Liebherr l586 2plus2 wheel loader service repair manual

en

Service Manual (20

Wheel loader (10 points)

L586 2plus2 (10

en

Service Manual (20

Wheel loader (10 points)

L586 2plus2 (10

Address Address:

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

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

LIEBHERR-WERK BISCHOFSHOFEN GMBH Wheel loader L5 4 1

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

 LBH / Technical Documentation Department 01

Preface

Intended readership

Contents

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.

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 and Italian.

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.

General information

1

Product description

2

Maintenance

3

Diesel engine and pump distributor gear

4

Cooling system

5

Travel hydraulics

6

Working hydraulics

7

Steering system

8

Brake system

9

Electrical system

10

Transfer gear

11

Axles and cardan shaft

12

Machine frame and ballast weight

13

Central lubrication system

14

Coverings and access

15

Cab, heating and air-conditioning

16

Lift arms and quick-change device

17

Equipment and accessories

18

Service codes and diagnosis

19

Options

20

1 General Informations 1.0 Chapter contents 1

General Informations........................................................... 1.0-1 1.1

Safety regulations ...........................................................................1.1-1 1.1.1

Introduction...........................................................................1.1-1

1.1.2

Overview of the safety regulations .......................................1.1-2

1.2

Special tools for maintenance and repair work...............................1.2-1 1.2.1

Special tools in general ........................................................1.2-1

1.2.2

Special tools for Liebherr diesel engines..............................1.2-2

1.2.3

Special tools for hydraulic cylinders .....................................1.2-3

1.2.4

Special tools for electronics..................................................1.2-3

1.2.5

Special tools for axles...........................................................1.2-3

1.2.6

Special tools for the transmission.........................................1.2-5

1.2.7

Central lubrication system ....................................................1.2-5

1.2.8

Special tools for the air conditioning system ........................1.2-5

1.2.9

Special tools for cab windows ..............................................1.2-5

1.3

Standard .........................................................................................1.3-1 1.3.1

L586 - 461 / from 17650

Tightening torques for screws ..............................................1.3-1

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1.0-1 o f 2

Service Manual

General Informations Safety regulations

1.1 Safety regulations Working on the machine poses safety risks to the operator, driver or maintenance engineers. You can prevent risks and accidents by regularly reading and observing the various safety instructions.

This is especially important for personnel who only occasionally work on the machine, for example, carrying out rigging or maintenance work. The safety regulations listed below, if conscientiously followed, will ensure your own safety and that of others, and will prevent the machine from being damaged.

All work must be carried out only by qualified expert personnel or under the guidance and responsibility of such personnel.

Qualified personnel are people, who: – on the basis of their education, experience and training have sufficient knowledge of earth moving machinery and the technology, – have in-depth knowledge of the regulations concerning the prevention of industrial accidents and of national regulations and guidelines, – can assess the safe operating condition of earth moving machinery, can carry out the required work without putting those carrying out the work, or other parties, into danger.

Whenever tasks which could cause danger to personnel or damage to the machine are described, the necessary safety precautions are explained in this manual.

These are indicated by the headings Danger, Warning, Caution or Notice.

1.1.1

Introduction 1. The symbols below have the following meanings: DANGER Denotes an urgent, dangerous situation.

Will result in death or serious injury.

Actions to avert the danger.

WARNING Denotes a dangerous situation.

Can result in death or serious injury.

Actions to avert the danger.

CAUTION Denotes a dangerous situation.

Can result in slight or moderate injury.

Actions to avert the danger.

NOTICE Denotes a dangerous situation.

Can cause material damage.

Actions to avert the danger.

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1.1-1 o f 2

General Informations

Service Manual

Safety regulations

Note Useful tips and instructions Possible benefits Actions to implement 2. Observance of these instructions does not exempt you from following any additional rules and guidelines that may apply The following should also be observed: – The safety rules in force at the operating site – Legally enforceable road traffic regulations – Guidelines issued by trade associations

1.1.2

Overview of the safety regulations For further information please see the safety regulations in the current edition of the operating instructions. You will find the latest edition of the operating instructions in your Liebherr Service documentation.

The following sections are included in the operating manual:

1.1-2 o f 2

1

General safety regulations

2

Instructions on preventing crushing injuries and burns

3

Instructions on preventing fires and explosions

4

Safety instructions for start-up

5

Safety precautions during start-up

6

Instructions for safe working

7

Safety instructions for driving on slopes

8

Parking safely

9

Transporting the machine safely

10

Towing the machine safely

11

Measures for ensuring safe maintenance

12

Safety instructions for working on machines with hydro accumulators

13

Safety instructions for welding work on the machine

14

Instructions for working safely on the working attachment

15

Safety instructions for transporting the machine by crane

16

Safe maintenance of hydraulic hoses and hose lines

17

Attachments and accessories

18

Protection against vibrations

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L586 - 461 / from 17650

Service Manual

General Informations Special tools for maintenance and repair work

1.2 Special tools for maintenance and repair work 1.2.1 Description

Special tools in general

Anti-freeze and battery tester

7408922

All wheel loaders

24 volt vacuum pump Filling and testing device with case Manometer 0 - 40 bar Manometer 0 - 250 bar Manometer 0 - 600 bar Manometer connection High pressure hose 1500 mm High pressure hose 4000 mm Screw connection M 10 x 1 Draining hose Drain piece

7408148

All wheel loaders

Remarks For checking the acid concentration (battery charging state) and anti-freeze For preventing oil loss

8145359

All wheel loaders

For checking the hydro accumulator

7361288 5002932 5002866 7002436 7002475 7009134 5005180 7005660 7402657

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

Safety cap 10 mm

7009315

All wheel loaders

Safety cap 13 mm Safety cap 17 mm Safety cap 19 mm

7615515 7615589 7009317

All wheel loaders All wheel loaders All wheel loaders

Safety cap 17 mm

7622068

All wheel loaders

USB dongle Diagnostic data cable (RS-232) Diagnostic data cable 1,5 m (ETHERNET) Diagnostic data cable 3,0 m (ETHERNET)

10333608

All wheel loaders

10035410

All wheel loaders

10225579

L550 - L586

10513200

L550 - L586

Adapter cable RS232<>USB

693190714 All wheel loaders

SDCF-03 memory card adapter

10223098

L550 - L586

Compact flash card

10223095

L550 - L586

Lifting device for travel pumps

8928677

L586

For checking the hydraulic pressure For checking the hydraulic pressure For checking the hydraulic pressure Connection for the manometer High pressure hose for manometer High pressure hose for manometer For checking the hydraulic pressure For draining oil via a drain valve For the drain hose For securing the valves on the variable adjustment motor For securing the valves on the pumps For securing the valves on the pumps For securing the valves on the pumps For securing the valves on the control block With SERVICE authorisation For adjusting the travel hydraulics, and testing the electrical system and options For adjusting the travel hydraulics, and testing the electrical system and options For adjusting the travel hydraulics, and testing the electrical system and options For communicating with the wheel loader electronics if there is an error with the RS232 interface on the notebook.

For writing to the compact flash card Blank compact flash card.

Data medium for application software.

For the removal and installation of travel pumps

L586 - 461 / from 17650

ID no.

Use

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1.2-1 o f 6

General Informations

Service Manual

Special tools for maintenance and repair work

1.2.2 Description

Special tools for Liebherr diesel engines ID no.

Use

Mandrel

9078118

L550 - L556 engine

Mandrel

9078119

L550 - L556 engine

Rotary angle device

0524062

L550 - L580 engine

Holder

0528464

L550 - L580 engine

Dial gauge holder

10023885

L550 - L580 engine

Compression tester Compression tester insert Adapter Claw

8008782 10012817 10297211 10117612

L550 - L580 engine L550 - L580 engine L550 - L580 engine L550 - L580 engine

Engine turner

0524045

L550 - L580 engine

Holder

0528464

L550 - L580 engine

Piston strap

8000592

L550 - L580 engine

Rotary angle device

0524062

L550 - L580 engine

Piston ring tongs

7009319

L550 - L580 engine

Extractor tool

0526855

L550 - L580 engine

Extractor tool

0528462

L550 - L580 engine

Mounting pin

0528470

L550 - L580 engine

Hook and lever

7019858

L550 - L580 engine

Inserter

10116249

L550 - L580 engine

Mounting pin

0528470

L550 - L580 engine

Inserter

10116250

L550 - L580 engine

Special spanner

10020852

L550 - L580 engine

Adapter

0524029

L550 - L580 engine

Adapter

10220689

L550 - L580 engine

Hammer puller

0524072

L550 - L580 engine

Pusher tube

10289319

L550 - L580 engine

Pusher tube

10289320

L550 - L580 engine

Mounting pin

0528472

L550 - L580 engine

1.2-2 o f 6

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Remarks For installing the mass equalisation shafts (D 934) For installing the mass equalisation shafts (D 934) For installing and removing the cylinder head For checking projection of the cylinder bushings For checking projection of the cylinder bushings For checking the compression For checking the compression For checking the compression For checking the compression For installing and removing the pistons and rods For installing and removing the pistons and rods For installing and removing the pistons and rods For installing and removing the pistons and rods For installing and removing the piston rings For installing and removing the cylinder bushing For installing and removing the cylinder bushing For installing and removing crankshaft attachments For installing and removing the front crankshaft seal For installing and removing the front crankshaft seal For installing and removing the flywheel For installing and removing the rear crankshaft seal For installing and removing the injection line For installing and removing the pressure pipe port and injection nozzles For installing and removing the pressure pipe port and injection nozzles For installing and removing the pressure pipe port and injection nozzles For installing and removing the injection pump and roller tappet For installing and removing the injection pump and roller tappet For installing and removing the exhaust pipe

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General Informations Special tools for maintenance and repair work

1.2.3 Description Assembly sleeve 110 mm Assembly sleeve 180 mm Assembly sleeve 200 mm Expansion sleeve 110 mm Expansion sleeve 180 mm Expansion sleeve 200 mm Bearing head assembly spanner 92/12 mm

ID no.

9170509 9998619 9107933 9170511 9110413 9110414

Use L586 steering cylinder L586 lift cylinder L586 tilt cylinder L586 steering cylinder L586 lift cylinder L586 tilt cylinder

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

9241799

L586 steering cylinder

For fitting the piston rod bearing

1.2.4 Description

Special tools for hydraulic cylinders

Special tools for electronics

ID no.

Digital multimeter

8502956

Test probe, red Test probe, black Magnet tester Stripping and crimping pliers 0.5 â&#x20AC;&#x201C; 6.0 mm2 Crimping pliers Wedge extractor tool Extraction tool size 12 for pin and bushing Extraction tool size 16 for pin and bushing Extraction tool size 20 for pin and bushing

Use All wheel loaders

884191214 All wheel loaders 884191114 All wheel loaders 8145743 All wheel loaders 8460263

All wheel loaders

For MATE-N-LOK connectors

8503647 7026267

All wheel loaders All wheel loaders

For DEUTSCH connectors For DEUTSCH connectors

8145674

All wheel loaders

For DEUTSCH connectors

8145673

All wheel loaders

For DEUTSCH connectors

8503630

All wheel loaders

For DEUTSCH connectors

1.2.5

Special tools for axles

Description

ID no.

Hand pump

8145835

L550 - L580 axles

Collet

7009536

L550 - L576 axles

Spring hook

8145767

L550 - L576 axles

Slip bushing 260 mm

7017559

Slip bushing 315 mm

7017556

Slip bushing M 90 x 1.5 mm Slip bushing M 110 x 1.5 mm Slip bushing M 130 x 1.5 mm Handle Handle Mounting tool

L586 - 461 / from 17650

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

Use

Remarks For finding leaks on disc brakes For installing and removing the snap ring in the planetary drive For attaching and detaching the return springs

L556 front axle L556 rear axle L566, L576 front axle L566, L576 rear axle

For fitting the brake piston For fitting the brake piston

7017558

L556 rear axle

For fitting ring gear carriers

7017557

L556 front axle L566, L576 rear axle

For fitting ring gear carriers

7017555

L566, L576 front axle

For fitting ring gear carriers

7017566 7011518 7017563

L550 - L576 axles L550 - L576 axles L556 rear axle

Handle for mounting tool Handle for various mounting tools For fitting cartridge seal ring

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1.2-3 o f 6

General Informations

Service Manual

Special tools for maintenance and repair work

Description

ID no.

7011522 7013922

Use L556, L566, L576 front axle; L566, L576 rear axle L556 - L576 axles L556 rear axle L556 front axle L566, L576 rear axle L566, L576 front axle L556 front axle L556, L566, L576 rear axle L566, L576, L580 front axle; L580 rear axle L556 - L580 axles L556 - L580 axles

Mounting tool

7017560

Centring bracket Groove nut spanner 111 mm

7013775 7009537

Groove nut spanner 140 mm

7011251

Groove nut spanner 169 mm Measuring screw M 16 x 1.5 Measuring screw M 16 x 1.5 Clamp fork Mounting tool Slotted nut spanner 81 mm Mounting tool (used with grip 7011518)

7013774

10017840

L550 - L576 axles

7624271

L550 axles, MT-L 3085

Mounting tool

7624272

L550 axles, MT-L 3085

Centring bracket

10008138

Centring bracket

10493498

Socket wrench

10493499

Socket wrench

10008139

Socket wrench

10218794

Clamp fork

10008140

L550 MT-L 3085 axles

10286181

L580 Hercules axles

10286183

L580 Hercules axles

10286186

L580 Hercules axles

Grip for seal driver and shell

10286788

L580 Hercules axles

Driver for inner lip seal

10286189

L580 Hercules axles

Driver for wear bushing with guide

10286190

L580 Hercules axles

Grooved nut socket

10286192

L580 Hercules axles

Seal holder installation tool Driver for oil bearing casings, bevel gear Driver for grease seal and disc

10286193

L580 Hercules axles

10286194

L580 Hercules axles

10286195

L580 Hercules axles

Rolling apparatus

10286196

L580 Hercules axles

Lifting tackle

10286197

L580 Hercules axles

Special tool kit for Hercules axles Driver for lubrication and oil seal 3â&#x20AC;&#x153; bushing driver with guide and grip

1.2-4 o f 6

7019556 8145771

L550 - L576 axles MT-L 3085-3105 L550 - L576 axles MT-L 3095-3105 L550 - L576 axles MT-L 3095-3105 L550 MT-L 3085 axles L556 rear axle L550 MT-L 3085 front axle L556 - L576 axles

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Remarks For fitting cartridge seal ring For groove nut spanner For fitting the grooved nuts For fitting the grooved nuts For fitting the grooved nuts For measuring wear on the brake discs For measuring wear on the brake discs For fitting the drive flange For fitting the shaft seal ring For fitting the grooved nuts on the axle shaft For fitting the dust protection axle insert For fitting the shaft seal ring axle insert For detaching the output For detaching the output For detaching the output For detaching the output For detaching the output For removing and fitting the drive pinion Contains the following items: 10286183 - 10286198 For fitting the lubrication and oil seal, to be used with grip 10286788 For installing bushing, including grip 10286788 For fitting the outer lip seal, to be used with appropriate driver For fitting the inner lip seal, to be used with grip 10286788 For installing the wear bushing For removing and fitting the grooved nuts For fitting the seal holder For installing the bearing casings, bevel gear For fitting the grease seal and disc, to be used with grip 10286788 For testing the rolling torque of the wheel hubs For removing the wheel hub

L586 - 461 / from 17650

Service Manual

General Informations Special tools for maintenance and repair work

Description Installation tool for Lifetime seal Nut socket for central nut wheel hub carrier

ID no.

Use

Remarks

10286198

L580 Hercules axles

For fitting the Lifetime seal

93011855

Front axle L586 Hercules

For installing and removing of the wheel hub carrier.

1.2.6 Description

Special tools for the transmission ID no.

Use

Fixing spanner

10016179

L550 - L586

Special socket

10016180

L550 - L586

Mounting tool

10016181

L550 - L586

1.2.7 Description

Remarks For loosening and tightening the grooved nut on the coupling 1 For loosening and tightening the grooved nut on the coupling 1 For removing and attaching the snap ring on the couplings

Central lubrication system ID no.

Use

BEKA Max filling press

10009239

All wheel loaders

Groeneveld filling press

10333342

All wheel loaders

7029283

All wheel loaders

7624289

All wheel loaders

7624290

All wheel loaders

Filling connection Grรถneveld central lubrication data cable Grรถneveld central lubrication plug adapter

1.2.8 Description

Remarks For quickly filling the BEKA Max reservoir For quickly filling the Groeneveld reservoir For filling the reservoir For inspecting the central lubrication system For inspecting the central lubrication system

Special tools for the air conditioning system ID no.

Use

Remarks

Vacuum pump

7027552

All wheel loaders

For evacuating the air conditioning system

4-valve test fitting

7027558

All wheel loaders

For testing, evacuating and filling the air conditioning system

Filling hose, blue 1500 mm

7027553

All wheel loaders

For the test fitting

Filling hose, yellow 1500 mm

7027554

All wheel loaders

For the test fitting

Filling hose, red 1500 mm

7027555

All wheel loaders

For the test fitting

Car coupling 253a

7027556

All wheel loaders

For the test fitting

Car coupling 254a

7027557

All wheel loaders

For the test fitting

1.2.9 Description Complete tool box with suction pads

L586 - 461 / from 17650

Special tools for cab windows ID no.

10021147

Use

Remarks

All wheel loaders

For installing and removing windows

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1.2-5 o f 6

Service Manual

General Informations Standard

1.3 Standard 1.3.1

Tightening torques for screws Pre-loading forces and tightening torques for screws with standard and fine metric threads.

Standard and fine metric threads All figures are for bolted connections with at least one Dacromet 500 coated element (screws, washers, nuts…)

Surface: - DACROMET 500

Thread

Assembly preloading forces FM in N

Class

Tightening torques MA in Nm

Standard and fine metric threads. All figures are for bolted connections without any Dacromet 500 coated elements (screws, washers, nuts…)

Surface: - black finish or phosphated - zinc-plated Thread

Class

for avg. coefficient of friction µG= 0.10

M4

M5

M6

M7

M8

M8x1

M9x1

M10

M10x1

M10x1,25

M12

M12x1,25

M12x1,5

M14

M14x1,5

8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9

Date 15.10.2008

Works LBH

4 200 6 200 7 300 6 900 10 100 11 900 9 700 14 300 16 700 14 200 20 900 24 500 17 900 26 000 30 500 19 600 28 500 33 500 25 500 38 000 44 000 28 500 42 000 49 000 32 500 48 000 56 000 30 500 45 000 53 000 41 500 61 000 71 000 46 500 68 000 80 000 44 000 65 000 76 000 57 000 84 000 98 000 63 000 92 000 108 000

2,5 3,7 4,3 4,9 7,3 8,5 8,5 12,5 14,5 14,0 20,5 24,0 20,5 30 35 22 32 38 32 46 54 41 60 71 45 67 78 43 64 74 71 104 121 77 112 130 74 108 125 113 165 195 121 175 205

Issued Roland Weber

Tightening torques MA in Nm

for avg. coefficient of friction µG= 0.12

8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9

M4

M5

M6

M7

M8

M8x1

M9x1

M10

M10x1

M10x1,25

M12

M12x1,25

M12x1,5

M14

M14x1,5

Reviewed Dr. Herbert Pfab

This document must not be copied or reproduced without prior permission. This document has been electronically prepared and is valid without requiring a signature.

L586 - 461 / from 17650

Assembly preloading forces FM in N

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4 050 6 000 7 000 6 600 9 700 11 400 9 400 13 700 16 100 13 700 20 100 23 500 17 200 25 000 29 500 18 800 27 500 32 500 24 800 36 500 42 500 27 500 40 000 47 000 31 500 46 500 54 000 29 500 43 000 51 000 40 000 59 000 69 000 45 000 66 000 77 000 42 500 62 000 73 000 55 000 80 000 94 000 61 000 89 000 104 000

2,8 4,1 4,8 5,5 8,1 9,5 9,5 14,0 16,5 15,5 23,0 27 23 34 40 24,5 36 43 36 53 62 46 68 79 52 76 89 49 72 84 79 117 135 87 125 150 83 122 145 125 185 215 135 200 235

Approved Dr. Herbert Pfab Liebherr-Norm_DE_V001.dot

1.3-1 o f 4

General Informations

Service Manual

Standard

Thread

Class

Assembly preloading forces FM in N

Tightening torques MA in Nm

Thread

Class

for avg. coefficient of friction ÂľG= 0.10

M16

M16x1,5

M18

M18x1,5

M18x2

M20

M20x1,5

M22

M22x1,5

M24

M24x1,5

M24x2

M27

M27x1,5

M27x2

M30

M30x1,5

M30x2

M33

M33x1,5

M33x2

M36

M36x1,5

8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9

78 000 115 000 134 000 85 000 125 000 147 000 98 000 140 000 164 000 114 000 163 000 191 000 106 000 151 000 177 000 126 000 180 000 210 000 144 000 206 000 240 000 157 000 224 000 260 000 177 000 255 000 295 000 182 000 260 000 305 000 215 000 306 000 358 000 203 000 290 000 340 000 239 000 340 000 400 000 276 000 394 000 461 000 265 000 375 000 440 000 290 000 415 000 485 000 346 000 493 000 576 000 332 000 472 000 553 000 360 000 520 000 600 000 423 000 603 000 705 000 410 000 580 000 680 000 425 000 600 000 710 000 508 000 724 000 847 000

170 250 300 180 270 310 245 350 410 270 390 450 260 370 430 350 490 580 380 540 630 470 670 780 510 720 840 600 850 1000 700 990 1170 640 920 1070 880 1250 1450 1010 1440 1690 940 1350 1550 1190 1700 2000 1410 2000 2340 1370 1940 2270 1600 2300 2700 1880 2670 3130 1750 2500 2900 2100 3000 3500 2450 3490 4090

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Tightening torques MA in Nm

for avg. coefficient of friction ÂľG= 0.12

M16

M16x1,5

M18

M18x1,5

M18x2

M20

M20x1,5

M22

M22x1,5

M24

M24x1,5

M24x2

M27

M27x1,5

M27x2

M30

M30x1,5

M30x2

M33

M33x1,5

M33x2

M36

M36x1,5

8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9

This document must not be copied or reproduced without prior permission. This document has been electronically prepared and is valid without requiring a signature.

1.3-2 o f 4

Assembly preloading forces FM in N 75 000 111 000 130 000 82 000 121 000 141 000 94 000 135 000 157 000 110 000 157 000 184 000 102 000 146 000 170 000 121 000 173 000 202 000 139 000 199 000 232 000 152 000 216 000 250 000 171 000 245 000 285 000 175 000 249 000 290 000 207 000 295 000 346 000 196 000 280 000 325 000 230 000 330 000 385 000 267 000 381 000 445 000 255 000 365 000 425 000 280 000 400 000 465 000 335 000 477 000 558 000 321 000 457 000 534 000 350 000 495 000 580 000 410 000 584 000 683 000 395 000 560 000 660 000 410 000 580 000 680 000 492 000 701 000 820 000

195 280 330 205 300 360 280 390 460 310 440 520 290 420 490 390 560 650 430 620 720 530 750 880 580 820 960 670 960 1 120 760 1 090 1 270 730 1 040 1 220 1 000 1 400 1 650 1 110 1 580 1 850 1 070 1 500 1 800 1 350 1 900 2250 1 540 2 190 2 560 1 490 2 120 2 480 1 850 2 600 3 000 2 050 2 920 3 420 2 000 2 800 3 300 2 350 3 300 3 900 2 680 3 820 4 470

Liebherr-Norm_DE_V001.dot L586 - 461 / from 17650

Service Manual

General Informations Standard

Thread

Class

Assembly preloading forces FM in N

Tightening torques MA in Nm

Thread

Class

for avg. coefficient of friction ÂľG= 0.10

M36x3

M39

M39x1,5

M39x3

8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9

455 000 650 000 760 000 510 000 730 000 850 000 601 000 857 000 1 002 000 550 000 780 000 910 000

2200 3100 3600 2700 3800 4500 3140 4470 5230 2800 4000 4700

Assembly preloading forces FM in N

Tightening torques MA in Nm

for avg. coefficient of friction ÂľG= 0.12

M36x3

M39

M39x1,5

M39x3

8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9

440 000 630 000 740 000 490 000 700 000 820 000 582 000 830 000 971 000 530 000 750 000 880 000

2 500 3 500 4 100 3 000 4 300 5 100 3 430 4 890 5 720 3 200 4 600 5 300

Comments concerning this standard: The tightening torques indicated on the drawings supersede the standard works values.

These must be observed and adhered to.

This standard only applies to Liebherr wheel loaders.

This document must not be copied or reproduced without prior permission. This document has been electronically prepared and is valid without requiring a signature.

L586 - 461 / from 17650

Copyright by

MJFCIFSS

Liebherr-Norm_DE_V001.dot

1.3-3 o f 6

2 Production description 2.0 Chapter contents 

  



  









 



 



 















 



 



















 



MJFCIFSS

2.0-1   



 

2.1 Technical data 2.1.1

Complete machine Wheel loader with Z lift arms                  

Description

Value Unit

 

 



 

 

 



 



 



 



 

 

 



 



 



 





 

 



 



 



 



MJFCIFSS

2.1-1    







Description

Value Unit



 



 



 



 



 



 



 



 



 

 

 

 

 

 

 

 

 

 

 

 

2.1.2

 

Diesel engine and pump distributor gear Diesel engine Description

Value Unit



 



 



 



 



 



 



 



 



 



 



 



 



  



 



 



 



 



 



2.1-2    



MJFCIFSS

 







 

Description

Value Unit



 



 



 



 



 



 



 



 





Fuel system Description

Value Unit



435 



 

Fuel Pre-filter Description

Value Unit



 

Fuel fine filter Description

Value Unit



 

Air filter vacuum switch Description

Value Unit

 

 

Coupling Description

Value Unit



 

Pump distributor gear Description

Value Unit





 



 



 

 

 

 

 



MJFCIFSS

2.1-3    







2.1.3

Cooling system Gear pump Description

Value Unit



   



Gear motor Description

Value Unit



 

 

 











 











 

Temperature sensor Description

Value Unit



   



 



 



 



 



 



 



 



 



 



 



 



 



2.1.4

 

Travel hydraulics Variable displacement pumps Description

Value Unit



 



 



 



2.1-4    



MJFCIFSS

 







 

Description

Value Unit  

 

 

  

   



 



 



 



 



 

 

  

  

   







































 

Variable displacement motor 1 Description

Value Unit



 



 



 



   



 

  

 



 



 

Variable displacement motor 2 Description

Value Unit



 



 



 



   



 

 





 



 



 



MJFCIFSS

2.1-5    







Distributor block - Variable displacement motors Description

Value Unit

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

 

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

 



 

Motor scavenging pump Description

Value Unit



2.1.5

 



 



 

Working hydraulics Working hydraulics pump Description

Value Unit



 



 



 



 



 



 



 



















 

Control block Description

Value Unit



 



 



 



 



  





































 

 



 

    

2.1-6    



MJFCIFSS







 

Pilot control device Description

Value Unit



 



 



 



 

Pilot control solenoid valve Description

Value Unit



 



 

Pilot control hydro accumulator Valid for:

ID 7622 448

Description

Value Unit



 



 

Float position pressure switch Valid for:

ID 6905 893

Description

Value Unit



 











 

Stabilisation module Description

Value Unit



 



















 



 



 



 

Hydro accumulator unit Description

Value Unit

 



    







 



MJFCIFSS



2.1-7    







Ride control pressure switch Valid for:

ID 6905 893

Description

Value Unit



 











 

Lift cylinder Valid for:

ld. 9284 849

Description

Value Unit



 



 



 



 



 



 



 

 

 



 

Tilt cylinder Gültig für:

Id. 9969 250

Description

Value Unit



 



 



 



 



 



 

 

 



 

Filter unit Description

2.1-8    

Value Unit



 



 



 



 



 



 



MJFCIFSS







 

Bleeder filter Description

Value Unit







2.1.6



 



 



 

Steering system Steering pump Description

Value Unit



 



 



 



   

 

 



  



 



 

Servostat Description

Value Unit



  









 

Steering cylinder Valid for:

ld. 9284 621

Description

Value Unit





 



 



 



 



 



 



MJFCIFSS

2.1-9    







Steering damper hydro accumulator Valid for:

ID 7623 934

Description

Value Unit



 



 



 

Emergency steering pump Valid for:

ID 1003 7552

Description

Value Unit



 











 



 



 

Emergency steering pressure switch Valid for:

Id. 1035 3428

Description

Value Unit  

 

 











 

Emergency steering check pressure switch Valid for:

Id. 1035 3428

Description

Value Unit



 



 







2.1.7





 

Brake system Brake system gear pump Description

Value Unit



2.1-10    

 



 



 



MJFCIFSS







 

Compact brake valve Valid for:

Id. 1029 5965

Description

Value Unit

 







 







 

 



 











 



 

Service brake hydro accumulator Valid for:

ID 1003 8487

Description

Value Unit

 

   



 

Brake light button Valid for:

ID 6905 535

Description

Value Unit



 











 

Accumulator charge pressure switch Valid for:

ID 1035 3433

Description

Value Unit  

 

 











 

Disc brake



Description

Value Unit











 



 



MJFCIFSS

2.1-11    







Parking brake hydro accumulator Valid for:

Id. 1028 8602

Description

Value Unit



 



 

Overspeed protection solenoid valve Description

2.1.8

Value Unit



 



 

Electrical system Description

Value Unit



 



 

Battery Description

Value Unit



 



 



 



Input - module

/

 

Output - module

Description

Value Unit

 





 



 



 



 

Main electronics (master) Description

Value Unit

 

 



 



 



 



 



2.1-12    



MJFCIFSS

 







 

2.1.9

Transmission Transmission Description

Value Unit



 



 



 



 



 

  

   

Gear shifting solenoid valves Description

Value Unit



 













 

Speed sensors Description

Value Unit

 















 



 

 

 

Gear pump Description

Value Unit



2.1.10

 



 



 

Axles and cardan shaft Front axle Description

Value Unit



 



 



 

     

  

MJFCIFSS

2.1-13    







Description

Value Unit



 



 



 

Flushing circuit gear motor Description

Value Unit



 

Flushing circuit gear pump Description

Value Unit



 

Rear axle Description

Value Unit



 



 



 



 



 



 



 



 



 



 

Front drive shaft Description

Value Unit



 



 



 



 

Rear drive shaft Description

Value Unit



 



 



 



2.1-14    



MJFCIFSS

 







 

2.1.11

Machine frame and ballast weight Ballast weight Description

Value Unit



 



 



2.1.12

 

Automatic central lubrication system Central lubrication pump EP1 Description

Value Unit



 

 

   



   



 



 



 



 



 



 



 

Central lubrication pump controller EP-1 and operation Description

Value Unit



 

 

   



   



 



 



 

Progressive distributor SXE-2 / MX-F Description

Value Unit

 

   

 

 



MJFCIFSS

 

2.1-15    







SXE-2 100 Description

Value Unit



 



 



 

SXE-2 150 Description

Value Unit



 



 



 

SXE-2 760 Description

Value Unit



 



 



 

Progressive distributor MX-F 25 Description

Value Unit



 



 



 

MX-F 45 Description

Value Unit



 



 



 

MX-F 75 Description

Value Unit



 



 



 

MX-F 105 Description

Value Unit



 



 



2.1-16    



MJFCIFSS

 







 

2.1.13

Cab, heating and air-conditioning Heating and ventilation Description

Value Unit



 



 



 



 



 

Air conditioning system Description

Value Unit



 



 



 









Air conditioning compressor Description

Value Unit



 



 



 



 



 



 

Condenser Description

Value Unit



 



 



 

Dryer collector unit Description

Value Unit



 



 



 



 





 



MJFCIFSS

2.1-17    







Pressure switch Description

Value Unit



 



 



 



 

Evaporator Description

Value Unit



  

 



 

 

 

Temperature sensor B26 Description

Value Unit



 

 

 

 

 

 

 

 

 

 

 

 

 



2.1.14

 

Lift arms and quick-change device Lift arm

Main dimensions Description

Value Unit



2.1-18    



MJFCIFSS

  





 

Description

Value Unit



 



 

 

 



 



 



 

Quick-change device

Main dimensions Description



Value Unit



 



 



 



 



 



MJFCIFSS

2.1-19    







2.1.15

Equipment and accessories Standard bucket

Main dimensions Description

Value Unit



 



 



 



 



 



 



 



2.1-20    



MJFCIFSS

 





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

Filling quantities and lubrication chart ............................................3.4-1 3.4.1

Filling quantities....................................................................3.4-1

3.4.2

Lubrication chart ...................................................................3.4-2

3.5

L586 - 461 / from 17650

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

Safety precautions for maintenance.....................................3.5-1

3.5.2

Secure the machine against rolling away with wheel wedgesPreparatory tasks for maintenance ..........................3.5-2

3.5.3

Removing loose parts, dirt, ice and snow from the machine ................................................................................3.5-6

3.5.4

Checking the machine for external damage.........................3.5-6

3.5.5

Making sure the bolted connections are tight.......................3.5-6

3.5.6

Sealing leaks ........................................................................3.5-6

3.5.7

Checking the engine oil level................................................3.5-7

3.5.8

Changing the engine oil........................................................3.5-7

3.5.9

Changing the diesel engine oil filter .....................................3.5-8

3.5.10

Checking / replacing the V-ribbed belt .................................3.5-9

3.5.11

Checking / adjusting the engine valve play ..........................3.5-9

3.5.12

Checking the diesel engine heating flange ........................3.5-11

3.5.13

Greasing the ring gear on the engine starter flywheel .......3.5-12

3.5.14

Changing the engine oil separator filter insert....................3.5-12

3.5.15

Checking the bearings and condition of the engine control units ........................................................................3.5-13

3.5.16

Checking the state of sensors and cable connections .......3.5-13

3.5.17

Changing the fuel pre-filter .................................................3.5-13

3.5.18

Changing the fuel fine filter.................................................3.5-15

3.5.19

Draining off condensate from the fuel pre-filter (or if the corresponding service code appears) ..........................3.5-16

3.5.20

Bleeding the fuel system ....................................................3.5-16

Copyright by

MJFCIFSS!

3.0-1 of 4

Maintenance

3.0-2 of 4

Service manual 3.5.21

Draining off condensate and sediment from the fuel tank .................................................................................... 3.5-18

3.5.22

Cleaning the air filter service cap and dust extraction valve................................................................................... 3.5-19

3.5.23

Testing the air filter vacuum switch ................................... 3.5-19

3.5.24

Changing the air filter primary element when indicated by the vacuum switch ........................................................ 3.5-20

3.5.25

Changing the air filter secondary element ......................... 3.5-21

3.5.26

Checking the air suction hoses for leaks and tight fitting .................................................................................. 3.5-22

3.5.27

Checking the exhaust lines for leaks and tight fitting ........ 3.5-23

3.5.28

Checking the oil level in the pump distributor gear............ 3.5-23

3.5.29

Changing the splitter box oil .............................................. 3.5-24

3.5.30

Checking the soot particle filter pressure monitor for function, leaks and blockages............................................ 3.5-25

3.5.31

Cleaning the soot particle filter .......................................... 3.5-26

3.5.32

Checking the coolant antifreeze and corrosion inhibitor concentration........................................................ 3.5-27

3.5.33

Cleaning the cooling system.............................................. 3.5-31

3.5.34

Changing the coolant......................................................... 3.5-32

3.5.35

Checking the oil level in the hydraulic tank........................ 3.5-34

3.5.36

Draining off condensate and sediment from the hydraulic tank..................................................................... 3.5-35

3.5.37

Change the oil in the hydraulic tank and check the return strainer..................................................................... 3.5-36

3.5.38

Checking and cleaning the magnetic rod on the hydraulic tank..................................................................... 3.5-36

3.5.39

Changing the hydraulic tank return suction filter ............... 3.5-37

3.5.40

Changing the hydraulic tank bleeder filter ......................... 3.5-38

3.5.41

Lubricating the pilot control device solenoids, universal joints and tappets ............................................... 3.5-38

3.5.42

Testing the steering ........................................................... 3.5-38

3.5.43

Testing the service brake and parking brake..................... 3.5-39

3.5.44

Checking the gap and wear on the parking brake linings................................................................................. 3.5-40

3.5.45

Checking the indicator lamps and lighting ......................... 3.5-41

3.5.46

Checking the batteries, fluid level and terminals ............... 3.5-42

3.5.47

Checking the transmission oil level ................................... 3.5-43

3.5.48

Changing the transmission oil............................................ 3.5-43

3.5.49

Changing the transmission oil filter.................................... 3.5-43

3.5.50

Checking the tightness of the wheels (once after 50, 100 and 250 h)................................................................... 3.5-44

3.5.51

Checking the oil level in the front axle ............................... 3.5-45

3.5.52

Checking the oil level in the rear axle................................ 3.5-45

3.5.53

Changing the oil in the front axle ....................................... 3.5-46

Copyright by

MJFCIFSS!

L586 - 461 / from 17650

Service manual

Maintenance 3.5.54

Changing the oil in the rear axle.........................................3.5-47

3.5.55

Lubricating the rear axle bevel gear seal ...........................3.5-48

3.5.56

Checking and lubricating the front drive shaft ....................3.5-48

3.5.57

Checking and lubricating the rear drive shaft .....................3.5-48

3.5.58

Testing and setting the tyre pressure for the machine's use and attachments .........................................3.5-48

3.5.59

Lubricating the articulated bearing and the rear oscillating bearing...............................................................3.5-49

3.5.60

Check the lubrication system grease reservoir level..........3.5-49

3.5.61

Checking the pipes, hoses and lubrication points of the lubrication system.........................................................3.5-50

3.5.62

Checking whether metered quantities are adequate at the bearing points (grease collars) of the central lubrication system...............................................................3.5-50

3.5.63

Lubricating the door hinges ................................................3.5-51

3.5.64

Cleaning the fresh air and recirculated air filter..................3.5-51

3.5.65

Changing the fresh air and recirculated air filter ................3.5-52

3.5.66

Checking the indicator beads in the dryer-collector unit ......................................................................................3.5-53

3.5.67

Lubricating the lift arms and attachment ............................3.5-54

3.5.68

Checking the bucket bearing seals and the bearing bushings on the lift arms.....................................................3.5-54

3.5.69

Checking the lift arms and bucket stops.............................3.5-56

3.5.70

Testing the quick-change device (optional)........................3.5-57

3.6

L586 - 461 / from 17650

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

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

3.6.2

Preparing for testing and adjustment ...................................3.6-2

3.6.3

Bringing the machine up to operating temperature ..............3.6-3

3.6.4

Checking the engine speed..................................................3.6-3

3.6.5

Checking the fan motor and fan control pressure relief valve ............................................................................3.6-4

3.6.6

Calibrating the pedals...........................................................3.6-5

3.6.7

Checking the replenishing pressure of the variable displacement pumps.............................................................3.6-5

3.6.8

Checking the pressure relief and replenishing valve of the variable displacement pumps.........................................3.6-6

3.6.9

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

3.6.10

Checking the sensor high pressure......................................3.6-8

3.6.11

Synchronise the variable displacement pumps....................3.6-9

3.6.12

Calibrating the block curve ...................................................3.6-9

3.6.13

Calibrating the variable displacement motors ....................3.6-11

3.6.14

Checking the engine output................................................3.6-12

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Maintenance

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3.7

3.0-4 of 4

3.6.15

Checking the flow controller (delta p) of the working hydraulics pump................................................................. 3.6-13

3.6.16

Checking the flow controller (start of delivery) of the working hydraulics pump ................................................... 3.6-13

3.6.17

Checking the secondary pressure relief valves on the control block....................................................................... 3.6-14

3.6.18

Checking the primary pressure relief valves on the control block....................................................................... 3.6-14

3.6.19

Checking the LS pressure cut-off on the control block...... 3.6-15

3.6.20

Checking the cut-off pressure in the stabilisation module ............................................................................... 3.6-15

3.6.21

Depressurising ride control and the hydro accumulators...................................................................... 3.6-15

3.6.22

Checking the nitrogen in the ride control hydro accumulator ....................................................................... 3.6-16

3.6.23

Checking the pressure cut-off of the steering pump.......... 3.6-17

3.6.24

Checking the flow controller of the steering pump ............ 3.6-17

3.6.25

Checking the brake pressure of the compact brake valve................................................................................... 3.6-17

3.6.26

Checking the brake pressure at the axles ......................... 3.6-18

3.6.27

Checking the capacity of the brake accumulator............... 3.6-18

3.6.28

Checking the accumulator charge pressure ...................... 3.6-19

3.6.29

Checking the brake light pressure switch and brake lights................................................................................... 3.6-19

3.6.30

Checking the transmission shift pressure.......................... 3.6-20

3.6.31

Checking the nitrogen in the transmission hydro accumulator ....................................................................... 3.6-20 Lubricants and fuels....................................................................... 3.7-1

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L586 - 461 / from 17650

Service manual

Maintenance Maintenance and inspection schedule

3.1 Maintenance and inspection schedule All relevant safety guidelines must be followed when carrying out all servicing, inspection or repair work. Regional work safety regulations, industrial accident prevention regulations and national legislation must be observed.

You will find a list of spare parts that you need for servicing and inspection work in the "SERVICE PACK" in the spare parts list.

Use only LIEBHERR original spare parts and servicing parts for all servicing, inspection and repair work. If the operating company requires the installation of other parts purchased elsewhere, a separate note must be on the inspection documents that this may result in a loss of guarantee.

Do not exceed the stated maintenance and inspection intervals and if necessary these should be reduced.

CAUTION Careful servicing can only be carried out if the machine is clean.

Clean the machine before you start any service work.

The following abbreviations are used in this section: h = service hours 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 â&#x20AC;&#x201C; 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) â&#x20AC;&#x201C; 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.

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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

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 Instruct the driver on the operating instructions and the safety regulations they contain.

Removing loose parts, dirt, ice and snow from the machine Check the machine for external damage Make sure the bolted connections are tight Sealing leaks Check the hydraulic pressure according to the testing and adjustment plan Diesel engine and pump distributor gear Check the engine oil level Change the engine oil (at least once a year): NOTE See the section on lubricants and fuels for the engine oil quality and complicating factors.

Change the engine oil filter (at least once a year): Check the V-ribbed belt and replace it if necessary Check / adjusting the engine valve play Check the diesel engine heating flange Lightly grease the ring gear on the engine starter flywheel Change the engine oil separator filter insert Check the bearings and condition of the engine control units Check the state of sensors and cable connections Replace the fuel pre-filter (or in the event of a lack of output) Replace the fuel fine filter (or in the event of a lack of output) Draining off condensate from the fuel pre-filter (or if the corresponding service code appears) Bleed air from fuel system (CAUTION: do not loosen injection lines) Drain off condensate and sediment from the fuel tank Clean the air filter service cap and dust extraction valve Test the air filter vacuum switch Change the main air filter element when indicated by the vacuum switch (or every year at the latest) Clean or replace the air filter secondary element (after replacing the main element 3 times or every year at the latest) Check the air suction hoses for leaks and tight fitting Check the exhaust lines for leaks and tight fitting Check the oil level in the pump distributor gear Change the splitter box oil

3.1-2 of 4

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L586 - 461 / from 17650

Service manual

Maintenance Maintenance and inspection schedule

Customer: ………………………

Machine type: …………… Ser. no.: …….……

Maintenance / inspection after service hours

Service hours: ………..……… Date: ………..……………

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

Diesel particle filter (optional) Check the diesel particle filter pressure monitor for function, leaks and blockages Clean the diesel particle filter (at least once a year): Cooling system Check the coolant antifreeze concentration Clean the cooling system 3000h Replace the coolant (at least every 2 years) Working hydraulics

250h

Check the oil level in the hydraulic tank Drain off condensate and sediment from the hydraulic tank Change the oil in the hydraulic tank and check the return strainer Check the oil in the hydraulic tank (affects all environmentally compatible hydraulic fluids) Check and cleaning the magnetic rod on the hydraulic tank Change the hydraulic tank return suction filter insert Change the hydraulic tank bleeder filter Lubricate the pilot control device solenoids, universal joints and tappets Steering system Test the steering Brake system Test the service brake and parking brake Check the gap and wear on the parking brake linings Electrical system Check the indicator lamps and lighting Check the batteries, fluid level and terminals Transmission Check the transmission oil level Change the transmission oil Change the transmission oil filter

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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

Axles and tyres Check the tightness of the wheels (once after 50, 100 and 250 h) Check the axle oil levels Change the axle oil Lubricate the bevel gear seal on the front and rear axles (if necessary, for example, if used in water every day).

Check and lubricate the cardan shaft(s) Check the tyre pressure Machine frame and ballast weight Grease the rear section cover lower hinges Central lubrication system Check the lubrication system grease reservoir level Check the pipes, hoses and lubrication points of the lubrication system Check whether metered quantities are adequate at the bearing points (grease collars) of the central lubrication system Cab, heating and air-conditioning Grease the cab door hinges Clean the fresh air and recirculated air filter Change the fresh air and recirculated air filter Check the indicator and filling level beads in the dryer-collector unit of the air conditioner Lift arms and quick-change device Lubricate the attachment Check the bucket bearing seals and the bearing bushings on the lift arms Check the lift arms and bucket stops Lubricate and test the quick-change device

3.1-4 of 4

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L586 - 461 / from 17650

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.

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Maintenance

Service manual

Testing and adjustment plan

Customer: ………………………

Machine type: ………...…

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

Maintenance / inspection after service hours

Date: ………..……………

TASKS TO BE PERFORMED By authorised specialist staff Once-only activity Repeat interval As necessary Diesel engine Synchronise pedals Check the engine speed Cooling system Check the fan motor and fan control pressure relief valve Travel hydraulics Check the replenishing pressure of the variable displacement pumps Check the pressure relief and replenishing valve of the variable displacement pumps Check the pressure cut-off of the variable displacement pumps Check the sensor high pressure Synchronise the variable displacement pumps Calibrate the block curve Calibrate the variable displacement motors Check the engine output Working hydraulics Check the flow controller (delta p) of the working hydraulics pump Check the flow controller (start of delivery) of the working hydraulics pump Check the secondary pressure relief valves on the control block Check the primary pressure relief valves on the control block Check the LS pressure cut-off on the control block Check the cut-off pressure in the stabilisation module Check the nitrogen in the ride control hydro accumulator Steering system Check the pressure cut-off of the steering pump Check the steering pump flow controller (standby pressure) Brake system Check the opening and closing pressure of the compact brake valve Check the brake pressure of the compact brake valve Check the capacity of the brake accumulator Check the accumulator charge pressure Check the brake light pressure switch and brake lights Transmission Check the transmission shift pressure Check the nitrogen in the transmission hydro accumulator

3.2-2 of 2

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L586 - 461 / from 17650

Service manual

Maintenance Testing and adjustment checklists

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.

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L586 Ser. No. 461 /

Customer:

Operating hours: Type of application: Checked by:

Job site:

Checked on date:

Check / Adjustment

Unit

Adjust. values

Value before adjust.

Value after adjust.

Adjust. point

Test point

Operating temperature Operating temperature (Temperature sensor – hydraulic oil)

°C

58

5

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

bar

175

5

Fan at high Diesel engine RPM / Prop. solenoid valve current less

bar

220

10

P 1

P

Diesel engine Calibration - pedals Accelarator pedal – angle sensor Inching pedal – angle sensor Diesel engine RPM Low idle RPM

min-1

High idle RPM

min

-1

10

900

0

206

Travel hydraulic Replenishing pressure Replenshing pressure pump 1

bar

34

1

8

G1

Replenshing pressure pump 2

bar

34

1

2

G2

bar

4

10

3+5

MA

bar

4

10

1+7

MB

High pressure

bar

400

5

4+6

Control pressure p pump 1 + 2

bar

< 0,5

X1 + X3

bar

<5

MA

Control pressure p at 930 min-1

bar

< 0,5

X1 + X3

Control pressure p at 1200 min-1

bar

< 0,5

X1 + X3

-1

Control pressure p at 1400 min

bar

< 0,5

X1 + X3

Control pressure p at 1800 min-1

bar

< 0,5

X1 + X3

Control pressure p at max. min-1

bar

< 0,5

X1 + X3

High pressure relief valves Forward Reverse Pressure cut off MA

High pressure sensor High pressure p at 00 bar Synchronisation of pumps

Calibration block curve Automatically calibration of the block curve Calibration variable displacement motor Automatically calibration of the variable displacement motors Engine performance at 10 km/h Diesel engine RPM

min-1

1960

60

= Blocked machine

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3.3

Check / Adjustment

Unit

Adjust. values

Value before adjust.

Value after adjust.

Adjust. point

Test point

Working hydraulic Control valve block Secondary pressure relief valve, lift

bar

400

5

3+4

P

Secondary pressure rel. valve, tilt in

bar

400

5

5

P

Secondary pressure rel. valve, tilt out

bar

400

5

7

P

bar

380

5

6

P

bar

330

5

8

P

bar

180

10

9

P / M1

bar

23

10

P / LS

bar

120

bar

25

Primary pressure relief valve Control valve block LS-Pressure cut off at boom lifting Working hydraulic pump Power regulator Working hydraulic pump Flow regulator - pressure difference at float position and 1500 rpm

2

Stabilization module Shut off pressure (LFD – turned off)

20

MX

Hydro accumulator LFD Pretension pressure (nitrogen filling)

2

11

11

1

P

2

P

Steering system Variable displacement pump Pressure cut off

bar

210

bar



5

Variable displacement pump Flow regulator - standby pressure

3.3

2

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L586 - 461 / from 17650

Check / Adjustment

Unit

Adjust. values

Value before adjust.

Value after adjust.

Adjust. point

Test point

M3

Brake system Compact brake valve 180

5

1

210

5

1

M3

2

M4 / M5

Cut in pressure

bar

Cut out pressure

bar

Brake pressure in axles

bar

70

bar

> 50

bar

120

5

Accumulator â&#x20AC;&#x201C; service brake After 9 braking actions

M4 / M5

Pressure switch â&#x20AC;&#x201C; brake system Switching point

5

M3

Transfer gear Transfer gear Switching pressure

bar

20

3

P

bar

12

2

1

Transmission - hydro accumulator Preload pressure (nitrogen filling) Remarks:

Signature:

Check and adjust only if required

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3.3

Service manual

Maintenance Lubrication chart and filling quantities

3.4 Filling quantities and lubrication chart 3.4.1

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 quantity 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.

Note Observe the data sheets and safety data sheets in “LH service documentation” / “General information” / “Lubricants”.

Assembly

Medium

Viscosity

Quantity

Diesel engine (with filter change)

Liebherr engine oil

SAE 10W-40

43.0 l

Pump distributor gear

Liebherr Gear Basic 90 LS

SAE 85W-90

7.7 l

Diesel engine cooling system Total capacity

Liebherr Antifreeze

Hydraulic system Total capacity

Liebherr Hydraulic Basic 68

ISO VG 68

350 l

Hydraulic tank

Liebherr Hydraulic Basic 68

ISO VG 68

180 l

Transmission

Liebherr Hydraulic Gear ATF

SAE 5W-20

11.5 l

Front axle

Liebherr Gear Basic 90 LS

SAE 85W-90

90.0 l

Rear axle

Liebherr Gear Basic 90 LS

SAE 85W-90

56.0 l

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59.0 l

3.4-1 of 4

Maintenance

Service manual

Lubrication chart and filling quantities

Assembly

Medium

Fuel tank

Diesel

435 l

Fuel reserve in tank, approx.

Diesel

35.0 l

Air conditioning system

Refrigerant R 134a

1250 +50 g

3.4.2

Viscosity

Quantity

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

You can find detailed information: – On performing maintenance tasks in the maintenance and inspection schedule and the section on maintenance tasks.

– About the required lubricants and service fuels in the section on lubricants and fuels.

– About the required filling quantities in the tables of filling quantities.

Key: 1 = Transmission 2 = Front axle 3 = Rear axle 1) = central lubricating rail, front section 2) = central lubricating rail, rear section

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L586 - 461 / from 17650

Service manual

Maintenance Lubrication chart and filling quantities

Symbol

Description

Symbol

Description

Symbol

Description

General lubrication points

Oil change

Hydraulic tank

Check the oil level

First oil change

Diesel engine

Splitter box

Gear oil

Central lubrication system

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