Liebherr l509 779 wheel loader service repair manual sn：9099

en

Service manual (20

Wheel loader (10 points)

L506 - L510 Stereo (10

en

Service manual (20

Wheel loader (10 points)

L506 - L510 Stereo (10

Address Address:

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

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

LIEBHERR-WERK BISCHOFSHOFEN GMBH Wheel loader L506 L507 L508 L509 L510 776 777 778 779 782 9099 9099 9099 9099 9099

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

1011 2640 LBH / T-DOK department 02

Foreword

Target group

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

Contents

In the first chapter you will find information about safety regulations as well as specifications of the special tools needed for maintenance and repair.

Chapter 2 provides an overview of all important technical data for the entire machine and the individual assemblies.

The following chapter, entitled Maintenance, contains the maintenance and inspection schedule, inspection and setting logs, lubrication schedules and filling quantity tables, a description of maintenance procedures and specifications for prescribed lubricants and fuels.

The technical description of the machine in the following chapters is divided into 15 functional groups. The design, function, and technical data for each group, component and part are explained.

How to use this manual

This manual describes a variety of types and finished forms. In general, this information applies to the types and serial number groups specified in the footnotes. One exception is that specific type and serial number data are indicated at the beginning of each section (e.g. the technical specifications of the components).

Whenever possible, parts and components are supplemented by indication of the identification number in the heading.

This manual is available in German, English and French.

Working instructions

It is imperative that safety regulations be observed with all tasks done on the machine. You will find information on this in the General Information chapter.

A complete set of tools in perfect condition is required for work on the machine, along with any special tools that might be needed. Absolute cleanliness must be observed with all tasks!

Sealing material such as O-rings and surface seals should be replaced whenever repairs are carried out.

DVD edition

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

General information

1

Product description

2

Maintenance

3

Diesel engine

4

Cooling system

5

Travel hydraulics

6

Working hydraulics

7

Steering system

8

Brake system

9

Electrical system

10

Transfer gear

11

Axles, drive shafts

12

Machine frame, ballast weight

13

Central lubrication system

14

Covering, cab access

15

Cab, heating, air-conditioning

16

Lift arm, quick-change device

17

Attachments, accessories

18

Repair work, troubleshooting

19

     

   

  

 



 



 

 







 











 



 



 

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  

 

        



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



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 

                                                             

    

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   



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   



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   

         

  

 

        













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                                                                    

          



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  

  





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 

     

















            

 

 

       







        

        







  

  

  







               

  





         

























 



 















  

       

 

        

















         





 





               















 























 













       























 

 

 

 







   

            

                  



          





  

  







 

    

  

















      



          

  





   

          

                     

 

 

     

     







   

   

   

























 

  

 

       



  

 

        















  







 



 



 



 

 

 



 



 



 

  

 



 



 

 

                        

          

        







        



          





  

  







 

  













 







 









































    





 

 



  

 

        







2 Product Description 2.0 Chapter contents 2

Product Description............................................................. 2.0-1 2.1

L506 - 776 / from 9099 L507 - 777 / from 9099 L508 - 778 / from 9099

Technical data ................................................................................2.1-1 2.1.1

Complete machine................................................................2.1-1

2.1.2

Diesel engine........................................................................2.1-8

2.1.3

Cooling system ...................................................................2.1-12

2.1.4

Travel hydraulics ................................................................2.1-13

2.1.5

Working hydraulics .............................................................2.1-15

2.1.6

Steering system..................................................................2.1-18

2.1.7

Brake system......................................................................2.1-18

2.1.8

Electrical system.................................................................2.1-19

2.1.9

Transfer gear ......................................................................2.1-19

2.1.10

Axles and cardan shaft .......................................................2.1-20

2.1.11

Machine frame and ballast weight......................................2.1-22

2.1.12

Automatic central lubrication system..................................2.1-23

2.1.13

Cab, heating and air-conditioning.......................................2.1-24

2.1.14

Lift arms and quick-change device.....................................2.1-25

2.1.15

Equipment and accessories ...............................................2.1-26

L509 - 779 / from 9099 L510 - 782 / from 9099

copyright by

MJFCIFSS

2.0-1 of 2

Service Manual

Product Description Technical Data

2.1 Technical data 2.1.1 Valid for:

Complete machine L506 - 776 / from 9099

The values stated refer to the standard version of the machine: – with 365 / 70 R18 tyres – tipping loads and weights include all lubricants, full fuel tank, ROPS/ FOPS cab and driver.

Description

Value Unit

Bucket capacity as per ISO 7546 Bucket width

1900 mm

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

2872 mm

C Maximum bucket base height

3011 mm

D Maximum bucket pivot point height

3211 mm

E Maximum bucket top height F Reach at maximum lifting height and 42° tilt-out angle Fmax. Reach at 42° tilt-out angle

4040 mm

G Digging depth

1.8 t/m³ 2550 mm

818 mm 1517 mm 80 mm

H Height above the cab

2725 mm

I Height above exhaust

2600 mm

J Ground clearance

295 mm

K Wheel base L506 - 776 / from 9099 L507 - 777 / from 9099 L508 - 778 / from 9099

0.8 m³

L509 - 779 / from 9099 L510 - 782 / from 9099

2150 mm copyright by

MJFCIFSS

2.1-1 of 28

Product Description

Service Manual

Technical Data

Description

Value Unit

L Overall length

5295 mm

Turning radius over bucket outer edge

3690 mm

Lifting force (SAE)

39 kN

Breakout force (SAE)

43 kN

Tipping load when straight

3540 kg

Tipping load articulated at 30°

3231 kg

Angle of articulation (to each side) Operating weight

5160 kg

Tractive force

4587 daN

Travel speed in travel range 1, forward and reverse

0 - 6 km/h

Travel speed in travel range 2, forward and reverse

0 - 20 km/h

Sound pressure level in cab in L pA according to ISO 6396 Valid for:

30 °

70 dB (A)

L507 - 777 / from 9099

The values stated refer to the standard version of the machine: – with 365 / 70 R18 tyres – tipping loads and weights include all lubricants, full fuel tank, ROPS/ FOPS cab and driver.

2.1-2 of 28

copyright by

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L506 - 776 / from 9099 L507 - 777 / from 9099

L508 - 778 / from 9099 L509 - 779 / from 9099 L510 - 782 / from 9099

Service Manual

Product Description Technical Data

Description

Value Unit

Bucket capacity as per ISO 7546 Bucket width

2050 mm

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

2872 mm

C Maximum bucket base height

3011 mm

D Maximum bucket pivot point height

3211 mm

E Maximum bucket top height F Reach at maximum lifting height and 42° tilt-out angle Fmax. Reach at 42° tilt-out angle

4040 mm

G Digging depth

1.8 t/m³ 2550 mm

818 mm 1517 mm 80 mm

H Height above the cab

2725 mm

I Height above exhaust

2600 mm

J Ground clearance

295 mm

K Wheel base

2150 mm

L Overall length

5295 mm

Turning radius over bucket outer edge

3690 mm

Lifting force (SAE)

44 kN

Breakout force (SAE)

48 kN

Tipping load when straight

3836 kg

Tipping load articulated at 30°

3501 kg

Angle of articulation (to each side)

30 °

Operating weight

5240 kg

Tractive force

4593 daN

Travel speed in travel range 1, forward and reverse

0 - 6 km/h

Travel speed in travel range 2, forward and reverse

0 - 20 km/h

Sound pressure level in cab in L pA according to ISO 6396

L506 - 776 / from 9099 L507 - 777 / from 9099 L508 - 778 / from 9099

0.9 m³

L509 - 779 / from 9099 L510 - 782 / from 9099

copyright by

MJFCIFSS

70 dB (A)

2.1-3 of 28

Product Description

Service Manual

Technical Data

Valid for:

L508 - 778 / from 9099

The values stated refer to the standard version of the machine: – with 405 / 70 R18 tyres – tipping loads and weights include all lubricants, full fuel tank, ROPS/ FOPS cab and driver.

Description

Value Unit

Bucket capacity as per ISO 7546 Bucket width

2100 mm

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

2896 mm

C Maximum bucket base height

3035 mm

D Maximum bucket pivot point height

3235 mm

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

4115 mm

G Digging depth

1.8 t/m³ 2555 mm

817 mm 1515 mm 56 mm

H Height above the cab

2749 mm

I Height above exhaust

2624 mm

J Ground clearance

2.1-4 of 28

1.0 m³

319 mm

K Wheel base

2150 mm

L Overall length

5371 mm

Turning radius over bucket outer edge

3820 mm

Lifting force (SAE)

48 kN

Breakout force (SAE)

49 kN

copyright by

MJFCIFSS

L506 - 776 / from 9099 L507 - 777 / from 9099

L508 - 778 / from 9099 L509 - 779 / from 9099 L510 - 782 / from 9099

Service Manual

Product Description Technical Data

Description

Value Unit

Tipping load when straight

4190 kg

Tipping load articulated at 30°

3824 kg

Angle of articulation (to each side) Operating weight

5480 kg

Tractive force

4364 daN

Travel speed in travel range 1, forward and reverse

0 - 6 km/h

Travel speed in travel range 2, forward and reverse

0 - 20 km/h

Sound pressure level in cab in L pA according to ISO 6396 Valid for:

30 °

70 dB (A)

L509 - 779 / from 9099

The values stated refer to the standard version of the machine: – with 405 / 70 R18 tyres – tipping loads and weights include all lubricants, full fuel tank, ROPS/ FOPS cab and driver.

Description

Value Unit

Bucket capacity as per ISO 7546 Bucket width

L506 - 776 / from 9099 L507 - 777 / from 9099 L508 - 778 / from 9099

1.1 m³ 2200 mm

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

3000 mm

C Maximum bucket base height

3139 mm

D Maximum bucket pivot point height

3339 mm

L509 - 779 / from 9099 L510 - 782 / from 9099

copyright by

MJFCIFSS

1.8 t/m³ 2641 mm

2.1-5 of 28

Product Description

Service Manual

Technical Data

Description

Value Unit

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

909 mm 1640 mm 95 mm

H Height above the cab

2750 mm

I Height above exhaust

2625 mm

J Ground clearance

335 mm

K Wheel base

2300 mm

L Overall length

5760 mm

Turning radius over bucket outer edge

4150 mm

Lifting force (SAE)

54 kN

Breakout force (SAE)

55 kN

Tipping load when straight

4645 kg

Tipping load articulated at 30째

4225 kg

Angle of articulation (to each side)

30 째

Operating weight

6080 kg

Tractive force

5592 daN

Travel speed in travel range 1, forward and reverse

0 - 6 km/h

Travel speed in travel range 2, forward and reverse

0 - 20 km/h

Sound pressure level in cab in L pA according to ISO 6396

2.1-6 of 28

4235 mm

copyright by

MJFCIFSS

L506 - 776 / from 9099 L507 - 777 / from 9099

70 dB (A)

L508 - 778 / from 9099 L509 - 779 / from 9099 L510 - 782 / from 9099

Service Manual

Product Description Technical Data

Valid for:

L510 - 782 / from 9099

The values stated refer to the standard version of the machine: – With 405 / 70 R20 tyres – Tipping loads and weights include all lubricants, full fuel tank, ROPS/ FOPS cab and driver.

Description

Value Unit

Bucket capacity as per ISO 7546 Bucket width

2330 mm

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

3035 mm

C Maximum bucket base height

3174 mm

D Maximum bucket pivot point height

3374 mm

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

4270 mm

G Digging depth

1.8 t/m³ 2676 mm

874 mm 1605 mm 60 mm

H Height above the cab

2785 mm

I Height above exhaust

2660 mm

J Ground clearance

L506 - 776 / from 9099 L507 - 777 / from 9099 L508 - 778 / from 9099

1.2 m³

370 mm

K Wheel base

2300 mm

L Overall length

5760 mm

Turning radius over bucket outer edge

4190 mm

Lifting force (SAE)

60 kN

Breakout force (SAE)

62 kN

L509 - 779 / from 9099 L510 - 782 / from 9099

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MJFCIFSS

2.1-7 of 28

Product Description

Service Manual

Technical Data

Description

Value Unit

Tipping load when straight

5036 kg

Tipping load articulated at 30°

4581 kg

Angle of articulation (to each side)

30 °

Operating weight

6250 kg

Tractive force

5002 daN

Travel speed in travel range 1, forward and reverse

0 - 6 km/h

Travel speed in travel range 2, forward and reverse

0 - 20 km/h

Sound pressure level in cab in L pA according to ISO 6396

2.1.2

70 dB (A)

Diesel engine Diesel engine

Valid for:

L506 - 776 / from 9099

Description

Value Unit

Engine model

D404T-00

Type / cylinders

4-cylinder inline

Combustion

Four-stroke direct injection

Capacity

2440 cm³

Rated power as per ISO 9249

2800 min-1

Rated speed Maximum torque at 1680 min-1 Lower idle speed

209 Nm 850

50

min-1

3040 +80 min-1

Upper idle speed Cylinder bore

86 mm

Stroke

105 mm

Compression ratio

18:1

Combustion pressure

24 - 28 bar

Injection nozzles / operating pressure Firing order

220 bar 1-3-4-2 Hydraulic adjustment

Inlet and outlet valve lash Injection pump

Pump elements

Controller

Mechanical

Turbocharger

Constant

Longitudinal / traverse inclinability Current / power consumption of starter

30 ° 12 / 2.2 V / kW

Alternator voltage output

12 V

Alternator current output

65 A

Conversion factor Frequency KL.W / engine speed Coolant thermostat opening temperature

2.1-8 of 28

42 / 57 kW / PS

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MJFCIFSS

L506 - 776 / from 9099 L507 - 777 / from 9099

4.115 82.2 °C L508 - 778 / from 9099 L509 - 779 / from 9099 L510 - 782 / from 9099

Service Manual

Product Description Technical Data

Description

Value Unit

Minimum pressure in cooling system after pump Auxiliary drive transmission

1.03 i

Weight

232 kg

Emission thresholds comply with Valid for:

EU – RL 97/68 EC Stage II

L506 - 777 / from 9099; L508 - 778 / from 9099

Description

Value Unit

Engine model

D404T-01

Type / cylinders

4-cylinder inline

Combustion

Four-stroke direct injection

Capacity

2440 cm³

Rated power as per ISO 9249

46 / 63 kW / PS 2800 min-1

Rated speed Maximum torque at 1680 min-1

227 Nm

Lower idle speed

850

50

min-1

3040 +80 min-1

Upper idle speed Cylinder bore

86 mm

Stroke

105 mm

Compression ratio

18:1

Combustion pressure

24 - 28 bar

Injection nozzles / operating pressure Firing order

220 bar 1-3-4-2 Hydraulic adjustment

Inlet and outlet valve lash Injection pump

Pump elements

Controller

Mechanical

Turbocharger

Constant

Longitudinal / traverse inclinability Current / power consumption of starter

30 ° 12 / 2.2 V / kW

Alternator voltage output

12 V

Alternator current output

65 A

Conversion factor Frequency KL.W / engine speed Coolant thermostat opening temperature Minimum pressure in cooling system after pump

4.115 82.2 °C 0.7 bar

Auxiliary drive transmission

1.03 i

Weight

232 kg

Emission thresholds comply with

L506 - 776 / from 9099 L507 - 777 / from 9099 L508 - 778 / from 9099

0.7 bar

L509 - 779 / from 9099 L510 - 782 / from 9099

copyright by

MJFCIFSS

EU – RL 97/68 EC Stage II

2.1-9 of 28

Product Description

Service Manual

Technical Data

Valid for:

L509 - 779 / from 9099

Description

Value Unit

Engine model

D405T-00

Type / cylinders

5-cylinder inline Four-stroke direct injection

Combustion Capacity

3050 cm³

Rated power as per ISO 9249

54 / 74 kW / PS 2800 min-1

Rated speed Maximum torque at 1680 min-1 Lower idle speed

262 Nm 850

Cylinder bore

86 mm

Stroke

105 mm

Compression ratio

18:1

Combustion pressure

24 - 28 bar

Injection nozzles / operating pressure Firing order

220 bar 1-2-4-5-3

Inlet and outlet valve lash

Hydraulic adjustment

Injection pump

Pump elements

Controller

Mechanical

Turbocharger

Constant

Longitudinal / traverse inclinability Current / power consumption of starter

30 ° 12 / 2.2 V / kW

Alternator voltage output

12 V

Alternator current output

65 A

Conversion factor Frequency KL.W / engine speed Coolant thermostat opening temperature Minimum pressure in cooling system after pump

4.115 82.2 °C 1.4 bar

Auxiliary drive transmission

1.03 i

Weight

237 kg

Emission thresholds comply with

EU – RL 97/68 EC Stage II

L510 - 782 / from 9099

Description

Value Unit

Engine model

D405T-01

Type / cylinders

5-cylinder inline

Combustion

Four-stroke direct injection

Capacity

3050 cm³

Rated power as per ISO 9249 Maximum torque at 1680 min-1 Lower idle speed copyright by

MJFCIFSS

58 / 79 kW / PS 2800 min-1

Rated speed

2.1-10 of 28

min-1

3040 +80 min-1

Upper idle speed

Valid for:

50

281 Nm 850

L506 - 776 / from 9099 L507 - 777 / from 9099

50

min-1

L508 - 778 / from 9099 L509 - 779 / from 9099 L510 - 782 / from 9099

Service Manual

Product Description Technical Data

Description

Value Unit 3040 +80 min-1

Upper idle speed Cylinder bore

86 mm

Stroke

105 mm

Compression ratio

18:1

Combustion pressure

24 - 28 bar

Injection nozzles / operating pressure Firing order

220 bar 1-2-4-5-3 Hydraulic adjustment

Inlet and outlet valve lash Injection pump

Pump elements

Controller

Mechanical

Turbocharger

Constant

Longitudinal / traverse inclinability Current / power consumption of starter

30 ° 12 / 2.2 V / kW

Alternator voltage output

12 V

Alternator current output

65 A

Conversion factor Frequency KL.W / engine speed Coolant thermostat opening temperature Minimum pressure in cooling system after pump

4.115 82.2 °C 1.4 bar

Auxiliary drive transmission

1.03 i

Weight

237 kg

Emission thresholds comply with

EU – RL 97/68 EC Stage II

Coupling Description

Value Unit

Type

CF-K-100-10- 64137

Tightening torque for elastic element fixing bolts (8 pcs.)

Tightening torque for start coupling fixing bolts (2 pcs.)

40 Nm 45+5 Nm

Fuel system Description

Value Unit

Tank capacity, FULL

80 l

Tank capacity, RESERVE

20 l

Fuel pre-filter Description

Value Unit

Type

In-line filter -

Filtration grade

L506 - 776 / from 9099 L507 - 777 / from 9099 L508 - 778 / from 9099

L509 - 779 / from 9099 L510 - 782 / from 9099

700 µ

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2.1-11 of 28

Product Description

Service Manual

Technical Data

Fuel fine filter Description

Value Unit Replaceable cartridge

Type Filtration grade

5 µ

Vaccum switch Description Air filter contamination vacuum switch activation point

Value Unit 50 mbar

Pre-glow system Description Resistance

2.1.3

Value Unit 1

Cooling system Cooling system Description

Value Unit

Fan speed (depending on engine speed and temperature) Operating pressure, fan speed at 1100 mA Coolant up to 87 °C, Hydraulic oil up to 57 °C At low idle: At high idle: Operating pressure, fan speed at 380 mA Coolant 92 °C to 100 °C Hydraulic oil 75 °C to 90 °C At low idle: At high idle:

470 - 3100 min-1

6 ±3 470 ±50 10 ±3 580 ±50

bar min-1 bar min-1

20 ±3 1000 ±100 140 ±10 2600 ±100

bar min-1 bar min-1

Proportional pressure relief valve resistance at 20 °C

4,8

Pressure relief valve

210 bar

Hydraulic oil and coolant temperature sensors Description

Value Unit

Measuring range

-30 to +130 °C

Resistance at 20°C

1112

Gear pump Description

Value Unit

Capacity

9 cm³

Flow rate (at rated speed)

2.1-12 of 28

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L506 - 776 / from 9099 L507 - 777 / from 9099

26 l/min L508 - 778 / from 9099 L509 - 779 / from 9099 L510 - 782 / from 9099

Service Manual

Product Description Technical Data

Gear motor Description

Value Unit

Displacement

8 cm³

Maximum pressure

2.1.4

210 bar

Travel hydraulics Variable displacement pump

Valid for:

L506 - 776 / from 9099; L507 - 777 / from 9099; L508 - 778 / from 9099; ID 10023219

Description

Value Unit

Control type

DA

Maximum capacity

40 cm³

Flow rate at rated speed

109 l/min

Maximum swivel angle (both sides)

20 °

Speed (at rated speed)

2800 min-1

Power L506

37.5 kW

Power L507, L508

41.5 kW

Replenishing pump capacity

8.6 cm³

Replenishing pump flow rate (at rated speed)

22 l/min

Inlet restrictor diameter

1.8 mm

Swivel restrictor diameter

0.8 mm

Travel direction solenoid current consumption

2.5 A

Travel direction solenoid resistance

5 Ohm

Replenishing pressure at upper idle speed

31

Start of regulation

2300

Pressure relief and replenishing valves

min-1

10

bar

5

bar

31 kg

L509 - 779 / from 9099; L510 - 782 / from 9099;

Description

ID 5717294

Value Unit

Control type

DA

Maximum capacity

56 cm³

Flow rate at rated speed

154 l/min

Maximum swivel angle (both sides)

L506 - 776 / from 9099 L507 - 777 / from 9099 L508 - 778 / from 9099

±100

430

Weight Valid for:

min-1

460

Pressure cut-off

bar

±50

1100

Pump output at 400 bar

2

20 °

Speed (at rated speed)

2800 min-1

Power L508

41.5 kW

Power L509

48.5 kW

Power L510

52.2 kW

Replenishing pump capacity

11.6 cm³

Replenishing pump flow rate

29.5 l/min

L509 - 779 / from 9099 L510 - 782 / from 9099

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MJFCIFSS

2.1-13 of 28

Product Description

Service Manual

Technical Data

Description (at rated speed)

Value Unit

Inlet restrictor diameter

1.8 mm

Swivel restrictor diameter

1.0 mm

Travel direction solenoid current consumption

2.5 A

Travel direction solenoid resistance

5 Ohm

Replenishing pressure at upper idle speed

30

Start of regulation

2300

Pressure relief and replenishing valves

min-1

±100

min-1

490

Pressure cut-off

bar

±50

1100

Pump output at 400 bar

2

460

Weight

10

bar

5

bar

38 kg

Variable displacement motor Valid for:

L506 - 776 / from 9099; L507 - 777 / from 9099; L508 - 778 / from 9099; ID 10023569

Description

Value Unit

Type

A6VM 80 DA

Maximum displacement

80 cm³

Minimum displacement

19.2 cm³

Maximum swivel angel

25 °

Minimum swivel angle

5.8 ° 5230 min-1

Maximum speed

509 Nm

Torque ( p 400 bar) Swivel restrictor (size)

0.30 mm

Regulating piston surface ratio

8 :100

Maximum discharge valve capacity

5.0 l

Discharge valve orifice diameter

1.4 mm

Current consumption of travel direction and travel range 1 solenoid valves

2.5 A

Resistance of travel direction and travel range 1 solenoid valves

5 Ohm

Weight

34 kg

Control range while driving L506

220

Control range while driving L507, L508 Valid for:

±10

bar bar

L509 - 779 / from 9099; L510 - 782 / from 9099; ID 10023204

Description

Value Unit

Type

A6VM 107 DA

Maximum displacement

107 cm³

Minimum displacement

32.3 cm³

Maximum swivel angel

25 °

Minimum swivel angle

7.3 ° 4480 min-1

Maximum speed

2.1-14 of 28

230

±10

Torque ( p 400 bar)

681 Nm

Swivel restrictor (size)

0.45 mm

copyright by

MJFCIFSS

L506 - 776 / from 9099 L507 - 777 / from 9099

L508 - 778 / from 9099 L509 - 779 / from 9099 L510 - 782 / from 9099

Service Manual

Product Description Technical Data

Description

Value Unit

Regulating piston surface ratio

8 :100

Maximum discharge valve capacity

8 l

Discharge valve orifice diameter

1.8 mm

Current consumption of travel direction and travel range 1 solenoid valves

2.5 A

Resistance of travel direction and travel range 1 solenoid valves

5 Ohm

Weight

47 kg

Control range while driving

2.1.5

210

±10

bar

Working hydraulics Working hydraulics pump

Valid for:

L506 - 776 / from 9099; L507 - 777 / from 9099; ID 10023207

Description

Value Unit

Capacity

23 cm³

Flow rate at rated speed

64.4 l/min

Speed at rated speed

2800 min -1

Power L506

22.5 KW

Power L507

24.7 KW

LS steering pressure relief valve Valid for:

180

10

bar

L508 - 778 / from 9099; L509 - 779 / from 9099; L510 - 782 / from 9099; ID 10023228

Description

Value Unit

Capacity

33 cm³

Flow rate at rated speed

92.4 l/min

Speed at rated speed

2800 min -1

Power L508, L509

29.3 KW

Power L510

33.8 KW

LS steering pressure relief valve

180

10

bar

Control block Description

Value Unit

Spool valve diameter

14 mm

Piston stroke, both sides

7.13 mm 230

5

bar

Primary pressure relief valve L508, L509

190

5

bar

Primary pressure relief valve L510

210

5

bar

Secondary pressure relief valve / lifting (+ 1 turn)

220

5

bar

Secondary pressure relief valve / tilting in (+ 1 turn)

220

5

bar

Secondary pressure relief valve / tilting out (+ 1 turn)

170

5

bar

Primary pressure relief valve L506, L507

L506 - 776 / from 9099 L507 - 777 / from 9099 L508 - 778 / from 9099

L509 - 779 / from 9099 L510 - 782 / from 9099

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MJFCIFSS

2.1-15 of 28

Product Description

Service Manual

Technical Data

Description

Value Unit

Secondary pressure relief valve / additional equipment (+ 1 turn)

195

Weight

5

bar

13.7 kg

Pilot control valve Description

Value Unit

Retaining solenoid voltage Retaining solenoid current consumption Retaining solenoid resistance Weight

12 V 1.22 A 60 Ohm 5.25 kg

Pilot control hydro accumulator Description

Value Unit

Hydro accumulator volume Preload pressure (nitrogen filling)

320 cmÂł 15 bar

Lift cylinder Valid for:

L506 - 776 / from 9099; L507 - 777 / from 9099

Description

Value Unit

Piston diameter

80 mm

Rod diameter

40 mm

Stroke length

510 mm

Minimum installation length

835 mm

Lifting at rated load

4.9 sec

Lowering empty

4.2 sec

Piston rod bearing tightening torque

Valid for:

Piston tightening torque

650 Nm

Weight

28.5 kg

L508 - 778 / from 9099; L509 - 779 / from 9099; L510 - 782 / from 9099

Description

Value Unit

Piston diameter

100 mm

Rod diameter

50 mm

Stroke length

510 mm

Minimum installation length

835 mm

Lifting at rated load

4.9 sec

Lowering empty

4.5 sec

Piston rod bearing tightening torque

2.1-16 of 28

WN 4122-026

WN 4122-026

Piston tightening torque

650 Nm

Weight

36.8 kg

copyright by

MJFCIFSS

L506 - 776 / from 9099 L507 - 777 / from 9099

L508 - 778 / from 9099 L509 - 779 / from 9099 L510 - 782 / from 9099

Service Manual

Product Description Technical Data

Tilt cylinder Valid for:

L506 - 776 / from 9099; L507 - 777 / from 9099

Description

Value Unit

Piston diameter

80 mm

Rod diameter

40 mm

Stroke length

450 mm

Minimum installation length

790 mm

Tilting out at rated load

1.5 sec

Piston rod bearing tightening torque

Valid for:

Piston tightening torque

650 Nm

Weight

27.3 kg

L508 - 778 / from 9099

Description

Value Unit

Piston diameter

100 mm

Rod diameter

50 mm

Stroke length

450 mm

Minimum installation length

790 mm

Tilting out at rated load

1.5 sec

Piston rod bearing tightening torque Piston tightening torque

WN 4122-026 650 Nm

Weight Valid for:

WN 4122-026

34 kg

L509 - 779 / from 9099; L510 - 782 / from 9099

Description

Value Unit

Piston diameter

100 mm

Rod diameter

50 mm

Stroke length

450 mm

Minimum installation length

875 mm

Tilting out at rated load

1.5 sec

Piston rod bearing tightening torque

WN 4122-026

Piston tightening torque

650 Nm

Weight

35.5 kg

Hydraulic tank Valid for:

L506 - 776 / from 9099; L507 - 777 / from 9099; L508 - 778 / from 9099

Description

Value Unit

Hydraulic tank capacity

55 l

Weight Valid for:

145 kg

L509 - 779 / from 9099; L510 - 782 / from 9099

Description

Value Unit

Hydraulic tank capacity

75 l

Weight

L506 - 776 / from 9099 L507 - 777 / from 9099 L508 - 778 / from 9099

L509 - 779 / from 9099 L510 - 782 / from 9099

200 kg

copyright by

MJFCIFSS

2.1-17 of 28

Product Description

Service Manual

Technical Data

Return suction filter Description

Value Unit

Type

RKM 201 -

Filtration grade

10 µm

Pre-tension valve

0.5 bar

Replenishing valve

Yes -

Replenishing strainer

125 µm

Bypass valve

2.5 bar

Temperature valve

55 - 60 C°

Bleeder filter Description

2.1.6

Value Unit

Bleeder filtration grade

7 µm

Inlet opening pressure

0.03 bar

Outlet opening pressure

0.35 bar

Filler strainer filtration grade

800 µm

Steering system Servostat Description

Value Unit

Displacement

250 cm³

Displacement in emergency operation

250 cm³

Secondary pressure relief valves Weight

240

10

bar

6.25 kg

Steering cylinder Description

Value Unit

Piston diameter

70 mm

Rod diameter

30 mm

Stroke length

300 mm

Minimum installation length

552 mm

Piston rod bearing tightening torque

2.1.7

WN 4122-011

Piston tightening torque

350 Nm

Weight

13.4 kg

Brake system Main brake cylinder Description

Value Unit

Type

SAFIM -

Maximum brake pressure (at 60 kg pedal force)

2.1-18 of 28

copyright by

MJFCIFSS

80 bar

L506 - 776 / from 9099 L507 - 777 / from 9099

L508 - 778 / from 9099 L509 - 779 / from 9099 L510 - 782 / from 9099

Service Manual

Product Description Technical Data

Drum brake Description

Value Unit

Drum diameter

203 mm

Brake pads with

60 mm

Equalising reservoir Description

Value Unit

Filling quantity

0.2 l Hydraulic oil HLPD SAE 10 W

Oil specification

Brake light pressure switch Description

Value Unit

Switch type

Normally open 10 ±1 bar

Switching point, falling Thread

2.1.8

M10 x 1 mm

Electrical system Batteries Description

Value Unit

Number of batteries

2.1.9

1 Unit

Voltage

12 V

Capacity

100 Ah

Cold test current (at -18°C – EN 60095-1)

760 A

Transfer gear Transfer gear

Valid for:

L506 - 776 / from 9099; L507 - 777 / from 9099; L508 - 778 / from 9099

Description

L506 - 776 / from 9099 L507 - 777 / from 9099 L508 - 778 / from 9099

Value Unit

Type

315 -

Transmission

2.23 -

Gear cover screw tightening torque

48 - 53 Nm

Drive flange cover screw tightening torque

52 - 58 Nm

Input shaft screw tightening torque

250 - 270 Nm

L509 - 779 / from 9099 L510 - 782 / from 9099

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2.1-19 of 28

Product Description

Service Manual

Technical Data

Valid for:

L509 - 779 / from 9099; L510 - 782 / from 9099

Description

Value Unit

Type

311 -

Transmission

2.28 -

Gear cover screw tightening torque

48 - 53 Nm

Drive flange cover screw tightening torque

52 - 58 Nm

Input shaft screw tightening torque

2.1.10

250 - 270 Nm

Axles and cardan shaft Front axle

Valid for:

L506 - 776 / from 9099; L507 - 777 / from 9099; L508 - 778 / from 9099

Description

Value Unit

Type

111/70 -

Self-locking differential

45 %

Width

1486 mm

Overall transmission

21.75 i

Differential transmission

3.63 i

Wheel hub transmission

6.0 i

Wheel lug tightening torque

450 Nm

Wheel lug spanner size

30 mm

Service brake

Drum -

Cardan shaft flange

DIN 120 -

Flange size

1530 mm

Weight Valid for:

212 kg

L509 - 779 / from 9099; L510 - 782 / from 9099

Description

Value Unit

Type

112/163 -

Self-locking differential

45 %

Width

1660 mm

Overall transmission

19.09 i

Differential transmission

3.18 i

Wheel hub transmission

6.0 i

Wheel lug tightening torque

450 Nm

Wheel lug spanner size

30 mm

Service brake

Drum -

Cardan shaft flange

DIN 120 -

Flange size

1660 mm

Weight

2.1-20 of 28

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280 kg

L506 - 776 / from 9099 L507 - 777 / from 9099

L508 - 778 / from 9099 L509 - 779 / from 9099 L510 - 782 / from 9099

Service Manual

Product Description Technical Data

Rear axle Valid for:

L506 - 776 / from 9099; L507 - 777 / from 9099; L508 - 778 / from 9099

Description

Value Unit

Type

315/211/164 -

Locking value

25 %

Width

1486 mm

Overall transmission

48.5 i

Differential transmission

3.44 i

Wheel hub transmission

6.0 i

Wheel lug tightening torque

450 Nm

Wheel lug spanner size

30 mm

Service brake

Drum -

Cardan shaft flange

DIN 120 -

Flange size

1530 mm

Swing angle

5 °

Weight Valid for:

290 kg

L509 - 779 / from 9099; L510 - 782 / from 9099

Description

Value Unit

Type

311/212/113 -

Locking value

25 %

Width

1660 mm

Overall transmission

43.53 i

Differential transmission

3.18 i

Wheel hub transmission

6.0 i

Wheel lug tightening torque

450 Nm

Wheel lug spanner size

30 mm

Service brake

Drum -

Cardan shaft flange

DIN 120 -

Flange size

1660 mm

Swing angle

5 °

Weight

408 kg

Cardan shaft Valid for:

L506 - 776 / from 9099; L507 - 777 / from 9099; L508 - 778 / from 9099

Description

Valid for:

Value Unit

Minimum length

1533 mm

Maximum length

1593 mm

Flange tightening torque

60 Nm

Weight

22 kg

L509 - 779 / from 9099; L510 - 782 / from 9099

Description

L506 - 776 / from 9099 L507 - 777 / from 9099 L508 - 778 / from 9099

Value Unit

Minimum length

1505 mm

Maximum length

1565 mm

L509 - 779 / from 9099 L510 - 782 / from 9099

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2.1-21 of 28

Product Description

Service Manual

Technical Data

Description

2.1.11

Value Unit

Flange tightening torque

60 Nm

Weight

21 kg

Machine frame and ballast weight Articulation bearing Description

Value Unit

Tightening torque of bolts

70 Nm

Left ballast weight Valid for:

L506 - 776 / from 9099; L507 - 777 / from 9099

Description

Value Unit

Weight

232 kg

Material Valid for:

GG10 -

L508 - 778 / from 9099; L509 - 779 / from 9099

Description

Value Unit

Weight per ballast weight

408 kg

Material Valid for:

GG10 -

L510 - 782 / from 9099

Description

Value Unit

Weight per ballast weight

567 kg

Material

GG10 -

Right ballast weight Valid for:

L506 - 776 / from 9099

Description

Value Unit

Weight per ballast weight

260 kg

Material Valid for:

GG10 -

L506 - 777 / from 9099; L508 - 778 / from 9099

Description

Value Unit

Weight per ballast weight

335 kg

Material Valid for:

GG10 -

L509 - 779 / from 9099; L510 - 782 / from 9099

Description

Value Unit

Weight per ballast weight

484 kg

Material

2.1-22 of 28

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GG10 -

L506 - 776 / from 9099 L507 - 777 / from 9099

L508 - 778 / from 9099 L509 - 779 / from 9099 L510 - 782 / from 9099

Service Manual

Product Description Technical Data

2.1.12

Automatic central lubrication system Central lubrication pump EP-1 Description

Value Unit

Flow per stroke

120 mm³ Greases up to NLGI class 2

Transfer medium Maximum flow pressure

280 bar

System operating temperature (taking into account the pumped medium) Power system

min. -35 °C max. +80 °C Electric

Power supply

12 V

Protection class

IP 65

Reservoir position

Upright Direction of arrow

Direction of rotation of agitator Default lubrication time

5 min

Default idle time

1 Hours

Adjustable lubrication time

1 - 16 min

Adjustable idle time

0.5 - 8 Hours

Progressive distributor MX-F Description

Value Unit

Maximum operating pressure at input Distributor temperature range (taking into account transfer medium) Transfer medium

300 bar min. -35 °C max. +100 °C Greases up to NLGI class 2

MX-F 25 Description

Value Unit

Flow per outlet

25 mm³

Flow per element

50 mm³

Piston diameter

3 mm

MX-F 45 Description

Value Unit

Flow per outlet

45 mm³

Flow per element

90 mm³

Piston diameter

L506 - 776 / from 9099 L507 - 777 / from 9099 L508 - 778 / from 9099

L509 - 779 / from 9099 L510 - 782 / from 9099

4 mm

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2.1-23 of 28

Product Description

Service Manual

Technical Data

MX-F 75 Description

Value Unit

Flow per outlet

75 mm³

Flow per element

150 mm³

Piston diameter

5 mm

MX-F 105 Description

Value Unit

Flow per outlet

105 mm³

Flow per element

210 mm³

Piston diameter

2.1.13

6 mm

Cab, heating and air-conditioning Heating and ventilation Description

Value Unit

Number of blower levels

3

Air flow at blower level 1 / 2 / 3 Fan speed at blower level 1 / 2 / 3 Current consumption, unhindered 1 / 2 / 3

615 / 750 / 1000 m³/h -1 2280 / 2735 / 3630 min

10.1 / 13.8 / 22.3 A 12 V

Voltage Heating power

11.3 kW

Fresh and circulated air filter Description

Value Unit

Filter class

EU5

Filtration grade

10 µ 0.58 m²

Filter surface (effective)

Air-conditioning system Description

Value Unit

Refrigerant

R134a

Coolant quantity

1400 g

Cooling power

6.4 kW PAG ZXL 100PG

Coolant oil

150 cm3

Coolant oil quantity

Pressure switch Description

2.1-24 of 28

Value Unit

Low pressure switch OFF

1.5 bar

Low pressure switch ON

2.9 bar

High pressure switch OFF

25.0 bar

High pressure switch ON

19.0 bar

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L506 - 776 / from 9099 L507 - 777 / from 9099

L508 - 778 / from 9099 L509 - 779 / from 9099 L510 - 782 / from 9099

Service Manual

Product Description Technical Data

Temperature switch Description

Value Unit

Temperature switch adjustment range

2.1.14

-1 to +14 °C

Temperature switch activation temperature

5 ±1 °C

Temperature switch deactivation temperature

1 ±1 °C

Lift arms and quick-change device Lift arm

Valid for:

L506 - 776 / from 9099; L507 - 777 / from 9099; L508 - 778 / from 9099

Description

Value Unit

Lift arm length

Valid for:

2150 mm

Weight of complete lift arms (without cylinder)

467 kg

Bucket arm weight

335 kg

Deflection lever weight

88 kg

Weight of complete connecting link

44 kg

L509 - 779 / from 9099; L510 - 782 / from 9099

Description

Value Unit

Lift arm length

2250 mm

Weight of complete lift arms (without cylinder)

507 kg

Bucket arm weight

375 kg

Deflection lever weight

88 kg

Weight of complete connecting link

44 kg

Quick-change device Description

Value Unit

Control, activation and operation Lockout

Changeover valve -

Lockout display

Visual -

A - system connection size

852 mm

B - width

852 mm

H - height

382 mm

T - depth

119 mm

Weight

L506 - 776 / from 9099 L507 - 777 / from 9099 L508 - 778 / from 9099

Additional control lever

L509 - 779 / from 9099 L510 - 782 / from 9099

49 kg

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2.1-25 of 28

Product Description

Service Manual

Technical Data

2.1.15

Equipment and accessories Standard bucket

Valid for:

L506 - 776 / from 9099

Description

Value Unit

B - bucket width

1900 mm

B1 - loading size

1830 mm

H - height

863 mm

L - length with teeth

936 mm

L1 - length without teeth

820 mm

Specific material weight

1.8 t/m3

Heaped bucket capacity (ISO 7546)

0.8 m3

Weight

307 kg

Type of teeth

ESCO V13 -

Number of teeth

2.1-26 of 28

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7 Pc.

L506 - 776 / from 9099 L507 - 777 / from 9099

L508 - 778 / from 9099 L509 - 779 / from 9099 L510 - 782 / from 9099

Service Manual

Product Description Technical Data

Valid for:

L507 -777 / from 9099

Description

Value Unit

B - bucket width

2050 mm

B1 - loading size

1980 mm

H - height

863 mm

L - length with teeth

910 mm

L1 - length without teeth

820 mm

Specific material weight

1.8 t/m 3

Heaped bucket capacity (ISO 7546)

0.9 m3

Weight

321 kg

Type of teeth

ESCO V13 -

Number of teeth Valid for:

7 Pc.

L508 - 778 / from 9099

Description

Value Unit

B - bucket width

2100 mm

B1 - loading size

2030 mm

H - height

901 mm

L - length with teeth

1032 mm

L1 - length without teeth

820 mm

Specific material weight

1.8 t/m 3

Heaped bucket capacity (ISO 7546)

1.0 m3

Weight

356 kg

Type of teeth

ESCO V13 -

Number of teeth Valid for:

7 Pc.

L509 - 779 / from 9099

Description

Value Unit

B - bucket width

2200 mm

B1 - loading size

2130 mm

H - height

915 mm

L - length with teeth

1062 mm

L1 - length without teeth

946 mm

Specific material weight

1.8 t/m 3

Heaped bucket capacity (ISO 7546)

1.1 m3

Weight

408 kg

Type of teeth

ESCO V13 -

Number of teeth

L506 - 776 / from 9099 L507 - 777 / from 9099 L508 - 778 / from 9099

L509 - 779 / from 9099 L510 - 782 / from 9099

7 Pc.

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2.1-27 of 28

Product Description

Service Manual

Technical Data

Valid for:

L510 - 782 / from 9099

Description

Value Unit

B - bucket width

2330 mm

B1 - loading size

2260 mm

H - height

915 mm

L - length with teeth

1062 mm

L1 - length without teeth

946 mm

Specific material weight

1.8 t/m3

Heaped bucket capacity (ISO 7546)

1.2 m3

Weight

422 kg

Type of teeth

ESCO V13 -

Number of teeth

7 Pc.

Forklift

2.1-28 of 28

Description

Value Unit

Prong length

1200 mm

L - Length (fork carrier + prongs)

1585 mm

K - Fork carrier width

1245 mm

H - Height (fork carrier + prongs)

860 mm

Weight (fork carrier + prongs)

255 kg

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L506 - 776 / from 9099 L507 - 777 / from 9099

L508 - 778 / from 9099 L509 - 779 / from 9099 L510 - 782 / from 9099

3 Maintenance 3.0 Chapter contents 3

Maintenance........................................................................ 3.0-1 3.1

Maintenance and inspection schedule ...........................................3.1-1

3.2

Testing and adjustment plan...........................................................3.2-1

3.3

Testing and adjustment checklists..................................................3.3-1

3.4

Lubrication chart and filling quantities ............................................3.4-1 3.4.1

Table of filling quantities .......................................................3.4-1

3.4.2

Lubrication chart ...................................................................3.4-3

3.5

L506 - 776 / from 9099 L507 - 777 / from 9099 L508 - 778 / from 9099

Maintenance tasks..........................................................................3.5-1 3.5.1

Preparatory tasks for maintenance ......................................3.5-1

3.5.2

Checking the machine for external damage.........................3.5-4

3.5.3

Checking that all screw connections are tight ......................3.5-5

3.5.4

Sealing any leaks .................................................................3.5-5

3.5.5

Checking the oil level in the diesel engine ...........................3.5-5

3.5.6

Changing the engine oil........................................................3.5-6

3.5.7

Replacing the oil filter ...........................................................3.5-6

3.5.8

Draining off condensate from the fuel fine filter....................3.5-7

3.5.9

Replacing the fuel pre-filter ..................................................3.5-8

3.5.10

Cleaning the service cap and dust extraction valve on the air filter ..................................................................................3.5-9

3.5.11

Changing the air filter main element when indicated by the vacuum switch ................................................................3.5-9

3.5.12

Checking the coolant level .................................................3.5-10

3.5.13

Checking the antifreeze......................................................3.5-11

3.5.14

Cleaning the cooling system ..............................................3.5-13

3.5.15

Checking the oil level in the hydraulic tank ........................3.5-13

3.5.16

Lubricating the universal joints on the pilot control device .3.5-14

3.5.17

Changing the hydraulic oil ..................................................3.5-14

3.5.18

Changing the return suction filter .......................................3.5-15

3.5.19

Replacing the bleeder filter on the hydraulic tank ..............3.5-15

3.5.20

Checking the steering.........................................................3.5-16

3.5.21

Lubricating the bearing points on the steering cylinders ....3.5-16

3.5.22

Checking the service brake and parking brake ..................3.5-16

L509 - 779 / from 9099 L510 - 782 / from 9099

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3.0-1 of 4

Maintenance

Service manual 3.5.23

Checking the oil level in the equalising reservoir of the brake system...................................................................... 3.5-17

3.5.24

Checking the gap and wear on the brake linings............... 3.5-18

3.5.25

Checking the indicator lamps and lighting ......................... 3.5-18

3.5.26

Checking the oil level in the transfer gear ......................... 3.5-18

3.5.27

Changing the gear oil in the transfer gear ......................... 3.5-19

3.5.28

Checking the tightness of the wheel lugs (once after 50, 100 and 250 h)................................................................... 3.5-19

3.5.29

Checking the tightening torque of the front axle fastening bolts.................................................................... 3.5-19

3.5.30

Greasing the lubrication points on the rear axle kingpin bearings ............................................................................. 3.5-20

3.5.31

Checking the axle oil levels ............................................... 3.5-20

3.5.32

Changing the axle gear oil ................................................. 3.5-21

3.5.33

Checking and lubricating the drive shaft............................ 3.5-22

3.5.34

Checking and adjusting the tyre pressure ......................... 3.5-22

3.5.35

Lubricating the articulated oscillating bearing and the rear oscillating bearing....................................................... 3.5-23

3.5.36

Lubriating the door hinges ................................................. 3.5-23

3.5.37

Cleaning or replacing the fresh air and recirculated air filter .................................................................................... 3.5-23

3.5.38

Lubricating the lift arms and attachment............................ 3.5-24

3.5.39

Lubricating the quick-change device ................................. 3.5-25

3.5.40

Check the bearing bushings on the lift arms ..................... 3.5-25

3.5.41

Checking that the quick-change device is working properly .............................................................................. 3.5-26

3.6

3.0-2 of 4

Testing and adjustment tasks ........................................................ 3.6-1 3.6.1

Preparing for testing and adjustment................................... 3.6-1

3.6.2

Safety precautions for testing and adjustment .................... 3.6-1

3.6.3

Bring the machine up to operating temperature .................. 3.6-2

3.6.4

Checking the diesel engine speed....................................... 3.6-2

3.6.5

Checking the fan motor pressure relief valve ...................... 3.6-3

3.6.6

Checking the travel hydraulics in a blocked condition......... 3.6-4

3.6.7

Check the replenishing pressure of the variable displacement pump.............................................................. 3.6-5

3.6.8

Checking the start of regulation of the travel pump ............. 3.6-5

3.6.9

Checking the output of the travel pump............................... 3.6-6

3.6.10

Checking the pressure relief and replenishing valve of the variable displacement pump.......................................... 3.6-7

3.6.11

Checking the pressure cut-off of the variable displacement pump.............................................................. 3.6-7

3.6.12

Checking the variable displacement motor in the control range.................................................................................... 3.6-8

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L506 - 776 / from 9099 L507 - 777 / from 9099

L508 - 778 / from 9099 L509 - 779 / from 9099 L510 - 782 / from 9099

Service manual

Maintenance 3.6.13

Checking the secondary pressure relief valves on the control block .........................................................................3.6-9

3.6.14

Checking the primary pressure relief valves on the control block .........................................................................3.6-9

3.6.15

Checking the pressure relief valve of the steering system ................................................................................3.6-10

3.6.16

Checking the play of the inch/brake pedal .........................3.6-10

3.7

L506 - 776 / from 9099 L507 - 777 / from 9099 L508 - 778 / from 9099

Lubricants and fuels........................................................................3.7-1 3.7.1

Lubricating oils for diesel engines ........................................3.7-2

3.7.2

Diesel fuels ...........................................................................3.7-3

3.7.3

Coolants for diesel engines ..................................................3.7-5

3.7.4

Hydraulic oils ........................................................................3.7-6

3.7.5

Lubricating oils for the transmission .....................................3.7-8

3.7.6

Brake oil................................................................................3.7-8

3.7.7

Grease for general lubrication points ...................................3.7-8

L509 - 779 / from 9099 L510 - 782 / from 9099

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3.0-3 of 4

Service manual

Maintenance Maintenance and inspection schedule

3.1 Maintenance and inspection schedule The following abbreviations are used in this section: – h = service hours – OM = operating manual – SM = service manual Various symbols (solid or empty circles, boxes and stars) are used to indicate the maintenance tasks, which fall into two main types.

The symbols have the following meanings: Table with solid circle, box or star – Responsibility for carrying out the maintenance work lies with the machine operator or his maintenance personnel.

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

The symbols have the following meanings: Table with empty circle, box or star, or service hours (h) – The maintenance and inspection work must be performed or supervised by authorised engineers from LIEBHERR or its authorised dealers.

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

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

L506 - 776 / from 9099 L507 - 777 / from 9099 L508 - 778 / from 9099

L509 - 779 / from 9099 L510 - 782 / from 9099

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3.1-1 of 4

Maintenance

Service manual

Maintenance and inspection schedule Customer: ............................................... Machine type: .................... Ser. no.: ............................. Service hours: .............. Date: ......................

Maintenance / inspection after service hours

Tasks to be performed by maintenance staff once-only activity repeat interval as necessary annually before the winter

by authorised specialist staff once-only activity repeat interval as necessary

Complete machine Have the driver lubricate the machine in accordance with the lubrication chart and instruct him on proper maintenance Instruct the driver in the operation of all functions Check the machine for external damage Check that all screw connections are tight Seal any leaks Check the hydraulic pressure according to the testing and adjustment plan Diesel engine Check the oil level in the diesel engine Change the engine oil (NOTE: the operating hours stated here only apply to the appropriate engine oil quality / for complicating factors see the lubricants and fuels section) Replace the oil filter Check or replace the V-ribbed belt Drain off condensate from the fuel fine filter Change the fuel fine filter Change the fuel pre-filter Clean the service cap and dust extraction valve on the air filter Check that the vacuum switch of the air filter works Replace the air filter main element if indicated by the vacuum switch (replace the safety element after having replaced the main element 3 times) Check the air suction hoses for leaks and tight fitting Check the exhaust system for leaks and tight fitting Cooling system Check the coolant level Check the antifreeze concentration in the coolant Replace the coolant and antifreeze (or every 2 years) Clean the cooling system Working hydraulics Lubricate the pilot control device, universal joints and tappets Check the oil level in the hydraulic tank Change the hydraulic oil (take an oil sample every 500 hours for bio oil) Change the return suction filter Replace the bleeder filter on the hydraulic tank Steering system Check the steering Lubricate the bearing points on the steering cylinders

3.1-2 of 4

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L506 - 776 / from 9099 L507 - 777 / from 9099

L508 - 778 / from 9099 L509 - 779 / from 9099 L510 - 782 / from 9099

Service manual

Maintenance Maintenance and inspection schedule

Customer: ............................................... Machine type: .................... Ser. no.: ............................. Service hours: .............. Date: ......................

Maintenance / inspection after service hours

TASKS TO BE PERFORMED by maintenance staff once-only activity repeat interval as necessary annually before the winter

by authorised specialist staff once-only activity repeat interval as necessary

Brake system Check the service brake and parking brake Check the oil level in the equalising reservoir of the brake system Check the gap and wear on the brake linings Electrical system Check the indicator lamps and lighting Check the batteries, fluid level and terminals Transfer gear Check the oil level in the transfer gear Change the gear oil in the transfer gear Axles and tyres Check the tightness of the wheel lugs (once after 50, 100 and 250 h) (450Nm) Check the tightening torque of the front axle fastening bolts (750 Nm) Grease the lubricating points on the rear axle kingpin bearings Check the axle oil levels Change the axle gear oil Check and lubricate the drive shaft Check and adjust the tyre pressure Machine frame and ballast weight Lubricate the articulated oscillating bearing and the rear oscillating bearing Check the tightening torque of the bolts on the pressure flange Check that the taper connection of the steering rods is tight Cab, heating and air-conditioning (optional) Check the indicator beads in the dryer-collector unit (optional) Check that the air-conditioning system is working (optional) Lubricate the door hinges Clean or replace the fresh air and recirculated air filter Lift arms and quick-change device Lubricate the lift arms and attachment Lubricate the quick-change device Check the bearing bushings on the lift arms Check the lift arms and bucket stops Check that the quick-change device is working properly

L506 - 776 / from 9099 L507 - 777 / from 9099 L508 - 778 / from 9099

L509 - 779 / from 9099 L510 - 782 / from 9099

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3.1-3 of 4

Service manual

Maintenance Testing and adjustment plan

3.2 Testing and adjustment plan The tasks in the testing and adjustment plan may only be carried out by authorised specialist staff of LIEBHERR or its contractual agents.

You can find brief instructions on performing these tasks in the section on “testing and adjustment checklists.”

Detailed instructions can be found in the section on “testing and adjustment tasks.”

Customer: ………………………

Machine type: ………...…

Ser. no.: ……....…… Service hours: …….…….…… Date: ………..…………

Maintenance / inspection after service hours

TASKS TO BE PERFORMED by authorised specialist staff once-only activity repeat interval as necessary Diesel engine Check the diesel engine speed Cooling system Check the pressure relief valve on the fan motor Travel hydraulics Check the replenishing pressure of the travel pump Check the start of regulation of the travel pump Check the output of the travel pump Check the pressure relief and replenishing valve of the travel pump Check the pressure cut-off of the travel pump Check the variable displacement motor in the control range Working hydraulics Check the secondary pressure relief valves on the control block Check the primary pressure relief valves on the control block Steering system Check the pressure relief valve of the steering system Check the secondary pressure relief valves of the servostat Brake system Check the play of the inch/brake pedal

L506 - 776 / from 9099 L507 - 777 / from 9099 L508 - 778 / from 9099

L509 - 779 / from 9099 L510 - 782 / from 9099

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3.2-1 of 2

Service manual

Maintenance Lubrication chart and filling quantities

3.3 Testing and adjustment checklists The testing and adjustment checklists contain all testing and adjustment tasks. You can find detailed descriptions of each activity in the section on testing and adjustment tasks.

L506 - 776 / from 9099 L507 - 777 / from 9099 L508 - 778 / from 9099

L509 - 779 / from 9099 L510 - 782 / from 9099

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3.3-1 of 6

Costumer:

L506, L507, L508 S/N:

/

Operating hours: Type of application: Job site:

Checked by: Checked on date:

Check / Adjustment

Unit

Adjust. values

Value at check

Value after adjust.

Adjust. point

Test point

1

Diesel Engine Diesel engine RPM Low idle RPM High idle RPM

12

HZ 205 HZ 740

+20

-1

min

-1

min

50

1

+80

1

850 3040

Cooling System Cooling system (fan control) Fan at high diesel engine RPM / Sensor unplugged

bar

14010

P

Driving Hydraulic Replenishing pressure At low idle RPM

bar

292

2

G

At high idle RPM

bar

312

2

G

bar

50

3

MA

Regulation begin–var. displ. pump High pressure Diesel engine RPM

HZ 265

12

Control pressure

-1

50

50

50

min

1100

bar

72

PST

Pump performance / 400 bar High pressure High pressure Diesel engine RPM

HZ 56025

Control pressure

bar

400

min-1

2300100

400

400

4

MA

bar

192

bar

46010

1

MA

bar

4305

5

MA

PST

High pressure relief valve Forward Pressure cut-off High pressure Engine speed drop, max. difference to high idle RPM HZ 15

-1

min

60

min-1

278050

High pressure when accelerating L506

bar

21010

7

MA

High pressure when accelerating L507, L508

bar

23010

7

MA

Variable displ. motor in regulating range Diesel engine RPM

HZ 67512

= Blocked Machine

L506 - 776 / from 9099 L507 - 777 / from 9099 L508 - 778 / from 9099

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MJFCIFSS

3.3

Check / Adjustment

Unit

Adjust. values

Value at Value after Adjust. point check adjust.

Test point

Working Hydraulic Control valve block 5

2

P

5

1

P

5

5

P

3/4

P

230

5

6

P

bar

1905

6

P

bar

16010

10

P

Secondary pressure relief valve, lift 1)

bar

220

Secondary press. relief valve, tilt in 1)

bar

220

Secondary press. rel. valve, tilt out 1)

bar

170

Secondary pressure rel. valve additional equipment 1)

bar

1955

bar

Control valve block Primary pressure relief valve L506, L507 Primary pressure relief valve

L508

Ride control Pressure relief valve plus ½ turn

Steering System Priority-valve working hydraulic pump Pressure relief valve - steering

bar

18010

7

bar

26010

8

Servostat Secondary pressure relief valves

Brake System Idle mouvement of the Brakeinching pedal Push the Inch- brake pedal softly by hand Check at running engine

mm

5

9

Remarks:

Signature:

1) Attention: The working hydraulic pump must not be loaded with more than 235 bar.

Turn out secondary relief valves by 1 turn Adjust the secondary relief valves to the value in the table After check / adjustment turn in secondary relief valves by 1 turn Checking the secondary valves and the primary valve must be conducted at a diesel engine speed of approx. 1000 rpm (242 Hz).

Check and adjust only if required

3.3

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MJFCIFSS

L506 - 776 / from 9099 L507 - 777 / from 9099 L508 - 778 / from 9099

Costumer:

L509, L510 S/N:

/

Operating hours: Type of application: Job site:

Checked by: Checked on date:

Check / Adjustment

Unit

Adjust. values

Value at check

Value after adjust.

Adjust. point

Test point

1

Diesel Engine Diesel engine RPM Low idle RPM High idle RPM

12

HZ 205 HZ 740

+20

-1

min

-1

min

50

1

+80

1

850 3040

Cooling System Cooling system (fan control) Fan at high diesel engine RPM / Sensor unplugged

bar

14010

P

Driving Hydraulic Replenishing pressure At low idle RPM

bar

282

2

G

At high idle RPM

bar

302

2

G

bar

50

3

MA

Regulation begin–var. displ. pump High pressure Diesel engine RPM

HZ 265

12

Control pressure

-1

50

50

50

min

1100

bar

62

PST

Pump performance / 400 bar High pressure High pressure Diesel engine RPM

HZ 56025

Control pressure

bar

400

min-1

2300100

400

400

4

MA

bar

152

bar

49010

1

MA

bar

460

5

5

MA

7

MA

PST

High pressure relief valve Forward Pressure cut-off High pressure Engine speed drop, max. difference to high idle RPM HZ 15

-1

min

60

min-1

278050

bar

21010

Variable displ. motor in regulating range Diesel engine RPM

HZ 67512

High pressure when accelerating = Blocked Machine

L509 - 779 / from 9099 L510 - 782 / from 9099

copyright by

MJFCIFSS

3.3

Check / Adjustment

Unit

Adjust. values

Value at Value after Adjust. point check adjust.

Test point

Working Hydraulic Control valve block 5

2

P

5

1

P

5

5

P

3/4

P

5

6

P

5

Secondary pressure relief valve, lift 1)

bar

220

Secondary press. relief valve, tilt in 1)

bar

220

Secondary press. rel. valve, tilt out 1)

bar

170

Secondary pressure rel. valve additional equipment 1)

bar

1955

bar

190

Control valve block Primary pressure relief valve L509 Primary pressure relief valve L510

bar

210

6

P

bar

16010

10

P

Ride control Pressure relief valve plus ½ turn

Steering System Priority-valve working hydraulic pump Pressure relief valve - steering

bar

18010

7

bar

26010

8

Servostat Secondary pressure relief valves

Brake System Idle mouvement of the Brakeinching pedal Push the Inch- brake pedal softly by hand Check at running engine

mm

5

9

Remarks:

Signature:

1) Attention: The working hydraulic pump must not be loaded with more than 235 bar.

Turn out relief valves by 1 turn Adjust the secondary relief valves to the value in the table After check / adjustment turn in secondary relief valves by 1 turn Checking the secondary valves and the primary valve must be conducted at a diesel engine speed of approx. 1000 rpm (242 Hz).

Check and adjust only if required

3.3

copyright by

MJFCIFSS

L509 - 779 / from 9099 L510 - 782 / from 9099

Service manual

Maintenance Lubrication chart and filling quantities

3.4 Lubrication chart and filling quantities 3.4.1

Table of filling quantities Specifications in the medium column: – The standard “lubricants and fuels” required for central European climate conditions are stated here.

– Before you change or top up the oil in the hydraulic system (hydraulic tank), always check if it is filled with petroleum or bio oil.

– For more detailed information about the required lubricants and service fuels, see the section on “lubricants and fuels.”

Specifications in the dosage column: – The values stated for the filling quantities in the table are only guidelines.

– The dipstick and level markings are always mandatory.

– Each time the oil is replaced or topped up, check the level in the unit in question.

Valid for:

L506 - 476 / from 9099; L507 - 477 / from 9099; L508 - 478 / from 9099;

Description Diesel engine (with filter change)

Medium Engine oil SAE 10W - 40

Diesel engine cooling system Total capacity

Coolant

10.0 l

Hydraulic system Total capacity

Engine oil SAE 20W - 20

90.0 l

Hydraulic tank

Engine oil SAE 20W - 20

55.0 l

Brake system Total capacity

Hydraulic oil HLPD (petroleum) SAE 10W Gear oil SAE 90 LS

0.8 l

Front axle differential

Gear oil SAE 90 LS

4.3 l

Front axle wheel hubs

Gear oil SAE 90 LS

2 x 0.9 l

Rear axle differential

Gear oil SAE 90 LS

3.7 l

Transfer gear

L506 - 776 / from 9099 L507 - 777 / from 9099 L508 - 778 / from 9099

L509 - 779 / from 9099 L510 - 782 / from 9099

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MJFCIFSS

Dosage

Unit 8.0 l

0.6 l

3.4-1 of 4

Maintenance

Service manual

Lubrication chart and filling quantities

Valid for:

3.4-2 of 4

Description Rear axle wheel hubs

Medium Gear oil SAE 90 LS

Air-conditioning system

Refrigerant R 134a

Dosage Unit 2 x 0.9 l

approx. g 1400

L509 - 779 / from 9099; L510 - 782 / from 9099

Description Diesel engine (with filter change)

Medium Engine oil SAE 10W - 40

Diesel engine cooling system Total capacity

Coolant

Hydraulic system Total capacity

Engine oil SAE 20W - 20

100.0 l

Hydraulic tank

Engine oil SAE 20W - 20

75.0 l

Brake system Total capacity

Hydraulic oil HLPD SAE 10W

0.8 l

Transfer gear

Gear oil SAE 90 LS

0.7 l

Front axle differential

Gear oil SAE 90 LS

7.5 l

Front axle wheel hubs

Gear oil SAE 90 LS

2 x 0.85 l

Rear axle differential

Gear oil SAE 90 LS

6.3 l

Rear axle wheel hubs

Gear oil SAE 90 LS

2 x 0.85 l

Air-conditioning system

Refrigerant R 134a

copyright by

MJFCIFSS

L506 - 776 / from 9099 L507 - 777 / from 9099

Dosage

Unit 11.25 l

12.0 l

approx. 1400 g

L508 - 778 / from 9099 L509 - 779 / from 9099 L510 - 782 / from 9099

Service manual

Maintenance Lubrication chart and filling quantities

3.4.2

Lubrication chart The lubrication chart provides an overview of the location of the maintenance points on the machine and of the maintenance intervals.

You will find detailed information in the “maintenance and inspection schedule”, as well as in the individual descriptions in the section on “maintenance tasks.”

For more detailed information about the required lubricants and service fuels, see the section on “lubricants and fuels.”

For information about the required filling quantities, see the “tables of filling quantities.”

L506 - 776 / from 9099 L507 - 777 / from 9099 L508 - 778 / from 9099

L509 - 779 / from 9099 L510 - 782 / from 9099

copyright by

MJFCIFSS

3.4-3 of 4

Maintenance

Service manual

Lubrication chart and filling quantities

Symbol

Description

Symbol

Description

General lubrication points

Lubrication

Check the oil level

Check the coolant level

Oil change

3.4-4 of 4

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MJFCIFSS

L506 - 776 / from 9099 L507 - 777 / from 9099

L508 - 778 / from 9099 L509 - 779 / from 9099 L510 - 782 / from 9099

Service manual

Maintenance Maintenance tasks

3.5 Maintenance tasks On completion of servicing, the machine should be returned to the operating position.

See the description of the “operating position” in the “operation” section of the operating manual.

3.5.1

Preparatory tasks for maintenance Before performing the various maintenance tasks, move the machine to maintenance position unless otherwise explicitly specified in the description.

The various maintenance tasks include: – Lubricating the lift arms, – Checking the oil level or changing the oil in the engine, gears, axles, hydraulic tank, etc., – Replacing filters as well as adjustment and repair work on the hydraulic system.

Safety precautions for maintenance Always observe the accident prevention regulations during maintenance work.

See the “safety regulations” section for measures to ensure safe maintenance.

Make sure that visual contact between the operator in the cab and maintenance personnel is always maintained.

Visual contact Danger

There is a risk of accidents for maintenance personnel!

The presence of unauthorised persons on the machine can place the maintenance personnel in extreme danger.

! Never enter a dangerous area of the machine without making your presence known.

Make sure you can be clearly seen before entering one of the machine's danger areas.

Secure the machine against rolling away with wheel wedges.

Wheel wedges

L506 - 776 / from 9099 L507 - 777 / from 9099 L508 - 778 / from 9099

L509 - 779 / from 9099 L510 - 782 / from 9099

copyright by

MJFCIFSS

3.5-1 of 26

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