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Liebherr L542-435 Wheel Loader Service Repair Manual SN FROM 17895 PDF
Liebherr L542-435 Wheel Loader Service Repair Manual SN FROM 17895 PDF
Liebherr L542-435 Wheel Loader Service Repair Manual SN FROM 17895 PDF
Service Manual
(20
Wheel loader
(10 points)
L524 – L542 2plus1
en
Service Manual
(20
Wheel loader
(10 points)
L524 – L542 2plus1
(10
Address
Address: LIEBHERR-WERK BISCHOFSHOFEN GMBH
Product ID
Manufacturer: LIEBHERR-WERK BISCHOFSHOFEN GMBH
Product group: Wheel loader
Type: L524 L528 L538 L542
Production number: 659 660 433 435
Serial number: 17890 17891 17893 17895
Document ID
Order number: 10411314
Author: LBH / Technical Documentation Department
Document version: 01
Manual number:
Owner:
Preface
Intended readership This service manual is addressed to anyone whose task it is to ensure that the
machines are ready for everyday use. This especially includes mechanics and
workshop staff of Liebherr dealers and branches.
Contents The first chapter contains information on safety regulations and on the
special tools needed for maintenance and repairs.
Chapter 2 gives you an overview of all the most important technical data of
the machine as a whole and its individual assemblies.
Next comes the maintenance chapter, with the maintenance and inspection
schedule, the testing and adjustment checklists, lubrication charts, description
of maintenance tasks, testing and adjustment tasks and specifications of fuel
and lubricants.
The technical description of the machine is in the following chapters,
structured according to fifteen function groups. The layout, function and
technical data of the groups, components and parts are explained.
Chapter 19 contains information on troubleshooting, the service code table
and a description of the “SCULI” service software.
Chapter 20 will be gradually updated with the latest options.
Instructions on use This manual describes several types and versions of machines. The
information generally applies to the types and serial numbers stated at the
bottom of the page. The exception to this is information which only applies to
specific types and serial numbers, which are stated at the beginning of the
section concerned (for example technical data of parts).
Where possible, the ID numbers of parts and components are stated in
the heading.
This manual is available in German, English, French, Spanish, Italian and
Russian.
Working instructions Always follow the safety regulations whenever you work on the machine.
You will find a reference to this in the “General Information” section.
In order to perform these tasks you need a complete set of basic tools
andcertain special tools, all in perfect working order. All tasks require
absolute cleanliness.
Replace seals such as O-rings and surface seals during repairs.
DVD edition Please note that this manual is not only available in printed form, but is also
available as electronic documentation on DVD (Lidos).
General information 1
Product description 2
Maintenance 3
Diesel engine and pump distributor gear 4
Cooling system 5
Travel hydraulics 6
Working hydraulics 7
Steering system 8
Brake system 9
Electrical system 10
Transfer gear 11
Axles and cardan shaft 12
Machine frame and ballast weight 13
Central lubrication system 14
Coverings and access 15
Cab, heating and air-conditioning 16
Lift arms and quick-change device 17
Equipment and accessories 18
Service codes and diagnosis 19
Options 20
1 General informations
1.0
Chapter contents
1 General informations........................................................... 1.0-1
1.1.1 Introduction
1. The symbols below have the following meanings:
DANGER
Denotes an urgent, dangerous situation.
Will result in death or serious injury.
Actions to avert the danger.
WARNING
Denotes a dangerous situation.
Can result in death or serious injury.
Actions to avert the danger.
CAUTION
Risk of personal injury.
Denotes a potentially dangerous situation which can lead to slight injury if
not avoided.
Actions to avert the danger.
NOTICE
Risk of damage to the machine.
Denotes actions or circumstances which may result in damage to the machine.
Actions to avert the danger.
Note
Useful information
Denotes information on correctly handling the machine and the lubricants
and fuels used.
Actions to implement.
1 Introduction
2 General safety regulations
3 Proper use
4 Decals on the machine
5 Instructions on preventing crushing injuries and burns
6 Instructions on preventing fires and explosions
7 Safety instructions for start-up
8 Safety precautions during start-up
9 Instructions for safe working
10 Safety instructions for driving on slopes
11 Parking safely
12 Transporting the machine safely
13 Towing the machine safely
14 Measures for ensuring safe maintenance
15 Safety instructions for working on machines with hydro accumulators
16 Safety instructions for welding work on the machine
17 Instructions for working safely on the working attachment
18 Safety instructions for transporting the machine by crane
19 Safe maintenance of hydraulic hoses and hose lines
20 Attachments and accessories
21 Protection against vibrations
1.3 Standard
1.3.1 Tightening torques for screws
Pre-loading forces and tightening torques for screws with standard and fine
metric threads.
Standard and fine metric threads
Standard and fine metric threads. All figures are for bolted connections
All figures are for bolted connections with at least one Dacromet
without any Dacromet 500 coated elements (screws, washers, nuts…)
500 coated element (screws, washers, nuts…)
Surface: Surface:
- DACROMET 500 - black finish or phosphated
- zinc-plated
Assembly pre- Tightening Assembly pre- Tightening
Thread Class loading forces torques Thread Class loading forces torques MA in
FM in N MA in Nm FM in N Nm
for avg. coefficient of friction µG= 0.10 for avg. coefficient of friction µG= 0.12
8.8 4 200 2,5 8.8 4 050 2,8
M4 10.9 6 200 3,7 M4 10.9 6 000 4,1
12.9 7 300 4,3 12.9 7 000 4,8
8.8 6 900 4,9 8.8 6 600 5,5
M5 10.9 10 100 7,3 M5 10.9 9 700 8,1
12.9 11 900 8,5 12.9 11 400 9,5
8.8 9 700 8,5 8.8 9 400 9,5
M6 10.9 14 300 12,5 M6 10.9 13 700 14,0
12.9 16 700 14,5 12.9 16 100 16,5
8.8 14 200 14,0 8.8 13 700 15,5
M7 10.9 20 900 20,5 M7 10.9 20 100 23,0
12.9 24 500 24,0 12.9 23 500 27
8.8 17 900 20,5 8.8 17 200 23
M8 10.9 26 000 30 M8 10.9 25 000 34
12.9 30 500 35 12.9 29 500 40
8.8 19 600 22 8.8 18 800 24,5
M8x1 10.9 28 500 32 M8x1 10.9 27 500 36
12.9 33 500 38 12.9 32 500 43
8.8 25 500 32 8.8 24 800 36
M9x1 10.9 38 000 46 M9x1 10.9 36 500 53
12.9 44 000 54 12.9 42 500 62
8.8 28 500 41 8.8 27 500 46
M10 10.9 42 000 60 M10 10.9 40 000 68
12.9 49 000 71 12.9 47 000 79
8.8 32 500 45 8.8 31 500 52
M10x1 10.9 48 000 67 M10x1 10.9 46 500 76
12.9 56 000 78 12.9 54 000 89
8.8 30 500 43 8.8 29 500 49
M10x1,25 10.9 45 000 64 M10x1,25 10.9 43 000 72
12.9 53 000 74 12.9 51 000 84
8.8 41 500 71 8.8 40 000 79
M12 10.9 61 000 104 M12 10.9 59 000 117
12.9 71 000 121 12.9 69 000 135
8.8 46 500 77 8.8 45 000 87
M12x1,25 10.9 68 000 112 M12x1,25 10.9 66 000 125
12.9 80 000 130 12.9 77 000 150
8.8 44 000 74 8.8 42 500 83
M12x1,5 10.9 65 000 108 M12x1,5 10.9 62 000 122
12.9 76 000 125 12.9 73 000 145
8.8 57 000 113 8.8 55 000 125
M14 10.9 84 000 165 M14 10.9 80 000 185
12.9 98 000 195 12.9 94 000 215
8.8 63 000 121 8.8 61 000 135
M14x1,5 10.9 92 000 175 M14x1,5 10.9 89 000 200
12.9 108 000 205 12.9 104 000 235
This document must not be copied or reproduced without prior permission. This Liebherr-Norm_DE_V001.dot
document has been electronically prepared and is valid without requiring a signature.
L524 - 659 / from 17890 copyright 1.3-1 of 4
L528 - 660 / from 17890
L538 - 433 / from 17890 MJFCIFSS
L542 - 435 / from 17890
General informations Service manual
Mjfcifss - Standard
This document must not be copied or reproduced without prior permission. This Liebherr-Norm_DE_V001.dot
document has been electronically prepared and is valid without requiring a signature.
1.3-2 of 4 L524 - 659 / from 17890
L528 - 660 / from 17890
L538 - 433 / from 17890
L542 - 435 / from 17890
Service manual General informations
Mjfcifss - Standard
This document must not be copied or reproduced without prior permission. This Liebherr-Norm_DE_V001.dot
document has been electronically prepared and is valid without requiring a signature.
L524 - 659 / from 17890 copyright 1.3-3 of 4
L528 - 660 / from 17890
L538 - 433 / from 17890 MJFCIFSS
L542 - 435 / from 17890
2 Product description
2.0
Chapter contents
2 Product description ............................................................. 2.0-1
Engine
Valid for: L524 - 659 / from 17890; L528 - 660 / from 17890;
Description Value Unit
Engine model Liebherr D 504 TI / John Deere CD 4045
Number of cylinders 4 4
Capacity 4500 4500 cm³
Rated power as per ISO 9249 86 / 117 86 / 117 kW /
hp
Rated speed 2400 2400 min-1
Maximum torque at 1500 min-1 430 430 Nm
Lower idle speed 850 10
850 10
min-1
Upper idle speed 2550 20
2550 20
min-1
Inlet valve play (cold) 0,36 0,36 mm
Outlet valve play (cold) 0,46 0,46 mm
Control thermostat opening temperature 82 82 °C
Longitudinal / traverse inclinability 30 / 30 30 / 30 °
Starter operating voltage 24 24 V
Starter power consumption 7 7 kW
Alternator voltage output 27,8 27,8 V
Alternator current output 55 55 A
Emission thresholds comply with EU RL 97/68 EC Stage IIIa
Engine
Valid for: L538 - 433 / from 17890; L542 - 435 / from 17890; ID 1011 8823
Description Value Unit
Engine model D 934 S A6
Number of cylinders 4
Firing order 1-3-4-2
Capacity 6360 cm³
Cylinder bore 122 mm
Stroke 136 mm
Fuel tank
Description Value Unit
Tank capacity, FULL 180 l
Tank capacity, RESERVE 30 l
Fuel pre-filter
Valid for: L524 - 659 / from 17890; L528 - 660 / from 17890; ID 9739 323
Description Value Unit
Filtration grade 30 µm
Valid for: L538 - 433 / from 17890; L542 - 435 / from 17890; ID 1011 8823
Description Value Unit
Filtration grade 10 µm
Vacuum switch
Description Value Unit
Air filter contamination vacuum switch 50 mbar
activation point
Clutch
Valid for: L524 - 659 / from 17890; L528 - 660 / from 17890; ID 9739 323
Description Value Unit
Torsion damper screw adhesive 241 Loctite
Torsion damper screw tightening torque 49 Nm
Hub star fastening screw tightening torque 86 Nm
Valid for: L538 - 433 / from 17890; L542 - 435 / from 17890; ID 1011 8823
Description Value Unit
Torsion damper screw adhesive 241 Loctite
Torsion damper screw tightening torque 117 Nm
Gear pump
Valid for: L524 - 659 / from 17890; L528 - 660 / from 17890; ID 1029 6814
Description Value Unit
Capacity 16 cm³
Rotary speed at rated engine speed 2323 min-1
Valid for: L538 - 433 / 17890 - 19018; L542 - 435 / 17890 - 19018; ID 1029 5259
Description Value Unit
Capacity 14 cm³
-1
Rotary speed at rated engine speed 2468 min
Valid for: L538 - 433 / from 19019; L542 - 435 / from 19019; ID 1041 2918
Description Value Unit
Capacity 16 cm³
Rotary speed at rated engine speed 2468 min-1
Gear motor
Valid for: ID 5717 099
Description Value Unit
Gear motor displacement 16 cm³
5
Pressure relief valve 175 bar
Coil resistance 4.5 Ohm
41
Screw tightening torque 124 Nm
Valid for: L538 - 433 / from 17890; L542 - 435 / from 17890
Description Value Unit
Control type EP
Maximum capacity 125 cm³
Flow rate at rated speed 246 l/min
Power 90 kW
Valid for: L538 - 433 / from 17890; L542 - 435 / from 17890
Description Value Unit
Control type HA1R
Maximum displacement 80 cm³
Minimum displacement 52 cm³
Maximum swivel angel 25 °
Minimum swivel angle 16.3 °
Maximum speed 4560 min-1
Torque ( p 400 bar) 520 Nm
5
Start of regulation 250 bar
Current consumption of travel direction 1,2 A
solenoid valve
Resistance of travel direction solenoid 22 Ohm
valve
Valid for: L538 - 433 / from 17890; L542 - 435 / from 17890
Description Value Unit
Control type EP
Maximum displacement 140 cm³
Maximum swivel angel 25 °
Minimum swivel angle 0 °
Maximum speed 5030 min-1
Torque ( p 400 bar) 855 Nm
Maximum discharge valve capacity 15 l/min
Discharge valve orifice diameter 2.5 mm
Weight 60 kg
Valid for: L538 - 433 / from 17890; L542 - 435 / from 17890
Description Value Unit
Control type LRDS
Maximum capacity 75 cm³
Flow rate at rated speed 143 l/min
Power 51 kW
Power controller start of regulation 190 bar
2
Flow regulator (delta p) 32 bar
Weight 45 kg
Control block
Description Value Unit
Piston diameter 18 mm
Lift arm up/down control piston flow 140 / 60 l/min
Tilt in/out control piston
120 / 80 l/min
(Z kinematics) flow rate
Tilt in/out control piston
140 / 90 l/min
(P kinematics) flow rate
5
LS pressure cut-off / L524, L528 315 bar
5
Working hydraulics L538, L542 330 bar
5
LS pressure cut-off / L524, L528 230 bar
5
Steering L538, L542 250 bar
3
Pressure relief valve pre-tension 16 bar
Weight 32 kg
Stabilisation module
Description Value Unit
Control piston diameter 16 mm
20
Cut-off pressure (LFD off) 120 bar
10
Safety valve 330 bar
Restrictor check valve diameter 2.0 / 0.4 mm
Solenoid valve current consumption 0.7 A
Solenoid valve resistance 40 Ohm
Weight 13 kg
Lift cylinder
Valid for: L524 - 659 / from 17890; L528 - 660 / from 17890; ID 9609 285
Description Value Unit
Piston diameter 100 mm
Rod diameter 60 mm
Stroke length 735 mm
Minimum installation length 1170 mm
Weight 80 kg
Lifting at rated load 6.0 sec
Lowering empty 4.0 sec
Piston rod bearing tightening torque (hex 290 Nm
screws)
Piston tightening torque WN - 4121-091 -
Valid for: L538 - 433 / from 17890; L542 - 435 / from 17890; ID 9655 214
Description Value Unit
Piston diameter 110 mm
Rod diameter 60 mm
Stroke length 735 mm
Minimum installation length 1170 mm
Weight 89 kg
Lifting at rated load 6.0 sec
Lowering empty 4.0 sec
Piston rod bearing tightening torque 290 Nm
(hex screws)
Piston tightening torque WN - 4121-092 -
Valid for: L538 - 433 / from 17890; L542 - 435 / from 17890; ID 9655 215
Description Value Unit
Piston diameter 140 mm
Rod diameter 80 mm
Stroke length 440 mm
Minimum installation length 870 mm
Weight 110 kg
Tilt in/out empty 3.0 sec
Piston rod bearing tightening torque 290 Nm
(hex screws)
Piston tightening torque WN - 4121-173 -
Valid for: L538 - 433 / from 17890; L542 - 435 / from 17890; ID 1030 1135
Description Value Unit
Piston diameter 90 mm
Rod diameter 50 mm
Stroke length 935 mm
Minimum installation length 1240 mm
Weight 57 kg
Filter unit
Description Value Unit
Filtration grade 10 µm
Pre-tension valve 0.5 bar
Replenishing valve 0.05 bar
Replenishing strainer 160 µm
Bypass valve 2.5 bar
Return strainer 80 µm
Bleeder filter
Description Value Unit
Filtration grade 10 m
Inlet opening pressure 0.03 bar
Outlet opening pressure 0.5 bar
Thread 3/4 inch
Servostat
Description Value Unit
Displacement 370 cm³
10
Secondary pressure relief 285 bar
Flow booster 1 : 1.6
Steering cylinder
Valid for: ID 1029 1027
Description Value Unit
Piston diameter 90 mm
Rod diameter 45 mm
Stroke length 500 mm
Weight 26.2 kg
Valid for: L538 - 433 / from 17890; L542 - 435 / from 17890
Description Value Unit
Capacity 4 cm³
Flow rate at rated speed 9.9 l/min
Speed at rated speed 2474 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
Description Value Unit
Battery voltage 12 V
Battery capacity 135 Ah
Acid density of charged battery 1.26 - 1.28 kg/l
Cold test current (at -18 °C EN 60095-1) 950 A
2.1.9 Transmission
Transmission
Valid for: L524 - 659 / from 17890; L528 - 660 / from 17890
Description Value Unit
Type 319
Variable displacement motor 1 1.55 -
transmission
Variable displacement motor 2 3.83 -
transmission
Cardan speed at 40 km/h 3098 min-1
Valid for: L538 - 433 / from 17890; L542 - 435 / from 17890
Description Value Unit
Type 319
Variable displacement motor 1 transmission 1.55 -
Variable displacement motor 2 transmission 3.83 -
Cardan speed at 40 km/h 2795 min-1
Speed sensors
Description Value Unit
Type Inductive sensor -
Resistance at 20 °C 1050 ±100 Ohm
Front axle
Valid for: L524 - 659 / from 17890; L528 - 660 / from 17890
Description Value Unit
Type 123/60
Self-locking differential level 45 %
Width 1960 mm
Overall transmission 18.6
Differential transmission 10/31
Wheel hub transmission 1/6
Wheel lug tightening torque 650 Nm
Wheel lug spanner size 30 mm
Flange size 1920 mm
Weight 570 kg
Valid for: L538 - 433 / from 17890; L542 - 435 / from 17890
Description Value Unit
Type 113/58
Self-locking differential level 45 %
Width 1900 mm
Rear axle
Valid for: L524 - 659 / from 17890; L528 - 660 / from 17890
Description Value Unit
Type 123/51
Self-locking differential level 45 %
Width 1960 mm
Overall transmission 18.6
Differential transmission 10/31
Wheel hub transmission 1/6
Wheel lug tightening torque 650 Nm
Wheel lug spanner size 30 mm
Swing angle (to each side) 6 °
Flange size 1920 mm
Weight 680 kg
Valid for: L538 - 433 / from 17890; L542 - 435 / from 17890
Description Value Unit
Type 113/50
Self-locking differential level 45 %
Width 1900 mm
Overall transmission 18.54
Differential transmission 11/34
Wheel hub transmission 1/6
Wheel lug tightening torque 650 Nm
Wheel lug spanner size 30 mm
Swing angle (to each side) 6 °
Flange size 1920 mm
Weight 840 kg
Cardan shaft
Valid for: L524 - 659 / from 17890; L528 - 660 / from 17890
Description Value Unit
Minimum length 1875 mm
Width 2020 mm
Weight 27.5 kg
Valid for: L538 - 433 / from 17890; L542 - 435 / from 17890
Description Value Unit
Minimum length 1967 mm
Width 2122 mm
Weight 30.5 kg
Ballast weight
Valid for: L524 - 659 / from 17890; L538 - 433 / from 17890
Description Value Unit
Left ballast weight 515 kg
Right ballast weight 565 kg
Valid for: L538 - 433 / from 17890; L542 - 435 / from 17890
Description Value Unit
Refrigerant R134a
Refrigerant oil (PAG oil) ZXL 100 PG
Coolant quantity 1250+50 g
10%
Cooling power 9.7 kW
Condenser
Description Value Unit
Maximum air flow 4000 m³/h
Heating power 9.7 ±1 kW
Test pressure 35 bar
Pressure switch
Description Value Unit
Low pressure OFF 1.5 ±0.5 bar
Low pressure ON 3.5 bar
High pressure OFF 25 ±2 bar
High pressure ON 18 ±1.5 bar
Fan OFF 15 ±1 bar
Fan ON 19 ±1 bar
Evaporator
Description Value Unit
Cooling power 9.7 kW
±10%
Temperature sensor activation temperature 5.5 °C
±10%
Temperature sensor deactivation temperature 4.5 °C
Valid for: L538 - 433 / from 17890; L542 - 435 / from 17890
Description Value Unit
L length 2500 mm
Weight 1072 kg
Valid for: L538 - 433 / from 17890; L542 - 435 / from 17890
Description Value Unit
L length 2500 mm
L high lift length 3000 mm
Weight (without QCD) 1165 kg
Bucket
Valid for: L524 - 659 / from 17890
Description Value Unit
B bucket width 2500 mm
Specific material weight 1.8 t/m³
Heaped bucket capacity (ISO 7546) 2 m³
Forklift
Description Value Unit
Fork carrier prong size FEM III
Prong length 1200 mm
Chapter contents
3 Maintenance........................................................................ 3.0-1