ge gear ar.. .... .... .... .... .... .... .... .... .... .... .... .... .... ....2 ..2.0 .0-9 -9

2.1. 2.1.3 3

Co Cool olin ing g syst system... em..... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... ....2 ..2.0 .0-1 -14 4

2.1. 2.1.4 4

Tr Trav avel el hy hydr drau auli lics cs .. .... .... .... .... .... .... .... .... .... .... ..... ..... .... .... .... ..... ..... .... .... .... .... .... .... .... .... .... .... .... .... ....2 ..2.0 .0-1 -15 5

2.1. 2.1.5 5

Wo Work rkin ing g hyd hydra raul ulic ics s .. .... ..... ..... .... .... .... ..... ..... .... .... .... ..... ..... .... .... .... .... .... .... .... .... .... .... .... .... .... ..... ....2. .2.00-17 17

2.1. 2.1.6 6

St Stee eeri ring ng syst system.. em.... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... ..... ..... .... .... .... .... .... .... .... .... .... .... ...2. .2.00-20 20

2.1. 2.1.7 7

Br Brak ake e syst system.. em.... .... .... .... ..... ..... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... ..... ..... .... .... .... .... ....2 ..2.0 .0-2 -21 1

2.1. 2.1.8 8

Elec El ectr tric ical al syst system em.. .... .... .... .... .... ..... ..... .... .... .... .... .... .... .... .... .... .... .... .... .... ..... ..... .... .... .... ..... ..... .... .... ....2 ..2.0 .0-2 -22 2

2.1. 2.1.9 9

Tr Tran ansf sfer er ge gear... ar...... ..... .... .... .... .... .... .... .... ..... ..... .... .... .... .... .... .... .... ..... ..... .... .... .... .... .... .... .... ..... ..... .... .... ...2. .2.00-22 22

2.1.10 2.1 .10

Axl Axles es and and tyr tyres es ... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ....2.0 .2.0-2 -23 3

2.1. 2.1.11 11

Mach Machin ine e fra frame me and and balla ballast st weigh weight... t..... ..... ..... .... .... .... .... .... .... .... .... .... .... .... .... .... ....2 ..2.0 .0-2 -24 4

2.1.12 2.1 .12

Cab Cab,, heati heating ng an and d air air-co -cond nditi ition oning ing... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ......2 ...2.0.0-24 24

2.1. 2.1.13 13

Lift Lift arms arms and and quick quick-ch -chan ange ge devi device.. ce.... .... ..... ...... ..... .... .... ..... ..... .... .... .... ..... ..... .... ...2. .2.00-25 25

2.1. 2.1.14 14

Eq Equi uipm pmen entt an and d ac acce cess ssor orie ies s .. ..... ..... .... .... .... ..... ..... .... .... .... ..... ..... .... .... .... .... .... .... .... .... ....2 ..2.0 .0-2 -26 6

 

Service Manual

Product Description Technical data

2.1 Technical data 2.1.1 Wheel loader with Z lift arms

Complete machine Valid for:

L524   - 438 / from 0101  

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

Dimensions - machine with Z lift arms

Description   Description

Value Unit  it 

Buckett capacity Bucke capacity as per ISO 7546

2.0 m³

Bu Bucke ckett wi widt dth h

25 2500 00 mm

Specific mate Specific material rial weig weight ht  A Dump height height at maximu maximum m lifting height height and 45° tilt-out angle B Dum Dump p heigh heightt

1.8 t/m³ 2850 mm

C Maxi Maximum mum buc bucket ket base height height D Maxi Maximum mum buck bucket et pivo pivott point point height height

3510 mm 3760 mm

E Maximum Maximum buck bucket et top height height F Reach at maximum lifting height and 42° tilt-out angle G Diggin Digging g depth depth

4840 mm

H Heigh Heightt above above the cab

3150 3150 mm

I Height Height above above exh exhau aust st

3090 3090 mm

33 3335 35 mm

870 mm 80 mm

 

Product Description

Service Manual

Technical data

Description   Description J Ground clearance

520 mm

K Wheel base

2700 mm

L Overall length Turning radius over bucket outer edge

6835 mm 5500 mm

Lifting force (SAE)

98 kN

Breakout force (SAE)

92 kN

Tipping load when straight

8030 kg

Tipping load articulated at 30°

7005 kg

 Angle of articulation articulation (to each each side) Swing angle (to each side) Operating weight

40 ° 6 ° 10100 kg

Tractive force

76.2 daN

Travel speed in travel range 1, forward and reverse

0 - 8 km/h

Travel speed in travel range 2, forward and reverse

0 - 33 km/h

Sound pressure level in the cab  L pA  Wheel loader with P lift arms

Value   Unit Value Unit  

Valid for:

75 dB (A)

L524   - 438 / from 0101

The values stated refer to the standard version of the machine:   With P lift arms ((2400 2400 mm) mm) and hydr hydraulic aulic quick-change quick-change device. device.   With 17.5 R2 R25 5 Goodyea Goodyearr GP-2B tyr tyres. es.   Tipping loads and weights include all lubricants, full fuel tank, ROPS/FOPS cab and driver. Tyre sizes and additional attachments affect the operating weight and tipping load.

Dimensions - machine with P lift arms  

Service Manual

Product Description Technical data

Description   Description Buckett capacity Bucke capacity as per ISO 7546 Bu Bucke ckett wi widt dth h

1.7 m³ 25 2500 00 mm

Specific mate Specific material rial weig weight ht  A Dump height height at maximu maximum m lifting height height and 45° tilt-out angle B Dum Dump p heigh heightt

33 3380 80 mm

C Maxi Maximum mum buc bucket ket base height height

350 3500 0 mm

D Maxi Maximum mum buck bucket et pivo pivott point point height height

3750 mm

E Maximum Maximum buck bucket et top height height F Reach at maximum lifting height and 42° tilt-out angle G Diggin Digging g depth depth

4895 4895 mm

H Heigh Heightt above above the cab

31 3150 50 mm

I Height Height above above exh exhau aust st

30 3090 90 mm

J Grou Ground nd clear clearanc ance e

1.8 t/m³ 2815 mm

1030 mm 55 mm

520 mm

K Whee Wheell ba base se L Overal Overalll length length

27 2700 00 mm 6890 mm 6890

Turning Turn ing rad radius ius over buck bucket et outer outer edge edge

5530 5530 mm

Liftin Lifting g for force ce (SA (SAE) E)

89 kN

Breako Bre akout ut for force ce (SA (SAE) E)

80 kN

Tipping Tipp ing load whe when n strai straight ght

710 7100 0 kg

Tipping Tipp ing load artic articulat ulated ed at 40°

625 6250 0 kg

 Angle of articulation articulation (to each each side) Swing Swi ng angle angle (to each each side) side) Opera Op eratin ting g wei weigh ghtt Tr Tract active ive for force ce

40 ° 6 ° 10200 102 00 kg 76 76.2 .2 kN

Travel speed in travel range 1, forward

0 - 8.0 km/h

and reverse Travel speed in travel range 2, forward and reverse

0 - 33. 3.0 0 km/ km/h

Sound pressure level in the cab  L pA  Wheel loader with Z lift arms

Value Unit 

Valid for:

L534   - 434 / from 0101

75 dB (A)

The values stated refer to the standard version of the machine:   With Z lift arms ((2500 2500 mm mm), ), without hydraulic hydraulic quick-change quick-change device. device.   With 20.5 R2 R25 5 Goodyea Goodyearr GP-2B tyres. tyres.   Tipping loads and weights include all lubricants, lubricants, full fuel tank, ROPS/FOPS cab and driver. Tyre sizes and additional attachments affect the operating weight and tipping load.

 

Product Description

Service Manual

Technical data

Dimensions - machine with Z lift arms

Description   Description Bucket capacity as per ISO 7546 Bucket width

Value   Unit Value Unit   2.4 m³ 2500 mm

Specific material weight  A Dump height height at maximum maximum lifting height height and 45° tilt-out angle B Dump height

3380 mm

C Maximum bucket base height

3650 mm

D Maximum bucket pivot point height

3900 mm

E Maximum bucket top height F Reach at maximum lifting height and 42° tilt-out angle G Digging depth

5450 mm 945 mm

H Height above the cab

3250 mm

I Height above exhaust

3150 mm

J Ground clearance K Wheel base

1.8 t/m³ 2890 mm

70 mm

460 mm 2900 mm

L Overall length

7235 mm

Turning radius over bucket outer edge

5825 mm

Lifting force (SAE)

135 kN

Breakout force (SAE)

105 kN

Tipping load when straight Tipping load articulated at 40°  Angle of articulation articulation (to each each side) Swing angle (to each side) Operating weight Tractive force

9745 kg 8625 kg 40 ° 6 ° 12100 kg 87.8 kN

 

Service Manual

Product Description Technical data

Description   Description

Value Unit 

Travel speed in travel range 1, forward and reverse

0 - 8.0 km/h

Travel speed in travel range 2, forward and reverse

0 - 36. 6.0 0 km/ km/h

Sound pressure level in the cab  L pA  Wheel loader with P lift arms

Valid for:

75 dB (A)

L534   - 434 / from 0101

The values stated refer to the standard version of the machine:   With P lift arms ((2600 2600 mm) and hydraulic hydraulic quick-change quick-change device. device.   With 20.5 R2 R25 5 Goodyea Goodyearr GP-2B tyres. tyres.   Tipping loads and weights include all lubricants, lubricants, full fuel tank, ROPS/FOPS cab and driver. Tyre sizes and additional attachments affect the operating weight and tipping load.

Dimensions - machine with P lift arms

Description   Description Buckett capacity Bucke capacity as per ISO 7546 Bu Bucke ckett wi widt dth h Specific Spec ific mate material rial weig weight ht

Value Unit  2.0 m³ 25 2500 00 mm 1.8 t/m³

 A Dump height height at maximu maximum m lifting height height and 45° tilt-out angle B Dum Dump p heigh heightt

34 3470 70 mm

C Maxi Maximum mum buc bucket ket base height height

373 3730 0 mm

D Maxi Maximum mum buck bucket et pivo pivott point point height height

3970 mm

E Maximum Maximum buck bucket et top height height F Reach at maximum lifting height and 42° tilt-out angle G Diggin Digging g depth depth

5230 5230 mm

2930 mm

1060 mm 65 mm

 

Product Description

Service Manual

Technical data

Description   Description

Value   Unit Value Unit  

H Height above the cab

3250 mm

I Height above exhaust

3150 mm

J Ground clearance

460 mm

K Wheel base

2900 mm

L Overall length

7535 mm

Turning radius over bucket outer edge

5925 mm

Lifting force (SAE) Breakout force (SAE)

95 kN 100 kN

Tipping load when straight

8550 kg

Tipping load articulated at 40°

7570 kg

 Angle of articulation articulation (to each each side) Swing angle (to each side) Operating weight Tractive force

40 ° 6 ° 12290 kg 87.8 kN

Travel speed in travel range 1, forward and reverse

0 - 8.0 km/h

Travel speed in travel range 2, forward and reverse

0 - 36.0 km/h

Sound pressure level in the cab  L pA 

75 dB (A)

 

Service Manual

Product Description Technical data

Wheel loader with Z lift arms

Valid for:

L538   - 432 / from 0101

The values stated refer to the standard version of the machine:   With Z lift arms ((2500 2500 mm mm), ), without hydraulic hydraulic quick-change quick-change device. device.   With 20.5 R2 R25 5 Goodyea Goodyearr GP-2B tyres. tyres.   Tipping loads and weights include all lubricants, lubricants, full fuel tank, ROPS/FOPS cab and driver. Tyre sizes and additional attachments affect the operating weight and tipping load.

Dimensions - machine with Z lift arms

Description   Description Buckett capacity Bucke capacity as per ISO 7546 Bu Bucke ckett wi widt dth h

Value Unit  2.5 m³ 25 2500 00 mm

Specific mate Specific material rial weig weight ht  A Dump height height at maximu maximum m lifting height height and 45° tilt-out angle B Dum Dump p heigh heightt

1.8 t/m³

3380 338 0 mm

C Maxi Maximum mum buc bucket ket base height height

3650 mm

D Maxi Maximum mum buck bucket et pivo pivott point point height height

3900 mm

E Maximum Maximum buck bucket et top height height F Reach at maximum lifting height and 42° tilt-out angle G Diggin Digging g depth depth

5150 mm

H Heigh Heightt above above the cab

3250 3250 mm

I Height Height above above exh exhau aust st

3150 3150 mm

J Grou Ground nd clear clearanc ance e K Whee Wheell ba base se

460 mm 29 2900 00 mm

2870 mm

970 mm 70 mm

L Overal Overalll length length

71 7135 35 mm

Turning Turn ing rad radius ius over buck bucket et outer outer edge edge

5795 mm

 

Product Description

Service Manual

Technical data

Description   Description Lifting force (SAE)

135 kN

Breakout force (SAE)

105 kN

Tipping load when straight Tipping load articulated at 40°  Angle of articulation articulation (to each each side) Operating weight Tractive force

10160 kg 9000 kg 40 ° 12300 kg 87.8 daN

Travel speed in travel range 1, forward and reverse

0 - 8.0 km/h

Travel speed in travel range 2, forward and reverse

0 - 36.0 km/h

Sound pressure level in the cab  L pA  Wheel loader with P lift arms

Value   Unit Value Unit  

Valid for:

75 dB (A)

L538   - 432 / from 0101

The values stated refer to the standard version of the machine:   With P lift arms ((2600 2600 mm) mm) and hydr hydraulic aulic quick-change quick-change device. device.   With 20.5 R2 R25 5 Goodyea Goodyearr GP-2B tyr tyres. es.   Tipping loads and weights include all lubricants, full fuel tank, ROPS/FOPS cab and driver. Tyre sizes and additional attachments affect the operating weight and tipping load.

Dimensions - machine with P lift arms

Description   Description Bucket capacity as per ISO 7546 Bucket width Specific material weight

Value   Unit Value Unit   2.1 m³ 2500 mm 1.8 t/m³

 

Service Manual

Product Description Technical data

Description  Description   A Dump height height at maximu maximum m lifting height height and 45° tilt-out angle B Dum Dump p heigh heightt

Value Unit  2910 mm 34 3470 70 mm

C Maxi Maximum mum buc bucket ket base height height

373 3730 0 mm

D Maxi Maximum mum buck bucket et pivo pivott point point height height

3970 mm

E Maximum Maximum buck bucket et top height height F Reach at maximum lifting height and 42°

5230 5230 mm 1075 mm

tilt-out angle G Diggin Digging g depth depth

65 mm

H Heigh Heightt above above the cab

32 3250 50 mm

I Height Height above above exh exhau aust st

31 3150 50 mm

J Grou Ground nd clear clearanc ance e

460 mm

K Whee Wheell ba base se

29 2900 00 mm

L Overal Overalll length length

7435 743 5 mm

Turning Turn ing rad radius ius over buck bucket et outer outer edge edge

5880 5880 mm

Liftin Lifting g for force ce (SA (SAE) E)

95 kN

Breako Bre akout ut for force ce (SA (SAE) E)

100 kN

Tipping Tipp ing load whe when n strai straight ght

864 8640 0 kg

Tipping Tipp ing load artic articulat ulated ed at 40°

765 7650 0 kg

 Angle of articulation articulation (to each each side) Swing Swi ng angle angle (to each each side) side)

40 ° 6 °

Opera Op eratin ting g wei weigh ghtt

12250 122 50 kg

Tr Tract active ive for force ce

87 87.8 .8 kN

Travel speed in travel range 1 forward and reverse

0 - 8.0 km/h

Travel speed in travel range 2 forward and reverse

0 - 36. 6.0 0 km/ km/h

Sound pressure level in the cab  L pA 

2.1.2

75 dB (A)

Diesel engine and pump distributor gear Diesel engine

Valid for:

L524    - 438 / 0101 - 8795;

ID no. 9739010

Description   Description

Value Unit 

En Engi gine ne mode modell

D 50 504 4T

Numbe Num berr of cyl cylind inder ers s

4

Capa Ca paci city ty

45 4500 00 cm³ cm³

Rated Rate d powe powerr as per ISO 924 9249 9

81 / 110 kW / PS -1

Rate Ra ted d spee speed d

24 2400 00 min min   -1

Maximum torque at 1400 min  

424 Nm 42 -1

Lower idle speed

850

50

min  

Upper idle speed

2500

+80

min  

Inlet Inlet val valve ve pla play y (co (cold) ld) Outlet valve play (cold) Outlet (cold) Control Cont rol thermost thermostat at ope opening ning tempera temperature ture

-1

0.35 mm 0.35 0.45 mm 82 °C

 

Product Description

Service Manual

Technical data

Description   Description

Value   Unit Value Unit  

Longitudinal Longitud inal / traverse inclinability

30 / 30 °C

Starter operating voltage

24 V

Starter power consumption

7.8 kW

 Alternator voltage ou output tput

27 V

 Alternator current ou output tput

55 A

Emission thresholds comply with

EU  RL 97/68 EC Stage I

L524 

Valid for:

 - 438 / from 8796; ID no. 9739021

Description

Value  Unit Value 

Engine model

D 504 TI - 02

Number of cylinders

4

Firing order

1-3-4-2

Capacity

4500 cm³

Cylinder bore

106.5 mm

Stroke

127 mm

Rated power as per ISO 9249

-1

Rated speed

2400 min   -1

Maximum torque at 1400 min  

850

50

Upper idle speed

2550

+80

Injection nozzle pressure Injection nozzles, maximum pressure difference between cylinders

-1

  min  

  min-1 

24

+3

241

±6

  bar   bar

7 bar

Inlet valve play (cold)

0.35 mm

Outlet valve play (cold)

0.45 mm

Direction of rotation, lo looking at ffly lyw wheel Number of teeth on flywheel gear Control thermostat opening temperature Longitudinal / traverse inclinability inclinabili ty

Anticlockwise 129 82 °C 30 / 30 °

Starter operating voltage

24 V

Starter power consumption

7.8 kW

 Alternator voltage ou output tput

27 V

 Alternator current ou output tput

55 A

 Auxiliary power power take-off transmission transmission Weight

L534    - 434 / 0101 - 8961;

1:1.0333 387 kg

Emission threshold thresholds s comply with Valid for:

422 Nm

Lower idle speed

Combustion pressure

 

81 / 110 kW / PS

EU  RL 97/68/EC Stage II

ID no. 9739011

Description   Description Engine model Number of cylinders Capacity Rated power as per ISO 9249

Value   Unit Value Unit   D 504 TI 4 4500 cm³ 100 / 136 kW / PS

 

Service Manual

Product Description Technical data

Description   Description

Value Unit  -1

Rate Ra ted d spee speed d

24 2400 00 min min   -1

Maximum torque at 1400 min  

-1

Lower idle speed

850

50

min  

Upper idle speed

2550

+80

min  

-1

Inlet Inlet val valve ve pla play y (co (cold) ld)

0.35 0.3 5 mm

Outlet Outl et valve play (cold) (cold)

0.45 mm

Longitu Lon gitudina dinall / trave traverse rse inclinab inclinability ility

30 / 30 °C

Starte Sta rterr opera operatin ting g vol voltag tage e

24 V

Starter Star ter powe powerr consumpt consumption ion

7.8 kW

 Alternator voltage voltage output output

27 V

 Alternator current ou output tput

55 A

Emission thresholds comply with Valid for:

498 Nm 49

L534  - 434 / fr from om 8962;

EU  RL 97/68 EC Stage I

ID no. 9739022

Descri Des cript ption ion

Value Val ue Unit Unit

Engine Eng ine mo model del

D 50 504 4 TI - 02

Numbe Num berr of cylind cylinder ers s

4

Fir Firing ing orde orderr

1-3-4 1-3 -4-2 -2

Capa Ca paci city ty

45 4500 00 cm³ cm³

Cylind Cyl inder er bore bore

106.5 106 .5 mm

Stro Stroke ke

12 127 7 mm

Rated powe powerr as per ISO 9249 9249

100 / 136 kW / PS -1

Rate Ra ted d spee speed d

24 2400 00 min min   -1

Maximum torque at 1400 min  

494 Nm 49 -1

Lower Lower idle idle sp spee eed d

850±5 850±50 0 min  

Upper Upp er idle idle sp speed eed

25 2550 50+8 +80 0 min  

Combustio Comb ustion n pre pressure ssure

-1

min. 24+3 bar

Injection Inje ction nozz nozzle le pressure pressure

241 241±6 ±6 bar

Injection nozzles, maximum pressure difference between cylinders

7 bar

Inlet Inlet val valve ve pla play y (co (cold) ld) Outlet valve play (cold) Outlet (cold) Direction of rotation, looking at flywheel

0.35 0.3 5 mm 0.45 mm Anticlockwise

Number Numb er of teeth on flywheel flywheel gear

129

Contro Con troll the therm rmost ostat at Longitud Long itudinal inal / trav traverse erse inclinab inclinability ility

82 °C 30 / 30 °

Starte Sta rterr opera operatin ting g vol voltag tage e

24 V

Starter Star ter powe powerr consumpt consumption ion

7.8 kW

 Alternator voltage voltage outpu outputt

27 V

 Alternator current ou output tput

55 A

 Auxiliary power power take-off tra transmission nsmission

1:1.0333

Weig We ight ht Emission threshold thresholds s comply with

39 396 6 kg EU  RL 97/68/EC Stage II

 

Product Description

Service Manual

Technical data

Valid for:

L538    - 432 / 0101 -8507; ID no. 9880051

Description   Description Engine model Number of cylinders

Value   Unit Value Unit   D924T-E-A1 4

Capacity

6640 cm

Rated power as per ISO 9249

100 / 136 kW / PS -1

Rated speed

2000 min   -1

Maximum torque at 1400 min   Lower idle speed

597 Nm 850

Upper idle speed Inlet valve play (cold)

-1

+80

-1

  min  

2100   min   0.25 mm

Outlet valve play (cold)

0.30 mm

Control thermostat

79 °C

Longitudinal Longitud inal / traverse inclinability

45 / 45 °C

Starter operating voltage

24 V

Starter power consumption

5.4 kW

 Alternator voltage ou output tput

28 V

 Alternator current ou output tput

55 A

Emission thresholds comply with Valid for:

50

L538  - 432 / from 8508;

EU  RL 97/68 EC Stage I

ID no. 9076608

Description Engine model

Value Unit D 924TI-E-A1

Number of cylinders

4

Firing order

1-3-4-2

Capacity

6640 cm³

Cylinder bore

122 mm

Stroke

142 mm

Rated power as per ISO 9249

100 / 136 kW / PS -1

Rated speed

2000 min   -1

Maximum torque at 1150 min   Lower idle speed

645 Nm 850

-1

50

  min   -1

Upper idle speed

2100+80 min  

Start of delivery

1. 1.4 4 0. 0.0 05 mm

Compression ratio Combustion pressure Injection nozzle pressure Injection nozzles, maximum pressure difference between cylinders

17.2:1 20 - 26 bar 225±6 bar 7 bar

Inlet valve play (cold)

0.25 mm

Outlet valve play (cold)

0.30 mm

Directio tion of rotation, lo looking at ffly lyw wheel Number of teeth on flywheel gear Control thermostat opening temperature Longitudinal Longitudi nal / traverse inclinability

Anticlockwise 147 79 °C 45 / 45 °

 

Service Manual

Product Description Technical data

Descri Des cript ption ion

Value Val ue Unit Unit

Starte Sta rterr opera operatin ting g vol voltag tage e

24 V

Starter Star ter powe powerr consumpt consumption ion

5.4 kW

 Alternator voltage voltage outpu outputt

28 V

 Alternator current ou output tput

55 A

 Auxiliary power power take-off tra transmission nsmission Weig We ight ht

1:1.275 74 740 0 kg

Emission levels comply with

EU  RL 97/68/EC Stage II

Fuel tank Valid for:

L524   - 438 / from 0101; L534   - 434 / from 0101; L538   - 432 / from 0101;

ID no. 7622943

Description   Description

Value Unit 

Tank Tan k cap capaci acity, ty, FUL FULL L

16 160 0 l

Tank Tan k cap capaci acity, ty, RES RESERV ERVE E

30 l

Fuel pre-filter (stage I) Valid for:   L524   - 438 / 0101 - 8795;

L534    - 434 / 0101 - 8961;

ID no. 7090480 

Description   Description

Value Unit 

Filtration grade

Valid for:

min. 0.6 mm max. 0.8 mm

L538    - 432 / 0101 -8507; ID no. 7381876 

Description   Description

Value Unit 

Filtration grade

min. 0.6 mm max. 0.8 mm

Fuel pre-filter (stage II) Valid for:

L524   - 438 / from 8796;

L534    - 434 / from 8962;

ID no. 7090562 

Description   Description

Value Unit 

Filtra Filtratio tion n grad grade e Valid for:

10 µm

L538    - 432 / from 8508; ID no. 738 7382133 2133

Description   Description

Value Unit 

Filtra Filtratio tion n grad grade e

30 µm

Fuel fine filter (stage I) Valid for:

L524   - 438 / from 0101;

L534    - 434 / from 0101;

ID no. 7090528 

Description   Description

Value Unit 

Filtra Filtratio tion n grad grade e Valid for:

5 µm

L538   -- 432 / 0101 - 8507;

ID no. 7381643

Description   Description

Value Unit 

Filtra Filtratio tion n grad grade e

5 µm

 

Product Description

Service Manual

Technical data

Fuel fine filter (stage II) Valid for:

L524   - 438 / from 0101;

L534   - 434 / from 0101; ID no. 7090528 

Description   Description Filtration grade Valid for:

Value   Unit Value Unit   5 µm

L538    - 432 / from 8508; ID no. 738 7382102  2102 

Description   Description Filtration grade

Vacuum switch

Value   Unit Value Unit   5 µm

Valid for:

L524   - 438 / from 0101; L534  -434  -434 / from 0101; L538   - 432 / from 0101;

ID no. 6906001

Description   Description

Value   Unit Value Unit  

 Air filter contamination contamination vacuum vacuum switch activation point

50 mbar

Coupling Valid for:

L524   - 438 / from 0101;

L534   - 434 / from 0101; ID no. 5717325, 10010559

Description   Description

Value   Unit Value Unit  

Glue for torsion 8 absorber bolts

Valid for:

241 Loctite

Tightening torque for 8 torsion absorber bolts

49 Nm

Hub star fastening screw tightening torque

50 Nm

L538    - 432 / from 0101; ID no. 560 5607974 7974

Description   Description

Value   Unit Value Unit  

Glue for torsion 8 absorber bolts Tightening torque for 8 torsion absorber bolts

241 Loctite 68 Nm

Valid for:   L538    - 432 / from 8508; ID no. 738 7382102  2102 

Description   Description

Value   Unit Value Unit  

Filtration grade

2.1.3

2 µm

Cooling system Cooling system Gear pump

Valid for:

L524    - 438 / 0101 -6316; ID no. 5717137 

Description   Description

Value   Unit Value Unit  

Capacity

14 cm³

 

Service Manual

Product Description Technical data

Valid for:

L524   - 438 / from 6317;

L534   - 434 / from 0101; ID no. 5717323

Description   Description Capa Ca paci city ty Valid for:

Value Unit  16 cm³ 16 cm³

L538    - 432 / from 0101; ID no. 571 5716912  6912 

Description   Description Capa Ca paci city ty

Value Unit  14 cm³ 14 cm³

Gear motor Valid for:

L524   - 438 / from 0101; L534   - 434 / from 0101; L538    - 432 / from 0101; ID no. 571 5717099 7099

Description  Description  Gear moto motorr displace displacemen mentt

Value Unit  16 cm³

Pressure relief valve

5

175

bar

Temperature sensor Valid for:

L524   - 438 / from 0101; L534   - 434 / from 0101; L538    - 432 / from 0101; ID no. 571 5717099 7099

Description   Description Measu Me asurin ring g rang range e

Value Unit  -3 -30 0 to +30 °C

Resi esista stance nce at 20°C

2.1.4

1112 112

Travel hydraulics Variable displacement pump

Valid for:

L524   - 438 / from 0101

Description   Description

Value Unit 

Cont Co ntro roll type type

DA

Maxim Ma ximum um ca capac pacity ity

90 cm³

Flow rate at rate rated d speed speed

212 l/min l/min

Powe Po werr

72 kW

Replenis Repl enishing hing pump capa capacity city

19.6 cm³

Weig We igh ht

60 kg 60

Pressure cut-off Valid for:

430

5

bar

L534   - 434 / from 0101

Description   Description

Value Unit 

Cont Co ntro roll type type

DA

Maxim Ma ximum um ca capac pacity ity

125 cm³

Flow rate at rate rated d speed speed

246 l/min l/min

Powe Po werr

90 kW

Replenis Repl enishing hing pump capa capacity city

19.6 cm³

Weig We igh ht

60 kg 60

Pressure cut-off

430

5

bar

 

Product Description

Service Manual

Technical data

Valid for:   L538   - 432 / from 0101

Description   Description Control type

Value   Unit Value Unit   DA

Maximum capacity

125 cm³

Flow rate at rated speed

246 l/min

Power Replenishing pump capacity Weight Pressure cut-off

90 kW 28.3 cm³ 80 kg 430

5

  bar

Variable displacement motor 1 Valid for:

L524   - 438 / from 0101

Description   Description

Value   Unit Value Unit  

Control type

DA

Maximum displacement

107 cm³

Minimum displacement

43 cm³ -1

Maximum speed

5490 min  

Torque (Dp 400 bar)

594 Nm

Weight

47 kg

Control range while driving Valid for:

230

  bar

L534   - 434 / from 0101

Description   Description

Value   Unit Value Unit  

Control type

DA

Maximum displacement

140 cm³

Minimum displacement

38 cm³ -1

Maximum speed

4800 min  

Torque (Dp 400 bar)

891 Nm

Weight

60 kg

Control range while driving Valid for:

5

260

5

  bar

L538   - 432 / from 0101

Description   Description

Value   Unit Value Unit  

Control type

DA

Maximum displacement

140 cm³

Minimum displacement

46 cm³ -1

Maximum speed

4800 min  

Torque (Dp 400 bar)

891 Nm

Weight

60 kg

Control range while driving

230

5

  bar

 

Service Manual

Product Description Technical data

Variable displacement motor 2 Valid for:

L524   - 438 / from 0101;

L538   - 432 / from 0101

Description   Description

Value Unit 

Cont Co ntro roll type type

HD1D HD 1D

Maxim Ma ximum um displa displacem cemen entt

160 160 cm³

Minimu Min imum m displ displace aceme ment nt

0 cm³ 4800 480 0 min  

Torqu Tor que e (Dp 400 400 bar bar))

1119 111 9 Nm

Weig We igh ht Control pressure start of regulation High pressure start of regulation Valid for:

-1

Maxim Ma ximum um sp speed eed

64 kg 64 6.0

1

bar

260

5

bar

L534   - 434 / from 0101

Description  Description 

Value Unit 

Cont Co ntro roll type type

HD1D HD 1D

Maxim Ma ximum um displa displacem cemen entt

160 160 cm³

Minimu Min imum m displ displace aceme ment nt

0 cm³

Maxim Ma ximum um sp speed eed

-1

4800 480 0 min  

Torqu Tor que e (Dp 400 400 bar bar))

1119 111 9 Nm

Weig We igh ht

64 kg 64

Control pressure start of regulation High pressure start of regulation

6.0

1

bar

290

5

bar

Motor scavenging pump Valid for:

L524   - 438 / from 0101;

L534   - 434 / from 0101

Description   Description

Valid for:

Value Unit 

Flow Flo w rate rate at rat rated ed speed speed

32.5 32.5 l

Speed Spe ed at rated rated speed speed

2322 2322 min  

-1

L538   - 432 / from 0101

Description   Description

2.1.5

Value Unit 

Flow Flo w rate rate at rat rated ed speed speed

35.7 35.7 l

Speed Spe ed at rated rated speed speed

2550 2550 min  

-1

Working hydraulics Working hydraulics pump

Valid for:

L524   - 438 / from 0101

Description   Description

Value Unit 

Cont Co ntro roll type type

DFLR DF LR

Maxim Ma ximum um ca capac pacity ity

45 cm³

Flow rate at rate rated d speed speed

105 l/min l/min

Powe Po werr

40 kW

Flow regulator (delta p)

28

1

bar

 

Product Description

Service Manual

Technical data

Description   Description

Value   Unit Value Unit  

Weight

215

1

Valid for:

L534   - 434 / from 0101

Description   Description

Value   Unit Value Unit  

Control type

DFLR

Maximum capacity Flow rate at rated speed Power Flow regulator (delta p) Weight Valid for:

  bar

60 cm³ 141 l/min 57 kW 25

1

  bar

215

1

  bar

L538   - 432 / from 0101

Description  Description  Control type Maximum capacity Flow rate at rated speed Power Flow regulator (delta p) Weight

Value  Unit Value  Unit   DFLR 71 cm³ 137 l/min 57 kW 25

1

  bar

215

1

  bar

Control block Valid for:

Valid for:

L524   - 438 / from 0101

Description   Description

Value   Unit Value Unit  

Piston diameter LS working hydraulics pressure cut-off

14.3 mm 5 305   bar

LS steering pressure cut-off

210

L534   - 434 / from 0101;

5

  bar

L538   - 432 / from 0101

Description   Description

Value   Unit Value Unit  

Piston diameter

18 mm

LS pressure relief valve

305

5

  bar

Pilot control hydro accumulator Description   Description

Value   Unit Value Unit  

Hydro accumulato accumulatorr volume Preload pressure (nitrogen filling)

320 cm³ 15 bar

Float position pressure switch Valid for:

L534   - 434 / from 0101;

L538   - 432 / from 0101

Description   Description Switch type Switch point, rising

Value   Unit Value Unit   Normally open 23

2

  bar

 

Service Manual

Product Description Technical data

Stabilisation module

Valid for:

Description   Description

Value Unit 

Cut-off valve

150

2

  cm³

L524   - 438 / from 0101

Description   Description Piston Pis ton diame diameter ter

Value Unit  100 100 mm

Rod Ro d diam diamet eter er

60 mm

Stroke Str oke len length gth

735 735 mm

Lift cylinder Valid for:

L524   - 438 / from 0101

Description   Description Piston Pis ton diame diameter ter

Value Unit  110 110 mm

Rod Ro d diam diamet eter er

60 mm

Stroke Str oke len length gth

735 735 mm

Z kinematics tilt cylinder Valid for:

L524   - 438 / from 0101

Description   Description Piston Pis ton diame diameter ter Rod Ro d diam diamet eter er

Value Unit  120 120 mm 70 mm

Stroke Str oke len length gth Valid for:

L534   - 434 / from 0101;

440 440 mm L538   - 432 / from 0101

Description   Description

Value Unit 

Piston Pis ton diame diameter ter

140 140 mm

Rod Ro d diam diamet eter er

80 mm

Stroke Str oke len length gth

440 440 mm

P kinematics tilt cylinder Valid for:

L524   - 438 / from 0101

Description   Description

Valid for:

Value Unit 

Piston Pis ton diame diameter ter

80 mm

Rod Ro d diam diamet eter er

50 mm

Stroke Str oke len length gth

775 775 mm

L534   - 434 / from 0101;

L538   - 432 / from 0101

Description   Description

Value Unit 

Piston Pis ton diame diameter ter

90 mm

Rod Ro d diam diamet eter er

50 mm

Stroke Str oke len length gth

970 970 mm

 

Product Description

Service Manual

Technical data

Return suction filter Description   Description

Value   Unit Value Unit  

Filtration grade

10 µm

Return strainer  Description   Description

Value   Unit Value Unit  

Filtration grade

40 µm

Bleeder filter  Description   Description

Value   Unit Value Unit  

Filtration grade Inlet opening pressure Outlet opening pressure

2.1.6

10 µm 0.03 bar 0.5 bar

Steering system Servostat Description   Description

Value   Unit Value Unit  

Displacement

462 cm³ ±10

Secondary pressure relief

285

Volume flow boost

1 : 1.6

  bar

Steering cylinder Description   Description

Value   Unit Value Unit  

Piston diameter

90 mm

Rod diameter

40 mm

Stroke length

500 mm

Emergency steering pump Description   Description

Value   Unit Value Unit  

Capacity

11 cm²

Pressure relief valve

55

±5

  bar

Emergency steering pump pressure switch Description   Description

Value   Unit Value Unit  

Switch type

Normally open

Switch point, rising

10

±1

  bar

Emergency steering check pressure switch Description   Description

Value   Unit Value Unit  

Switch type

Normally open

Switch point, rising

5

±0.5

  bar

 

Service Manual

Product Description Technical data

2.1.7

Brake system Brake system gear pump

Valid for:

L524   - 438 / to 6316 

Description   Description

Valid for:

Value Unit 

Flow rate at rate rated d speed speed

32.5 l/min

Speed Spe ed at rated rated speed speed

2322 2322 min  

L524   - 438 / from 6317;

-1

L534   - 434 / from 0101

Description   Description

Valid for:

Value Unit 

Flow rate at rate rated d speed speed

37.2 l/min

Speed Spe ed at rated rated speed speed

2322 2322 min  

-1

L538   - 432 / from 0101

Description   Description

Value Unit 

Flow rate at rate rated d speed speed

35.7 l/min

Speed Spe ed at rated rated speed speed

2550 2550 min  

-1

Compact brake valve Description   Description

Value Unit 

 Accumulator charge valv valve e activation pressure

145

±5

bar

 Accumulator charge valv valve e deactivation pressure

175

±5

bar

65

±5

bar

Maximum service brake pressure

Service brake hydro accumulator  Description   Description Hydro Hydr o accu accumula mulator tor volum volume e

Value Unit  750 cm³

Preload Prel oad pre pressur ssure e (nitrogen (nitrogen filling) filling)

50 bar

Brake light pressure switch Description   Description

Value Unit 

Switch Swi tch typ type e

Norma No rmally lly op open en

Switching point, falling

90

±5

bar

Disc brake Description  Description  Brake pad gap

Value Unit  ±0.5 1.0 mm

Brake Brak e lining lining thic thicknes kness, s, new

4.5 mm

Minimum Mini mum bra brake ke linin lining g thick thickness ness

1.0 mm

 

Product Description

Service Manual

Technical data

Parking brake hydro accumulator Description   Description

Value   Unit Value Unit  

Hydro accumulato accumulatorr volume Preload pressure (nitrogen filling)

160 cm³ 30 bar

Parking brake pressure switch Description   Description

Value   Unit Value Unit  

Switch type

Change-over switch

Switching point, falling

2.1.8

100

±5

  bar

Electrical system Electrical system with circuit diagrams Description   Description

Value   Unit Value Unit  

System voltage

24 V

Battery Valid for:

L524   - 438 / from 0101;

L534   - 434 / from 0101

Description   Description Battery voltage

12 V

Battery capacity

100  Ah

 Acid density of of charged b battery attery Valid for:

 

1.26 - 1.28 kg/l

L538   - 432 / from 0101

Description   Description

Value   Unit Value Unit  

Battery voltage

12 V

Battery capacity

110  Ah

 Acid density of of charged b battery attery

2.1.9

Value   Unit Value Unit  

Transfer gear

 

1.26 - 1.28 kg/l

Transfer gear Valid for:

L524   - 438 / from 0101

Description   Description

Value   Unit Value Unit  

Variable displacement motor 1 transmission transmissi on

1.829 -

Variable displacement motor 2 transmission transmissi on

1.641 2640 min-1 

Cardan speed at 34 km/h Speed sensor Valid for:

Inductive Inductiv e

L534   - 434 / from 0101;

L538   - 432 / from 0101

Description   Description

Value lue Unit 

Variable Variab le displacemen displacementt motor 1 transmission transmission

1.641 -

Variable Vari able disp displace lacemen mentt moto motorr 2 transmis transmission sion

1.641 1.641 -

 

Service Manual

Product Description Technical data

Description   Description

Value Unit 

Cardan Car dan speed speed at 34 km/h km/h Speed Spe ed sensor sensor

-1

2895 2895 min min   Induct Ind uctive ive

Speed sensor Description   Description

Value Unit 

Type Typ e

Induct Ind uctive ive sensor sensor -

Distance to spur gear A

2.1.10

min. 1.2 mm max. 1.8 mm

Axles and tyres Front axle

Valid for:

L524   - 438 / from 0101

Description   Description

Value Unit  it 

Self-loc Self -locking king different differential ial level level Wi Widt dth h

45 % 19 1900 00 mm

Wheel Whe el lug tight tightenin ening g torq torque ue

650 Nm

Wheel Whe el lug spa spann nner er size size Weig We ight ht Valid for:

L534   - 434 / from 0101;

30 mm 490 kg

L538   - 432 / from 0101

Description   Description Self-loc Self -locking king different differential ial level level Wi Widt dth h Wheel Whe el lug tight tightenin ening g torq torque ue Wheel Whe el lug spa spann nner er size size Weig We ight ht

Value Unit  it  45 % 19 1900 00 mm 650 Nm 30 mm 600 kg

Rear axle Valid for:

L524   - 438 / from 0101

Description   Description

Value Unit  it 

Self-loc Self -locking king different differential ial level level

45 %

Swing Swi ng angle angle (to each each side) side)

6 °

Wi Widt dth h

19 1900 00 mm

Wheel Whe el lug tight tightenin ening g torq torque ue

650 Nm

Wheel Whe el lug spa spann nner er size size

30 mm

Weig We ight ht Valid for:

L534   - 434 / from 0101;

600 kg L538   - 432 / from 0101

Description   Description

Value Unit  it 

Self-loc Self -locking king different differential ial level level

45 %

Swing Swi ng angle angle (to each each side) side)

6 °

Wi Widt dth h

19 1900 00 mm

 

Product Description

Service Manual

Technical data

Description   Description Wheel lug tightening torque Wheel lug spanner size Weight

2.1.11

Value   Unit Value Unit   650 Nm 30 mm 680 kg

Machine frame and ballast weight Ballast weight

Valid for:

L524   - 438 / from 0101

Description   Description

Valid for:

Left ballast weight

570 kg

Right ballast weight

650 kg

L534   - 434 / from 0101

Description   Description

Valid for:

Value   Unit Value Unit  

Left ballast weight

825 kg

Right ballast weight

975 kg

L538   - 432 / from 0101

Description   Description

2.1.12

Value   Unit Value Unit  

Value   Unit Value Unit  

Left ballast weight

740 kg

Right ballast weight

810 kg

Cab, heating and air-conditioning Heating and ventilation Description   Description Blower speeds Heating power

Value   Unit Value Unit   3 4.0 kW

Blower Description   Description  Air flow Blower speeds Voltage

Value   Unit Value Unit   630 m³/h 3 24 V

Current consumption (max) free blowing

10.5 A

Power consumption (min) free blowing

245 W

Air filter  Description   Description Filter class

Value   Unit Value Unit   EU3

Filtration Filtrati on grade

10 µ

Filter surface (effective)

1.8 m²

 

Service Manual

Product Description Technical data

Air-conditioning system Description   Description Coola Coo lant nt oil

Value Unit  ZXL 100PG 100PG

Cool Co olin ing g po powe werr

4. 4.8 8 kW

Coolant Cool ant filli filling ng quantiti quantities es

1,4 kg ±1

2.1.13

Temperature switch activation temperature Temperature switch deactivation temperature

4 ±1 °C 1 °C

Low pressure switch OFF

1.5 bar

Low pressure switch ON

2.9 bar

High pressure switch OFF

25.0 bar

High Hig h pre pressu ssure re switch switch ON

19 19.0 .0 bar

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

Valid for:

L524   - 438 / from 0101

Description  Description  L - leng length th

Value Unit  it  24 2400 00 mm

Valid for:   L534   - 434 / from 0101; L538   - 432 / from 0101

Description   Description L - leng length th

Value Unit  it  25 2500 00 mm

Lift arms with P kinematics Valid for:

L524   - 438 / from 0101

Description   Description L - leng length th

Value Unit  it  24 2400 00 mm

Valid for:   L534  -434  -434 / from 0101; L538   - 432 / from 0101

Description   Description L - leng length th

Value Unit  it  26 2600 00 mm

Hydraulic quick-change device for Z lift arms (hydraulic actuation) Description   Description  A  system connection connection size Weig We ight ht

Hydraulic quick-change device for Z lift arms (electrohydraulic actuation)

Value Unit  it  1000 mm 300 kg

Description   Description

Value Unit  it 

 A  system connection connection size

1000 mm

Weig We ight ht

300 kg

 

Product Description

Service Manual

Technical data

Hydraulic quick-change device for P lift arms (electrohydraulic actuation) Description   Description  A  system connection connection size Weight

2.1.14

Value   Unit Value Unit   1000 mm 230 kg

Equipment and accessories Bucket

 

Valid for:

L524   - 438 / from 0101

Description   Description B  bucket width

Valid for:

2500 mm

Specific material weight

1.8 t/m³

Heaped bucket capacity (ISO 7546)

2.0 m³

L534   - 434 / from 0101

Description   Description B  bucket width

Valid for:

Value   Unit Value Unit  

Value   Unit Value Unit   2500 mm

Specific material weight

1.8 t/m³

Heaped bucket capacity (ISO 7546)

2.4 m³

L538   - 432 / from 0101

Description   Description B  bucket width

Value   Unit Value Unit   2500 mm

Specific material weight

1.8 t/m³

Heaped bucket capacity (ISO 7546)

2.5 m³

Forklift Description   Description Fork carrier prong size Prong length

Value   Unit Value Unit   FEM III 1200 mm

High dump bucket (optional) Description   Description B  bucket width

Value   Unit Value Unit   2700 mm

Specific material weight (L524-438 with P kinematics)

0.9 t/m³

Specific material weight (L534-434 with P kinematics)

1.0 t/m³

Specific material weight (L538-432 with P kinematics)

1.1 t/m³

Bucket capacity as per ISO 7546 Maximum operating pressure for attachment hydraulics

3.0 m³ 250 bar

 

3 Maintenance 3.0 Chapter contents 3

Ma Main inte tena nanc nce. e... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... 3. 3.00-1 1 3.1 3.1

Main Mainte tena nanc nce e and and in insp spec ectio tion n sc sche hedu dule le .. .... .... .... .... ..... ..... .... .... .... .... .... .... .... .... .... ..... ..... .... .... ...3. .3.11-1 1

3.2 3.2

Te Testi sting ng and and adj adjus ustm tmen entt plan. plan... .... .... ..... ..... .... .... .... .... .... .... .... ..... ..... .... .... .... .... .... .... .... ..... ..... .... .... .... .... ...3. .3.22-1 1

3.3 3.3

Te Testi sting ng and and ad adju just stme ment nt che check ckli list sts.. s.... .... .... .... .... .... .... .... .... .... .... .... .... .... ..... ..... .... .... .... ..... ..... .... ....3 ..3.3 .3-1 -1

3.4 3.4

Lu Lubr bric icat atio ion n cha chart rt an and d ffil illi ling ng qu quan anti titi ties es .. .... .... ..... ..... .... .... .... .... .... .... .... ..... ..... .... .... .... .... .... .... ....3 ..3.4 .4-1 -1 3.4. 3.4.1 1

Ta Tabl ble e of fi fill llin ing g qu quan anti titi ties es (L (L52 524) 4) .. ..... ..... .... .... .... .... .... .... .... ..... ..... .... .... .... .... .... .... .... .....3 ...3.4 .4-1 -1

3.4. 3.4.2 2

Ta Tabl ble e of fi fill llin ing g qu quan anti titi ties es (L (L53 534) 4) .. ..... ..... .... .... .... .... .... .... .... ..... ..... .... .... .... .... .... .... .... .....3 ...3.4 .4-1 -1

3.4. 3.4.3 3

Ta Tabl ble e of fi fill llin ing g qu quan anti titi ties es (L (L53 538) 8) .. ..... ..... .... .... .... .... .... .... .... ..... ..... .... .... .... .... .... .... .... .....3 ...3.4 .4-2 -2

3.4. 3.4.4 4

Lu Lubr bric icat atio ion n ch char artt ... ..... .... .... .... .... .... .... .... ..... ..... .... .... .... .... .... .... .... ..... ..... .... .... .... .... .... .... .... ..... ..... .... .... ...3.4 .3.4-3 -3

3.5 3.5

 

Main Mainte tena nanc nce e task tasks.... s...... .... .... .... .... .... .... .... ..... ..... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... ..... ..... .... ....3 ..3.5 .5-1 -1 3.5. 3.5.1 1

Pr Prep epar arat ator ory y ta task sks s fo forr main mainte tena nanc nce e .. .... .... .... .... .... .... .... .... .... .... ..... ..... .... .... .... .... .... ...3. .3.55-1 1

3.5. 3.5.2 2

Ch Chec ecki king ng tthe he mac machi hine ne for for ext exter erna nall dama damage ge.. .... .... .... .... .... .... .... .... .... .... .... ...3 .3.5 .5-6 -6

3.5. 3.5.3 3

Ma Makin king g su sure re th the e bo bolt lted ed conn connec ecti tion ons s ar are e ti tigh ght.. t.... ..... ..... .... .... .... .... .... .... ....3 ..3.5 .5-6 -6

3.5. 3.5.4 4

Se Seal alin ing g le leak aks s .. .... .... .... .... .... .... .... .... .... .... ..... ..... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... ..... ..... .... .... .... ....3 ..3.5 .5-6 -6

3.5. 3.5.5 5

Ch Chec ecki king ng tthe he eng engin ine e oil oil leve levell (L52 (L524 4, L534 L534)) .. .... .... .... .... .... .... .... .... .... .... .... ....3 ..3.5 .5-7 -7

3.5. 3.5.6 6

Ch Chan angi ging ng th the e en engi gine ne oi oill (L (L52 524, 4, L534 L534)) .. .... ..... ..... .... .... .... ..... ..... .... .... .... .... .... .... ....3 ..3.5 .5-8 -8

3.5. 3.5.7 7

Ch Chan angi ging ng th the engi engine ne oil oil ffil ilte terr (L52 (L524, 4, L5 L534 34)) .. .... .... .... .... .... .... .... .... .... .... ....3 ..3.5 .5-1 -10 0

3.5. 3.5.8 8

Ch Chan angi ging ng th the e en engi gine ne oi oill filte filterr (L (L53 538) 8) .. .... .... .... .... .... .... .... .... .... .... .... .... .... ..... ..... ...3. .3.55-11 11

3.5. 3.5.9 9

Ch Chec ecki king ng th the e VV-ri ribb bbed ed be belt lt (L (L52 524, 4, L5 L534 34). )... .... .... .... ..... ..... .... .... .... .... .... .... ....3 ..3.5 .5-1 -11 1

3.5. 3.5.10 10

Chec Checki king ng the VV-ri ribb bbed ed belt belt (L538 (L538).. )..... ...... ..... .... .... .... .... .... .... .... .... .... .... .... .... .... ....3 ..3.5 .5-1 -12 2

3.5. 3.5.11 11

Chec Checki king ng th the e eng engin ine e val valve ve pl play ay (L (L52 524, 4, L5 L534 34)) .. .... .... .... .... .... .... .... ..... ....3. .3.55-15 15

3.5. 3.5.12 12

Chec Checki king ng th the e eng engin ine e valve valve pl play ay (L5 (L538 38)) .. .... .... .... ..... ..... .... .... .... .... .... .... .... .... ...3. .3.55-18 18

3.5. 3.5.13 13

Chec Checki king ng th the e ffla lame me gl glow ow syst system em (L (L53 538) 8) .. .... .... .... .... ..... ..... .... .... .... .... .... .... ...3. .3.55-19 19

3.5. 3.5.14 14

Grea Greasin sing g tthe he ring ring gea gearr o on n the en engi gine ne fl flyw ywhe heel el (L (L53 538) 8) .. .... .... ...3. .3.55-20 20

3.5. 3.5.15 15

Chan Changi ging ng th the e di dies esel el en engi gine ne oi oill s sep epar arat ator or (L (L53 538) 8) .. ..... ...... ..... ..... .....3 ..3.5 .5-2 -20 0

3.5. 3.5.16 16

Bl Blee eedi ding ng the the fue fuell syste system m (L52 (L524, 4, L53 L534).. 4).... .... .... .... .... .... .... .... .... .... .... .... .... .... ...3. .3.55-21 21

3.5. 3.5.17 17

Bl Blee eedi ding ng the the fuel fuel system system (L53 (L538).. 8)..... ..... .... .... .... .... .... .... .... .... .... ..... ..... .... .... .... .... .... ...3. .3.55-22 22

3.5. 3.5.18 18

Bl Blee eedi ding ng the the fuel fuel system system (L53 (L538).. 8)..... ..... .... .... .... .... .... .... .... .... .... ..... ..... .... .... .... .... .... ...3. .3.55-23 23

3.5. 3.5.19 19

Repl Replac acin ing g th the e fuel fuel pre pre-fi -filt lter er (L5 (L524 24,, L534 L534).... )...... .... .... .... .... .... ..... ..... .... .... ....3 ..3.5 .5-2 -24 4

3.5. 3.5.20 20 3.5. 3.5.21 21

Repl Replac acin ing g the fu fuel el pre-f pre-fil ilte terr (L538)... (L538)..... .... .... .... .... ..... ..... .... .... .... .... .... ..... ..... .... ....3 ..3.5 .5-2 -25 5 Repl Replac acin ing g th the e fi filt lter er in inse sert rt in th the e fu fuel el se sepa para rato torr ((L5 L538 38)) .. ..... .....3 ..3.5 .5-2 -26 6

Maintenance

Service Manual 3.5. 3.5.22 22

Repl Replac acin ing g tthe he fu fuel el fi fine ne filte filterr (L52 (L524, 4, L53 L534).. 4).... .... ..... ..... .... .... .... .... .... ..... ..... .. 3. 3.55-27 27

3.5. 3.5.23 23

Chan Changi ging ng the the fue fuell ffin ine e filt filter er (L (L53 538) 8) .. ..... ..... .... .... .... ..... ..... .... .... .... .... .... .... .... .... .... .. 3. 3.55-29 29

3.5. 3.5.24 24

Drai Draini ning ng off off co cond nden ensa sate te fro from m the the fuel fuel fil filte terr (L52 (L524, 4, L53 L534 4 fine filter) ............................................................................ ............................................................................ 3.5-30

3.5. 3.5.25 25

Drai Draini ning ng off off cond conden ensa sate te fr from om the fu fuel el fi filt lter er (L (L53 538) 8) .. .... .... .... .... .... .. 3. 3.55-32 32

3.5. 3.5.26 26

Drai Draini ning ng off off cond conden ensa sate te fr from om th the e fu fuel el se sepa para rato torr (L (L53 538)... 8)..... 3. 3.55-33 33

3.5. 3.5.27 27

Drai Draini ning ng off off con conde dens nsat ate e and and sed sedimen imentt ffro rom m the the fu fuel el tank ................................................ .................................................................................... .................................... 3.5-33

3.5. 3.5.28 28

Ch Chec ecki king ng the the a air ir su suct ctio ion n ho hose ses s for for lea leaks and and ti tigh ghtt fitt fittin ing g .. 3. 3.55-34 34

3.5. 3.5.29 29

Cle Clean anin ing g the the air air ffil ilte terr ser servi vice ce cap cap an and d dus dustt e ext xtra ract ctio ion n valve................................................................................... valve............................................... .................................... 3.5-34

3.5. 3.5.30 30

Chec Checki king ng that that th the e ai airr ffil ilte terr v vac acuu uum m swit switch ch works. works... .... .... .... ..... ..... .... 3. 3.55-35 35

3.5. 3.5.31 31

Ch Chan angi ging ng the the a air ir ffil ilte terr main main el elem emen entt when when in indi dica cate ted d by by the vacuum switch ............................................................. ............................................................. 3.5-36

3.5. 3.5.32 32

Ch Chec ecki king ng the the e exh xhau aust st line lines s ffor or le leak aks s and and ti tigh ghtt ffit itti ting ng (L524)................................................................................. 3.5-37 (L524).................................................................................

3.5. 3.5.33 33

Ch Chec ecki king ng the the e exh xhau aust st line lines s ffor or le leak aks s and and ti tigh ghtt ffit itti ting ng (L534)................................................................................. 3.5-38 (L534).................................................................................

3.5. 3.5.34 34

Ch Chec ecki king ng the the e exh xhau aust st line lines s ffor or le leak aks s and and ti tigh ghtt ffit itti ting ng (L538)................................................................................. (L538).......................... ....................................................... 3.5-39

3.5. 3.5.35 35

Chec Checki king ng the cool coolan antt le leve vel... l..... .... .... .... .... .... .... .... .... .... .... .... .... ..... ..... .... .... .... .... .... .... .... .... 3. 3.55-40 40

3.5. 3.5.36 36

Chan Changi ging ng the the c coo oola lant nt filte filterr ((L5 L538 38)) .. .... ..... ..... .... .... .... ..... ..... .... .... .... .... .... .... .... .... .... 3. 3.55-40 40

3.5. 3.5.37 37

Ch Chec ecki king ng the the c coo oola lan nt anti antifr free eeze ze co conc ncen entr trat atio ion n (L52 (L524 4, L534).................................................................................. L534)................................................................ .................. 3.5-41

3.5.3 .5.38 8

Chec heckin king the the coo oollant anti tifr fre eez eze e an and DCA DCA 4 concentration concentratio n (L538).......................................................... 3.5-45

3.5. 3.5.39 39

Clea Cleani ning ng th the e coo cooli ling ng sy syst stem. em... .... .... ..... ..... .... .... .... .... .... .... .... .... .... ..... ..... .... .... .... .... .... .... 3. 3.55-49 49

3.5. 3.5.40 40

Chan Changi ging ng co cool olan antt wi with th an anti tifre freez eze e (L (L52 524, 4, L5 L534 34).... )...... .... .... .... .... .... .. 3. 3.55-50 50

3.5. 3.5.41 41

Ch Chan angi ging ng the the co cool olan antt wit with h ant antii-fr free eeze ze an and d DCA DCA 4 (L538)................................................................................. (L538).......................... ....................................................... 3.5-51

3.5. 3.5.42 42

Lu Lubr bric icat atin ing g the the pi pilo lott co cont ntro roll un unit it,, cl clea eani ning ng th the e magn magnet ets s and lubricating lubricating the uni universal versal joint (L524) (L524) ........................... 3.5-52

3.5. 3.5.43 43

Lu Lubr bric icat atin ing g the the pi pilo lott co cont ntro roll un unit it,, cl clea eani ning ng th the e magn magnet ets s and lubricating lubricating the universal joint (L5 (L534, 34, L538)................. 3.5-53

3.5. 3.5.44 44

Chec Checki king ng the the o oil il le leve vell iin n the the hyd hydra raul ulic ic tan tank.. k.... .... .... ..... ...... ..... .... .... ..... ..... 3. 3.55-53 53

3.5. 3.5.45 45

Drai Draini nin ng wa wate terr a and nd sed sedim imen entt fr from om th the e hyd hydra rau ulic lic tank tank .. .... .... .... 3. 3.5 5-5 -54 4

3.5. 3.5.46 46

Chan Changi ging ng the the hyd hydra raul ulic ic oil oil .. .... .... .... .... ..... ..... .... .... .... .... .... .... .... ..... ..... .... .... .... .... .... .... .... .... 3. 3.55-54 54

3.5. 3.5.47 47

Ch Chec ecki king ng an and d clea cleani ning ng th the e magn magnet etic ic ro rod d on th the e hydraulic tank..................................................................... 3.5-55

3.5. 3.5.48 48

Chan Changi ging ng the the hy hydr drau auli lic c ta tank nk re retu turn rn suct suctio ion n fi filt lter er ... ..... .... .... .... .... .... .. 3. 3.55-55 55

3.5. 3.5.49 49

Chan Changi ging ng the the h hyd ydra raul ulic ic ta tank nk ble bleed eder er fi filt lter er .. .... .... .... .... .... .... .... .... .... .... .... .... 3. 3.55-56 56

3.5. 3.5.50 50

Chec Checki king ng the the ste steer erin ing g .. .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... ..... ..... 3. 3.55-56 56

3.5. 3.5.51 51

Lu Lub brica ricati tin ng the the bear bearin ing g poin points ts on on the the stee steeri ring ng cyl cylin inde ders rs .. .... 3. 3.55-56 56

3.5. 3.5.52 52 3.5. 3.5.53 53

Chec Checki king ng the the se serv rvic ice e br brak ake e and and pa park rkin ing g br brak ake e .. .... .... .... .... ..... ..... .... .. 3. 3.55-57 57 Ch Chec ecki king ng the the g gap ap an and d we wear on on tthe he pa park rkin ing g bra brake ke lini lining ngs.. s.. 3. 3.55-57 57

 

Service Manual

Maintenance

3.5. 3.5.54 54

Chec Checki king ng tthe he ind indic icat ator or lamp lamps s and and ligh lighti ting. ng... .... .... .... .... .... .... .... .... .... .... .... ...3. .3.55-58 58

3.5. 3.5.55 55

Chec Checki king ng th the e bat batte teri ries es,, fl flui uid d leve levell and and term termin inal als.... s...... ..... ..... ..... .....3 ..3.5 .5-5 -59 9

3.5. 3.5.56 56

Chec Checki king ng tthe he tra trans nsfe ferr gear gear oil oil level... level...... ..... .... .... .... .... .... .... .... .... .... .... .... .... .... ....3 ..3.5 .5-6 -60 0

3.5. 3.5.57 57

Chan Changi ging ng th the e transfe transferr gear gear oil .. ..... ..... .... .... .... ..... ..... .... .... .... .... .... .... .... .... .... .... .... .... ....3 ..3.5 .5-6 -60 0

3.5. 3.5.58 58

Chec Checki king ng the ax axle le oil leve levels ls .. .... .... .... .... .... .... .... .... .... .... .... .... .... .... ..... ..... .... .... .... ..... ..... ....3 ..3.5 .5-6 -61 1

3.5.59 3.5 .59

Cha Changi nging ng the axle axle ge gear ar oil..... oil........ ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ......3 ...3.5.5-62 62

3.5. 3.5.60 60

Ch Chec ecki king ng th the e ttig ight htne ness ss of th the e wh whee eels ls (o (onc nce e aft after er 50 50,, 100 and 250 h) ...................................................................3.5-63 ...................................................................3.5-63

3.5. 3.5.61 61

Chec Checki king ng and and lubr lubric icat atin ing g the the driv drive e shaf shaftt .. .... .... .... .... ..... ..... .... .... .... .... .... .... ...3. .3.55-64 64

3.5. 3.5.62 62

Chec Checki king ng and and adj adjus usti ting ng the ty tyre re pre press ssur ure... e...... ..... .... .... .... ..... ..... .... .... .... ...3.5 .3.5-6 -64 4

3.5. 3.5.63 63

Lu Lubr bric icat atin ing g th the e ar arti ticu cula lati tion on be bear arin ing g and and re rear ar os osci cill llat atin ing g bearing................................................................................3.5-65

3.5. 3.5.64 64

Grea Greasin sing g the c cab ab door door hing hinges es .. ..... ..... .... .... .... ..... ..... .... .... .... .... .... .... .... .... .... .... .... .... ....3 ..3.5 .5-6 -65 5

3.5. 3.5.65 65

Clea Cleani ning ng or re repl pla acing cing th the e ffre resh sh ai airr a and nd re reci circ rcul ulat ated ed ai airr filter ........................................... .....................................................................................3.5-65 ..........................................3.5-65

3.5. 3.5.66 66

Ch Chec ecki king ng th the e iind ndic icat ator or an and d ffil illi ling ng le leve vell b bea eads ds in th the e dryer-collector unit unit of the air conditioner ............................3.5-66

3.5. 3.5.67 67

Ch Chec ecki king ng a and nd lu lubr bric icat atin ing g the the bea beari ring ngs s and and lubr lubric icat atio ion n points on Z lift arms .................................................... ............................................................3.5-67 ........3.5-67

3.5. 3.5.68 68

Ch Chec ecki king ng a and nd lu lubr bric icat atin ing g the the bea beari ring ngs s and and lubr lubric icat atio ion n

3.5. 3.5.69 69

points on P lift arms............................................................3.5-68 Ch Chec ecki king ng an and d llub ubri rica cati ting ng th the e buc bucke kett b bea eari ring ng on Z llif iftt arms....................................................................................3.5-70

3.5. 3.5.70 70

Ch Chec ecki king ng an and d llub ubri rica cati ting ng th the e buc bucke kett b bea eari ring ng on P lif liftt arms....................................................................................3.5-71

3.5. 3.5.71 71

Chec Checki king ng th the e buc bucke kett sto stops ps on Z lif liftt a arm rms s .. .... .... .... ..... ..... .... .... .... .... .... .... ....3 ..3.5 .5-7 -72 2

3.6 3.6

Te Testi sting ng and and a adj djus ustm tmen entt task tasks.... s...... .... .... .... .... .... ..... ..... .... .... .... ..... ..... .... .... .... .... .... .... .... ..... ..... .... .... ....3 ..3.6 .6-1 -1 3.6. 3.6.1 1

Pr Prep epar arin ing g fo forr te test stin ing g an and d ad adju just stme ment nt .. .... .... .... .... .... ..... ..... .... .... .... ..... ..... .... .... .... ...3. .3.66-1 1

3.6. 3.6.2 2

Ch Chec ecki king ng th the e en engi gine ne spee speed d L5 L524 24,, L5 L534. 34... ..... ..... .... .... .... .... .... .... .... .... .... .... .... ...3. .3.66-2 2

3.6. 3.6.3 3

Ch Chec ecki king ng th the e en engi gine ne spee speed d L5 L538.. 38.... .... .... .... .... .... .... .... ..... ..... .... .... .... .... .... .... .... ..... ....3. .3.66-3 3

3.6. 3.6.4 4

Ch Che eck ckiing th the e ffa an mo moto torr an and ffa an co contr tro ol p pre ress ssu ure reli relie ef

3.6. 3.6.5 5

valve .....................................................................................3.6-4 .....................................................................................3.6-4 Ch Chec ecki king ng th the e ttra rave vell h hyd ydra rau ulics lics blo block cked ed co cond ndit itio ion n .. .... .... .... .... .... .... ....3 ..3.6 .6-6 -6

3.6. 3.6.6 6

Ch Chec ecki king ng th the e ttra rave vell p pum ump p repl replen enis ishi hing ng pr pres essu sure.. re.... .... .... .... .... .... .... ...3. .3.66-7 7

3.6. 3.6.7 7

Ch Che eck ckiing th the e st sta art of regu regula lati tion on of th the e va vari ria able displacement displaceme nt pum pump p .................................................... ..............................................................3.6-7 ..........3.6-7

3.6. 3.6.8 8

Ch Chec ecki king ng th the e ou outp tput ut of the tr trav avel el pu pump mp... ..... .... .... .... .... .... .... .... .... .... .... .... .... .... ...3. .3.66-8 8

3.6. 3.6.9 9

Ch Che eck ckiing th the e pre press ssu ure reli relie ef a an nd rre eple len nish ishin ing g va valve lve of of the travel pump.....................................................................3.6-9

3.6. 3.6.10 10

Chec Checki king ng th the e pr pres essu sure re cutcut-of offf of th the e tr trav avel el pu pump mp .. .... .... .... .... ..... ....3. .3.66-10 10

3.6. 3.6.11 11

Ch Chec ecki king ng th the e var varia iabl ble e dis displ plac acem emen entt mot motor or 1 in in th the e control range.......................................................................3.6-11 range.......................................................................3.6-11

3.6. 3.6.12 12

Ch Chec ecki king ng th the e ser servo vo pre ress ssur ure e reg regul ulat atio ion n of of var varia iabl ble e displacement displaceme nt motor 2 .........................................................3.6-12 .........................................................3.6-12

 

Maintenance

Service Manual 3.6. 3.6.13 13

Ch Chec ecki king ng the the pre ress ssur ure e re reg gul ulat atio ion n of va vari riab able le displacement displaceme nt motor 2 ........................................................ 3.6-12

3.6. 3.6.14 14

Chec Checki king ng the the wo worki rking ng hydr hydrau auli lics cs pu pump mp fl flow ow cont contro roll ller. er... .... .... 3. 3.66-13 13

3.6. 3.6.15 15

Ch Chec ecki king ng the the s sec econ onda dary ry pr pres essu sure re re reli lief ef va valv lves es on th the e control block block L524.............................. L524.............................................................. ................................ 3.6-14

3.6. 3.6.16 16

Ch Chec ecki king ng the the s sec econ onda dary ry pr pres essu sure re re reli lief ef va valv lves es on th the e control block L534, L53 L538.................................................... 8.................................................... 3.6-14

3.6. 3.6.17 17

Ch Chec ecki king ng the the L LS S pre press ssur ure e cut cut-o -off ff on th the e con contr trol ol bl bloc ock k L524 ................................................................................... L524.................................................. ................................. 3.6-15

3.6. 3.6.18 18

Ch Chec ecki king ng the the L LS S pre press ssur ure e cut cut-o -off ff on th the e con contr trol ol bl bloc ock k L534, L538 L538..................................................... ......................................................................... .................... 3.6-15

3.6. 3.6.19 19

Ch Chec ecki kin ng the the P kin kinem emat atic ics s pre pre-t -ten ensi sion on va valv lve e on on tth he control block L534, L L538.................................... 538.................................................... ................ 3.6-16

3.6. 3.6.20 20

Ch Chec ecki king ng the the o ope peni ning ng an and d clo closi sing ng pre ress ssur ure e of of tthe he compact brake valve.......................................................... 3.6-16

3.6. 3.6.21 21

Chec Checki king ng the the ac accu cumu mula lato torr ch char arge ge pr pres essu sure... re..... ..... ..... .... .... .... .... .... .... .. 3. 3.66-17 17

3.6. 3.6.22 22

Ch Chec ecki king ng the the b bra rake ke pr pres essu sure re on th the e com compa pact ct br brak ake e valve................................................................................... valve............................................... .................................... 3.6-17

3.6. 3.6.23 23

Chec Checki king ng the the b bra rake ke ligh lightt p pre ressu ssure re sw swit itch... ch..... .... .... .... .... .... .... .... .... .... .... .... 3. 3.66-18 18

3.6. 3.6.24 24

Chec Checkin king g tthe he ca capa paci city ty of th the e br brak ake e accu accumu mula lato tor... r..... .... .... .... .... .... .. 3. 3.66-19 19

3.6. 3.6.25 25

Chec Checkin king g the the in inch ch/b /bra rake ke syst system em ov over erla lap... p...... ..... .... .... .... .... .... .... .... .... .... .... 3. 3.66-19 19

3.7 3.7

 

 

Lu Lubr bric ican ants ts and and fue fuels... ls..... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .. 3. 3.77-1 1 3.7. 3.7.1 1

Hand Handli ling ng lubr lubric ican ants ts an and d fu fuel els. s... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .. 3. 3.77-1 1

3.7. 3.7.2 2

Lu Lubr bric icat atin ing g oils oils fo forr di dies esel el engi engine nes s .. .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... 3. 3.77-2 2

3.7. 3.7.3 3

Dies Diesel el ffue uels ls ..... ....... .... .... .... .... .... .... ..... ..... .... .... .... ..... ..... .... .... .... .... .... .... .... ..... ..... .... .... .... .... .... .... .... ..... ..... .... 3. 3.77-4 4

3.7. 3.7.4 4

En Engi gine ne cool coolan ants ts (L (L52 524, 4, L5 L534 34)... )..... .... .... .... .... .... .... .... .... .... .... .... .... .... ..... ..... .... .... ..... ...... ... 3. 3.77-5 5

3.7. 3.7.5 5

Cool Coolan ants ts for for dies diesel el en engi gine nes s (L (L53 538).. 8).... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .. 3. 3.77-6 6

3.7. 3.7.6 6

Hydr Hydrau auli lic c oils oils.. .... .... .... .... .... ..... ..... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... ..... ..... .... .... .... .... .... .. 3. 3.77-9 9

3.7. 3.7.7 7

Lu Lubr bric icat atin ing g oils oils for the the trans transmi miss ssio ion n .. .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .. 3. 3.77-10 10

3.7. 3.7.8 8

Grea Grease se for for ge gene nera rall lu lubri brica cati tion on po poin ints. ts... .... .... .... .... ..... ...... ..... .... .... .... .... ..... ..... .... 3. 3.77-11 11