Liebherr L534-434 Wheel Loader Service Repair Manual SN：0101

en

Service Manual (20

Wheel Loader (10 points)

L524 / L534 / L538(10

en

Service Manual (20

Wheel Loader (10 points)

L524 / L534 / L538 (10

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

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

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

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

8450818 LBH / T-DOK department 02

Preface

Target group This service manual is addressed to anyone whose task it is to ensure that the machines are ready for everyday use. This especially includes mechanics and workshop staff of Liebherr dealers and branches.

Contents The first chapter contains information on safety regulations and on the special tools needed for maintenance and repairs.

Chapter 2 gives you an overview of all the most important technical data of the machine as a whole and its individual assemblies.

Next comes the maintenance chapter, with the maintenance and inspection schedule, the testing and adjustment checklists, lubrication charts, description of maintenance tasks, testing and adjustment tasks and specifications of fuel and lubricants.

The technical description of the machine is in the following chapters, structured according to fifteen function groups. The layout, function and technical data of the groups, components and parts are explained.

Instructions on use

This manual describes several types and versions of machines. The information generally applies to the types and serial numbers stated at the bottom of the page. The exception to this is information which only applies to specific types and serial numbers, which are stated at the beginning of the section concerned (for example technical data of parts).

Where possible, the ID numbers of parts and components are stated in the heading.

This manual is available in German, English and French.

Working instructions

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

You will find a reference to this in the “General Information� section.

In order to perform these tasks you need a complete set of basic tools and certain special tools, all in perfect working order. All tasks require absolute cleanliness.

Replace seals such as O-rings and surface seals during repairs.

DVD edition

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

General information

1

Product description

2

Maintenance

3

Diesel engine

4

Cooling system

5

Travel hydraulics

6

Working hydraulics

7

Steering system

8

Brake system

9

Electrical system

10

Transfer gear

11

Axles and cardan shaft

12

Machine frame and ballast weight

13

Central lubrication system

14

Coverings and access

15

Cab, heating and air-conditioning

16

Lift arms and quick-change device

17

Equipment and accessories

18

Repairs and troubleshooting

19

Options

20

1 General Information 1.0 Chapter contents 1

General Information ............................................................ 1.0-1 1.1

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

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

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..............................1.2-1

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...........................................................1.2-4

1.2.6

Central lubrication system ....................................................1.2-4

1.2.7

Special tools for the air conditioning system ........................1.2-4

MJFCIFSS

1.0-1 of 2

Service Manual

General Information Safety regulations

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

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

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

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

1.1.1

Introduction 1. The symbols below have the following meanings:

Danger

Warning

Caution

Danger Warning that without appropriate precautions, certain procedures could result in fatal accidents.

Warning Warning that without appropriate precautions, certain procedures could result in severe physical injuries.

Caution Warning that without appropriate precautions, certain procedures could result in minor physical injuries or damage to the machine.

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

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

MJFCIFSS

1.1-1 of 2

General Information

Service Manual

Safety regulations

1.1.2

Overview of the safety regulations A detailed description of these can be read in the relevant section of the safety regulations chapter in the operating manual.

The following sections are included in the operating manual:

1.1-2 of 2

1

Introduction

2

General safety regulations

3

Proper use

4

Decals on the machine

5

Instructions on preventing crushing injuries and burns

6

Instructions on preventing fires and explosions

7

Safety instructions for start-up

8

Safety precautions during start-up

9

Instructions for safe working

10

Safety instructions for driving on slopes

11

Parking safely

12

Transporting the machine safely

13

Towing the machine safely

14

Measures for ensuring safe maintenance

15

Safety instructions for working on machines with hydro accumulators

16

Safety instructions for welding work on the machine

17

Instructions for working safely on the working attachment

18

Safety instructions for transporting the machine by crane

19

Safe maintenance of hydraulic hoses and hose lines

20

Attachments and accessories

MJFCIFSS

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

Service Manual

General Information Special tools for maintenance and repair work

1.2 Special tools for maintenance and repair work 1.2.1 Description

Special tools in general ID no.

Digital thermometer

7020372

All wheel loaders

DCA 4 water testing kit

5608459

All wheel loaders

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

8145359

All wheel loaders

For checking the hydro accumulator

7361288 5002932 5002866 7002436 7002475 7009134 5005180 7005660 7402657

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

Safety cap SW 10

7009315

All wheel loaders

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

7615515 7615589 7009317

All wheel loaders All wheel loaders All wheel loaders

Safety cap SW 17

7622068

All wheel loaders

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

1.2.2

Use

Special tools for Liebherr diesel engines

Description Compression tester Nozzle tester Adapter for compression tester Adapter for compression tester Injection valve extraction tool Extraction tool adapter

ID no.

8008782 7361236 0524044 7090397 0524072 0524029

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

Piston ring tensioning belt

8000952

All wheel loaders

Krikit 2 V-belt tester Flywheel cranking device

8042829 0524045

L524 - L538 engine L538 engine

Stopwatch

7022418

L538 engine

Measuring device

7022420

L538 engine

Adapter

7022419

L538 engine

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

MJFCIFSS

Remarks For checking the compression For checking the injection valves Instead of the injection valve Instead of the injection valve For removing the injection valves For use with the extraction tool For pushing the piston rings together during installation of the pistons For testing the V-belt tension For cranking the engine via the flywheel For adjusting the start of delivery of the distributor injection pump For adjusting the start of delivery of the distributor injection pump For adjusting the start of delivery of the distributor injection pump

1.2-1 of 4

General Information

Service Manual

Special tools for maintenance and repair work

Description

ID no.

Use

Crankshaft turning device

0541887

L524, L534 engine

Crankshaft turning device

9183785

L538 engine

Installation pin Adjusting pin for injection pump DE10

7090360

L524, L534 engine L524, L534 engine with electronic injection

Extractor

7090374

L524, L534 engine

Shaft seal ring installation tool

7090373

L524, L534 engine

Extractor tool Extractor tool Seal remover

7090377 7090395 7090372

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

Adjusting device

7090384

L524, L534 engine

Extractor tool

7090364

L524, L534 engine

Installation tool

7090382

L524, L534 engine

Cleaning tool

7090375

L524, L534 engine

Installation set

7090378

L524, L534 engine

Depth gauge

7090370

L524, L534 engine

Extractor tool

7090376

L524, L534 engine

Extractor tool

7090363

L524, L534 engine

Angle wrench

0524062

L538 engine

MURPHY GAGE diagnostic tool with cable

10030461

Adapter cable

9067863

1.2-2 of 4

7090592

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

MJFCIFSS

Remarks For cranking the engine via the V-belt pulley For cranking the engine via the crankshaft For fixing the engine at UDC For static adjustment when installing the injection pump For removing the drive gearwheel of the Stanadyne injection pump For installing the front crankshaft oil seal For removing the front wear ring For removing the front wear ring For removing the front crankshaft oil seal For dynamically adjusting the start of delivery of the distributor injection pump For removing Stanadyne injection nozzles For inserting the carbon seal in the injection nozzle groove For cleaning the injection nozzle bore hole in the cylinder head For installing the rear oil seal ring and wear ring For measuring the valve depth in the cylinder head and the piston and bushing height For removing the rear crankshaft oil seal ring and wear ring For installing and removing the cylinder bushings For screws on cylinder head, main bearing and big end bearing For diagnosing controls and ECU (A14) engine controller For diagnosis with the MURPHY GAGE

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

Service Manual

General Information Special tools for maintenance and repair work

1.2.3 Description

Special tools for hydraulic cylinders ID no.

Assembly sleeve 80 mm

9227165

Assembly sleeve 90 mm

9227161

Assembly sleeve 100 mm Assembly sleeve 110 mm

9998626 9170509

Assembly sleeve 120 mm

9998778

Assembly sleeve 140 mm

9998623

Expansion sleeve 80 mm

9227166

Expansion sleeve 90 mm

9227162

Expansion sleeve 100 mm Expansion sleeve 110 mm

9110405 9170511

Expansion sleeve 120 mm

9110407

Expansion sleeve 140 mm

9110409

Piston spanner

9211967

Piston spanner 80/12 mm

8007364

Piston spanner

4002681

Piston spanner 88/12 mm

8007365

Piston spanner 100/14 mm

8007366

1.2.4 Description Digital multimeter Test probe, red Test probe, black Magnet tester Stripping and crimping pliers 0.5 - 6.0 mm2 Insertion tool Extractor tool Crimping pliers Wedge extractor tool Extraction tool size 12 for pin and bushing Extraction tool size 16 for pin and bushing Extraction tool size 20 for pin

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

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

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 For fitting the seals

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

Special tools for electronics ID no.

8502956

Use All wheel loaders

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

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

8460263

All wheel loaders

For MATE-N-LOK connectors

8145432 7366655 8503647 7026267

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

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

8145674

All wheel loaders

For DEUTSCH connectors

8145673

All wheel loaders

For DEUTSCH connectors

8503630

All wheel loaders

For DEUTSCH connectors

MJFCIFSS

1.2-3 of 4

General Information

Service Manual

Special tools for maintenance and repair work

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

ID no.

Use

Remarks

8145834

All wheel loaders

7091022

L524, L534

7091023

L524, L534

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

1.2.5 Description

Special tools for axles ID no.

Measuring tool

8145535

1.2.6 Description Filling press Filling connection BEKA MAX central lubrication data cable + software Gröneveld central lubrication

data cable Gröneveld central lubrication

plug adapter Gröneveld central lubrication

software

Use L524 - L538 front axle L524 - L538 rear axle

Remarks For measuring wear on the service brake discs

Central lubrication system

ID no.

10009239 7029283

Use All wheel loaders All wheel loaders

10008427

All wheel loaders

7624289

All wheel loaders

7624290

All wheel loaders

As below

All wheel loaders

Remarks For quickly filling the reservoir For inspecting the central lubrication system For inspecting the central lubrication system For inspecting the central lubrication system For inspecting the central lubrication system

The software for the Gröneveld central lubrication system must be purchased from Gröneveld and enabled with a registration code.

Procedure and necessary data: – Company name and department – A six-digit number of your choice This data must be e-mailed to the following address: support@groeneveld.nl

1.2.7 Description

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

1.2-4 of 4

MJFCIFSS

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

2 Product Description 2.0 Chapter contents 2

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

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

Technical data ................................................................................2.0-1 2.1.1

Complete machine................................................................2.0-1

2.1.2

Diesel engine and pump distributor gear..............................2.0-9

2.1.3

Cooling system ...................................................................2.0-14

2.1.4

Travel hydraulics ................................................................2.0-15

2.1.5

Working hydraulics .............................................................2.0-17

2.1.6

Steering system..................................................................2.0-20

2.1.7

Brake system......................................................................2.0-21

2.1.8

Electrical system.................................................................2.0-22

2.1.9

Transfer gear ......................................................................2.0-22

2.1.10

Axles and tyres ...................................................................2.0-23

2.1.11

Machine frame and ballast weight......................................2.0-24

2.1.12

Cab, heating and air-conditioning.......................................2.0-24

2.1.13

Lift arms and quick-change device.....................................2.0-25

2.1.14

Equipment and accessories ...............................................2.0-26

MJFCIFSS

2.0-1 of 2

Service Manual

Product Description Technical data

2.1 Technical data 2.1.1 Wheel loader with Z lift arms

Complete machine Valid for:

L524 - 438 / from 0101

The values stated refer to the standard version of the machine: With Z lift arms (2400 mm), without hydraulic quick-change device.

With 17.5 R25 Goodyear GP-2B tyres.

Tipping loads and weights include all lubricants, full fuel tank, ROPS/FOPS cab and driver.

Tyre sizes and additional attachments affect the operating weight and tipping load.

Dimensions - machine with Z lift arms Description Bucket capacity as per ISO 7546 Bucket width

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

Value Unit 2.0 m³ 2500 mm

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

3335 mm

C Maximum bucket base height

3510 mm

D Maximum bucket pivot point height

3760 mm

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

4840 mm

H Height above the cab

3150 mm

I Height above exhaust

3090 mm

MJFCIFSS

1.8 t/m³ 2850 mm

870 mm 80 mm

2.0-1 of 26

Product Description

Service Manual

Technical data

Description J Ground clearance

520 mm

K Wheel base

2700 mm

L Overall length

6835 mm

Turning radius over bucket outer edge

5500 mm

Lifting force (SAE)

98 kN

Breakout force (SAE)

92 kN

Tipping load when straight

8030 kg

Tipping load articulated at 30°

7005 kg

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

40 ° 6 ° 10100 kg

Tractive force

76.2 daN

Travel speed in travel range 1, forward and reverse

0 - 8 km/h

Travel speed in travel range 2, forward and reverse

0 - 33 km/h

Sound pressure level in the cab LpA Wheel loader with P lift arms

Value Unit

Valid for:

75 dB (A)

L524 - 438 / from 0101

The values stated refer to the standard version of the machine: With P lift arms (2400 mm) and hydraulic quick-change device.

With 17.5 R25 Goodyear GP-2B tyres.

Tipping loads and weights include all lubricants, full fuel tank, ROPS/FOPS cab and driver.

Tyre sizes and additional attachments affect the operating weight and tipping load.

Dimensions - machine with P lift arms

2.0-2 of 26

MJFCIFSS

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

Service Manual

Product Description Technical data

Description Bucket capacity as per ISO 7546 Bucket width

1.7 m³ 2500 mm

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

3380 mm

C Maximum bucket base height

3500 mm

D Maximum bucket pivot point height

3750 mm

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

4895 mm

H Height above the cab

3150 mm

I Height above exhaust

3090 mm

J Ground clearance

1.8 t/m³ 2815 mm

1030 mm 55 mm

520 mm

K Wheel base

2700 mm

L Overall length

6890 mm

Turning radius over bucket outer edge

5530 mm

Lifting force (SAE)

89 kN

Breakout force (SAE)

80 kN

Tipping load when straight

7100 kg

Tipping load articulated at 40°

6250 kg

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

40 ° 6 ° 10200 kg 76.2 kN

Travel speed in travel range 1, forward and reverse

0 - 8.0 km/h

Travel speed in travel range 2, forward and reverse

0 - 33.0 km/h

Sound pressure level in the cab LpA Wheel loader with Z lift arms

Value Unit

Valid for:

75 dB (A)

L534 - 434 / from 0101

The values stated refer to the standard version of the machine: With Z lift arms (2500 mm), without hydraulic quick-change device.

With 20.5 R25 Goodyear GP-2B tyres.

Tipping loads and weights include all lubricants, full fuel tank, ROPS/FOPS cab and driver.

Tyre sizes and additional attachments affect the operating weight and tipping load.

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

MJFCIFSS

2.0-3 of 26

Product Description

Service Manual

Technical data

Dimensions - machine with Z lift arms Description Bucket capacity as per ISO 7546 Bucket width

2.4 m³ 2500 mm

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

3380 mm

C Maximum bucket base height

3650 mm

D Maximum bucket pivot point height

3900 mm

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

5450 mm

H Height above the cab

3250 mm

I Height above exhaust

3150 mm

J Ground clearance

1.8 t/m³ 2890 mm

945 mm 70 mm

460 mm

K Wheel base

2900 mm

L Overall length

7235 mm

Turning radius over bucket outer edge

5825 mm

Lifting force (SAE)

135 kN

Breakout force (SAE)

105 kN

Tipping load when straight

9745 kg

Tipping load articulated at 40°

8625 kg

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

2.0-4 of 26

Value Unit

MJFCIFSS

40 ° 6 ° 12100 kg 87.8 kN L524 - 438 / from 0101 L534 - 434 / from 0101 L538 - 432 / from 0101

Service Manual

Product Description Technical data

Description

Value Unit

Travel speed in travel range 1, forward and reverse

0 - 8.0 km/h

Travel speed in travel range 2, forward and reverse

0 - 36.0 km/h

Sound pressure level in the cab LpA Wheel loader with P lift arms

Valid for:

75 dB (A)

L534 - 434 / from 0101

The values stated refer to the standard version of the machine: With P lift arms (2600 mm) and hydraulic quick-change device.

With 20.5 R25 Goodyear GP-2B tyres.

Tipping loads and weights include all lubricants, full fuel tank, ROPS/FOPS cab and driver.

Tyre sizes and additional attachments affect the operating weight and tipping load.

Dimensions - machine with P lift arms Description Bucket capacity as per ISO 7546 Bucket width

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

Value Unit 2.0 m³ 2500 mm

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

3470 mm

C Maximum bucket base height

3730 mm

D Maximum bucket pivot point height

3970 mm

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

5230 mm

MJFCIFSS

1.8 t/m³ 2930 mm

1060 mm 65 mm

2.0-5 of 26

Product Description

Service Manual

Technical data

Description H Height above the cab

3250 mm

I Height above exhaust

3150 mm

J Ground clearance

460 mm

K Wheel base

2900 mm

L Overall length

7535 mm

Turning radius over bucket outer edge

5925 mm

Lifting force (SAE) Breakout force (SAE)

95 kN 100 kN

Tipping load when straight

8550 kg

Tipping load articulated at 40°

7570 kg

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

40 ° 6 ° 12290 kg 87.8 kN

Travel speed in travel range 1, forward and reverse

0 - 8.0 km/h

Travel speed in travel range 2, forward and reverse

0 - 36.0 km/h

Sound pressure level in the cab LpA

2.0-6 of 26

Value Unit

MJFCIFSS

75 dB (A)

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

Service Manual

Product Description Technical data

Wheel loader with Z lift arms

Valid for:

L538 - 432 / from 0101

The values stated refer to the standard version of the machine: With Z lift arms (2500 mm), without hydraulic quick-change device.

With 20.5 R25 Goodyear GP-2B tyres.

Tipping loads and weights include all lubricants, full fuel tank, ROPS/FOPS cab and driver.

Tyre sizes and additional attachments affect the operating weight and tipping load.

Dimensions - machine with Z lift arms Description Bucket capacity as per ISO 7546 Bucket width

2.5 m³ 2500 mm

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

3380 mm

C Maximum bucket base height

3650 mm

D Maximum bucket pivot point height

3900 mm

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

5150 mm

H Height above the cab

3250 mm

I Height above exhaust

3150 mm

J Ground clearance

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

Value Unit

1.8 t/m³ 2870 mm

970 mm 70 mm

460 mm

K Wheel base

2900 mm

L Overall length

7135 mm

Turning radius over bucket outer edge

5795 mm

MJFCIFSS

2.0-7 of 26

Product Description

Service Manual

Technical data

Description Lifting force (SAE)

135 kN

Breakout force (SAE)

105 kN

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

10160 kg 9000 kg 40 ° 12300 kg 87.8 daN

Travel speed in travel range 1, forward and reverse

0 - 8.0 km/h

Travel speed in travel range 2, forward and reverse

0 - 36.0 km/h

Sound pressure level in the cab LpA Wheel loader with P lift arms

Value Unit

Valid for:

75 dB (A)

L538 - 432 / from 0101

The values stated refer to the standard version of the machine: With P lift arms (2600 mm) and hydraulic quick-change device.

With 20.5 R25 Goodyear GP-2B tyres.

Tipping loads and weights include all lubricants, full fuel tank, ROPS/FOPS cab and driver.

Tyre sizes and additional attachments affect the operating weight and tipping load.

Dimensions - machine with P lift arms Description Bucket capacity as per ISO 7546 Bucket width Specific material weight

2.0-8 of 26

MJFCIFSS

Value Unit 2.1 m³ 2500 mm 1.8 t/m³

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

Service Manual

Product Description Technical data

Description A Dump height at maximum lifting height and 45° tilt-out angle B Dump height

Value Unit 2910 mm 3470 mm

C Maximum bucket base height

3730 mm

D Maximum bucket pivot point height

3970 mm

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

5230 mm

H Height above the cab

3250 mm

I Height above exhaust

3150 mm

J Ground clearance

1075 mm 65 mm

460 mm

K Wheel base

2900 mm

L Overall length

7435 mm

Turning radius over bucket outer edge

5880 mm

Lifting force (SAE) Breakout force (SAE)

95 kN 100 kN

Tipping load when straight

8640 kg

Tipping load articulated at 40°

7650 kg

Angle of articulation (to each side)

40 °

Swing angle (to each side) Operating weight Tractive force

6 ° 12250 kg 87.8 kN

Travel speed in travel range 1 forward and reverse

0 - 8.0 km/h

Travel speed in travel range 2 forward and reverse

0 - 36.0 km/h

Sound pressure level in the cab LpA

2.1.2

75 dB (A)

Diesel engine and pump distributor gear Diesel engine

Valid for:

L524 - 438 / 0101 - 8795; ID no. 9739010

Description Engine model

Value Unit D 504 T

Number of cylinders Capacity Rated power as per ISO 9249 Rated speed Maximum torque at 1400 min-1 Lower idle speed Upper idle speed

4500 cm³ 81 / 110 kW / PS 2400 min-1 424 Nm 850

50

min-1

2500 +80 min-1

Inlet valve play (cold)

0.35 mm

Outlet valve play (cold)

0.45 mm

Control thermostat opening temperature L524 - 438 / from 0101 L534 - 434 / from 0101 L538 - 432 / from 0101

4

MJFCIFSS

82 °C

2.0-9 of 26

Product Description

Service Manual

Technical data

Description Longitudinal / traverse inclinability

30 / 30 °C

Starter operating voltage

24 V

Starter power consumption

7.8 kW

Alternator voltage output

27 V

Alternator current output

55 A

Emission thresholds comply with Valid for:

Value Unit

EU RL 97/68 EC Stage I

L524 - 438 / from 8796; ID no. 9739021

Description Engine model

Value Unit D 504 TI - 02

Number of cylinders Firing order

4500 cm³

Cylinder bore

106.5 mm 127 mm

Rated power as per ISO 9249 Rated speed Maximum torque at 1400 min-1 Lower idle speed Upper idle speed Combustion pressure Injection nozzle pressure Injection nozzles, maximum pressure difference between cylinders

81 / 110 kW / PS 2400 min-1 422 Nm 850

50

min-1

2550 +80 min-1 24 +3 bar 241 ±6 bar 7 bar

Inlet valve play (cold)

0.35 mm

Outlet valve play (cold)

0.45 mm

Direction of rotation, looking at flywheel Number of teeth on flywheel gear Control thermostat opening temperature Longitudinal / traverse inclinability

Anticlockwise 129 82 °C 30 / 30 °

Starter operating voltage

24 V

Starter power consumption

7.8 kW

Alternator voltage output

27 V

Alternator current output

55 A

Auxiliary power take-off transmission Weight

1:1.0333 387 kg

Emission thresholds comply with

EU RL 97/68/EC Stage II

L534 - 434 / 0101 - 8961; ID no. 9739011

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

2.0-10 of 26

1-3-4-2

Capacity Stroke

Valid for:

4

MJFCIFSS

Value Unit D 504 TI 4 4500 cm³ 100 / 136 kW / PS L524 - 438 / from 0101 L534 - 434 / from 0101 L538 - 432 / from 0101

Service Manual

Product Description Technical data

Description

Value Unit

Rated speed

2400 min-1

Maximum torque at 1400 min-1 Lower idle speed Upper idle speed

50

min-1

2550 +80 min-1 0.35 mm

Outlet valve play (cold)

0.45 mm 30 / 30 °C

Starter operating voltage

24 V

Starter power consumption

7.8 kW

Alternator voltage output

27 V

Alternator current output

55 A

Emission thresholds comply with

EU RL 97/68 EC Stage I

L534 - 434 / from 8962; ID no. 9739022

Description Engine model Number of cylinders Firing order

Value Unit D 504 TI - 02 4 1-3-4-2

Capacity

4500 cm³

Cylinder bore

106.5 mm

Stroke Rated power as per ISO 9249 Rated speed Maximum torque at 1400 min-1

127 mm 100 / 136 kW / PS 2400 min-1 494 Nm

Lower idle speed

850±50 min-1

Upper idle speed

2550+80 min-1

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

min. 24+3 bar 241±6 bar 7 bar

Inlet valve play (cold)

0.35 mm

Outlet valve play (cold)

0.45 mm

Direction of rotation, looking at flywheel Number of teeth on flywheel gear Control thermostat Longitudinal / traverse inclinability

Anticlockwise 129 82 °C 30 / 30 °

Starter operating voltage

24 V

Starter power consumption

7.8 kW

Alternator voltage output

27 V

Alternator current output

55 A

Auxiliary power take-off transmission Weight Emission thresholds comply with

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

850

Inlet valve play (cold) Longitudinal / traverse inclinability

Valid for:

498 Nm

MJFCIFSS

1:1.0333 396 kg EU RL 97/68/EC Stage II

2.0-11 of 26

Product Description

Service Manual

Technical data

Valid for:

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

Description Engine model

Value Unit D924T-E-A1

Number of cylinders Capacity Rated power as per ISO 9249 Rated speed Maximum torque at 1400 min-1 Lower idle speed Upper idle speed

4 6640 cm³ 100 / 136 kW / PS 2000 min-1 597 Nm 850

Inlet valve play (cold)

0.25 mm

Outlet valve play (cold)

0.30 mm

Longitudinal / traverse inclinability

79 °C 45 / 45 °C

Starter operating voltage

24 V

Starter power consumption

5.4 kW

Alternator voltage output

28 V

Alternator current output

55 A

Emission thresholds comply with

EU RL 97/68 EC Stage I

L538 - 432 / from 8508; ID no. 9076608

Description Engine model

Value Unit D 924TI-E-A1

Number of cylinders Firing order Capacity

4 1-3-4-2 6640 cm³

Cylinder bore

122 mm

Stroke

142 mm

Rated power as per ISO 9249 Rated speed Maximum torque at 1150 min-1 Lower idle speed

100 / 136 kW / PS 2000 min-1 645 Nm 850

50

min-1

Upper idle speed

2100+80 min-1

Start of delivery

1.4 0.05 mm

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

17.2:1 20 - 26 bar 225±6 bar 7 bar

Inlet valve play (cold)

0.25 mm

Outlet valve play (cold)

0.30 mm

Direction of rotation, looking at flywheel Number of teeth on flywheel gear Control thermostat opening temperature Longitudinal / traverse inclinability

2.0-12 of 26

min-1

2100 +80 min-1

Control thermostat

Valid for:

50

MJFCIFSS

Anticlockwise 147 79 °C 45 / 45 °

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

Service Manual

Product Description Technical data

Description

Value Unit

Starter operating voltage

24 V

Starter power consumption

5.4 kW

Alternator voltage output

28 V

Alternator current output

55 A

Auxiliary power take-off transmission

1:1.275

Weight Emission levels comply with

740 kg EU RL 97/68/EC Stage II

Fuel tank Valid for:

L524 - 438 / from 0101; L534 - 434 / from 0101; L538 - 432 / from 0101; ID no. 7622943

Description Tank capacity, FULL

Value Unit 160 l

Tank capacity, RESERVE

30 l

Fuel pre-filter (stage I) Valid for:

L524 - 438 / 0101 - 8795; L534 - 434 / 0101 - 8961; ID no. 7090480

Description Filtration grade

Valid for:

Value Unit min. 0.6 mm max. 0.8 mm

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

Description Filtration grade

Value Unit min. 0.6 mm max. 0.8 mm

Fuel pre-filter (stage II) Valid for:

L524 - 438 / from 8796; L534 - 434 / from 8962; ID no. 7090562

Description

Value Unit

Filtration grade Valid for:

10 µm

L538 - 432 / from 8508; ID no. 7382133

Description

Value Unit

Filtration grade

30 µm

Fuel fine filter (stage I) Valid for:

L524 - 438 / from 0101; L534 - 434 / from 0101; ID no. 7090528

Description Filtration grade Valid for:

5 µm

L538 - 432 / 0101 - 8507; ID no. 7381643

Description Filtration grade

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

Value Unit

MJFCIFSS

Value Unit 5 µm

2.0-13 of 26

Product Description

Service Manual

Technical data

Fuel fine filter (stage II) Valid for:

L524 - 438 / from 0101; L534 - 434 / from 0101; ID no. 7090528

Description Filtration grade Valid for:

Value Unit 5 µm

L538 - 432 / from 8508; ID no. 7382102

Description Filtration grade

Value Unit 5 µm

Vacuum switch Valid for:

L524 - 438 / from 0101; L534 -434 / from 0101; L538 - 432 / from 0101; ID no. 6906001

Description Air filter contamination vacuum switch activation point

Value Unit 50 mbar

Coupling Valid for:

L524 - 438 / from 0101; L534 - 434 / from 0101; ID no. 5717325, 10010559

Description Glue for torsion 8 absorber bolts

Valid for:

49 Nm

Hub star fastening screw tightening torque

50 Nm

L538 - 432 / from 0101; ID no. 5607974

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

Value Unit 241 Loctite 68 Nm

L538 - 432 / from 8508; ID no. 7382102

Description Filtration grade

2.1.3

241 Loctite

Tightening torque for 8 torsion absorber bolts

Description

Valid for:

Value Unit

Value Unit 2 µm

Cooling system Cooling system Gear pump

Valid for:

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

Description Capacity

2.0-14 of 26

MJFCIFSS

Value Unit 14 cm³

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

Service Manual

Product Description Technical data

Valid for:

L524 - 438 / from 6317; L534 - 434 / from 0101; ID no. 5717323

Description Capacity Valid for:

Value Unit 16 cm³

L538 - 432 / from 0101; ID no. 5716912

Description Capacity

Value Unit 14 cm³

Gear motor Valid for:

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

Description Gear motor displacement Pressure relief valve

Value Unit 16 cm³ 5

175

bar

Temperature sensor Valid for:

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

Description Measuring range Resistance at 20°C

2.1.4

Value Unit -30 to +30 °C 1112

Travel hydraulics Variable displacement pump

Valid for:

L524 - 438 / from 0101

Description Control type

DA

Maximum capacity

90 cm³

Flow rate at rated speed Power Weight

19.6 cm³ 60 kg

Pressure cut-off

430

5

bar

L534 - 434 / from 0101

Description

Value Unit

Control type

DA

Maximum capacity

125 cm³

Flow rate at rated speed

246 l/min

Power

90 kW

Replenishing pump capacity Weight

19.6 cm³ 60 kg

Pressure cut-off

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

212 l/min 72 kW

Replenishing pump capacity

Valid for:

Value Unit

MJFCIFSS

430

5

bar

2.0-15 of 26

Product Description

Service Manual

Technical data

Valid for:

L538 - 432 / from 0101

Description

Value Unit

Control type

DA

Maximum capacity

125 cm³

Flow rate at rated speed

246 l/min

Power

90 kW

Replenishing pump capacity Weight

28.3 cm³ 80 kg

Pressure cut-off

430

5

bar

Variable displacement motor 1 Valid for:

L524 - 438 / from 0101

Description Control type

DA

Maximum displacement

107 cm³

Minimum displacement

43 cm³

Maximum speed Torque (Dp 400 bar) Weight

230

5

bar

Value Unit

Control type

DA

Maximum displacement

140 cm³

Minimum displacement

38 cm³

Maximum speed Torque (Dp 400 bar) Weight

4800 min-1 891 Nm 60 kg

Control range while driving

260

5

bar

L538 - 432 / from 0101

Description

Value Unit

Control type

DA

Maximum displacement

140 cm³

Minimum displacement

46 cm³

Maximum speed Torque (Dp 400 bar) Weight

4800 min-1 891 Nm 60 kg

Control range while driving

2.0-16 of 26

594 Nm

L534 - 434 / from 0101

Description

Valid for:

5490 min-1 47 kg

Control range while driving Valid for:

Value Unit

MJFCIFSS

230

5

bar

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

Service Manual

Product Description Technical data

Variable displacement motor 2 Valid for:

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

Description

Value Unit

Control type

HD1D

Maximum displacement

160 cm³

Minimum displacement

0 cm³

Maximum speed

4800 min-1

Torque (Dp 400 bar)

1119 Nm

Weight

Valid for:

64 kg

Control pressure start of regulation

6.0

1

bar

High pressure start of regulation

260

5

bar

L534 - 434 / from 0101

Description

Value Unit

Control type

HD1D

Maximum displacement

160 cm³

Minimum displacement

0 cm³

Maximum speed

4800 min-1

Torque (Dp 400 bar)

1119 Nm

Weight

64 kg

Control pressure start of regulation High pressure start of regulation

6.0

1

bar

290

5

bar

Motor scavenging pump Valid for:

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

Description

Valid for:

Flow rate at rated speed

32.5 l

Speed at rated speed

2322 min -1

L538 - 432 / from 0101

Description

2.1.5

Value Unit

Value Unit

Flow rate at rated speed

35.7 l

Speed at rated speed

2550 min -1

Working hydraulics Working hydraulics pump

Valid for:

L524 - 438 / from 0101

Description

Value Unit

Control type

DFLR

Maximum capacity Flow rate at rated speed Power

105 l/min 40 kW

Flow regulator (delta p) L524 - 438 / from 0101 L534 - 434 / from 0101 L538 - 432 / from 0101

45 cm³

MJFCIFSS

28

1

bar

2.0-17 of 26

Product Description

Service Manual

Technical data

Valid for:

Description

Value Unit

Weight

215

bar

L534 - 434 / from 0101

Description

Value Unit

Control type

DFLR

Maximum capacity Flow rate at rated speed Power

60 cm³ 141 l/min 57 kW

Flow regulator (delta p) Weight Valid for:

1

25

1

bar

215

1

bar

L538 - 432 / from 0101

Description

Value Unit

Control type

DFLR

Maximum capacity Flow rate at rated speed Power

71 cm³ 137 l/min 57 kW

Flow regulator (delta p) Weight

25

1

bar

215

1

bar

Control block Valid for:

L524 - 438 / from 0101

Description Piston diameter LS working hydraulics pressure cut-off LS steering pressure cut-off Valid for:

Value Unit 14.3 mm 305

5

bar

210

5

bar

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

Description Piston diameter LS pressure relief valve

Value Unit 18 mm 305

5

bar

Pilot control hydro accumulator Description Hydro accumulator volume Preload pressure (nitrogen filling)

Value Unit 320 cm³ 15 bar

Float position pressure switch Valid for:

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

Description Switch type Switch point, rising

2.0-18 of 26

MJFCIFSS

Value Unit Normally open 23

2

bar

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

Service Manual

Product Description Technical data

Stabilisation module

Valid for:

Description

Value Unit

Cut-off valve

150

2

cmÂł

L524 - 438 / from 0101

Description Piston diameter

Value Unit 100 mm

Rod diameter

60 mm

Stroke length

735 mm

Lift cylinder Valid for:

L524 - 438 / from 0101

Description Piston diameter

Value Unit 110 mm

Rod diameter

60 mm

Stroke length

735 mm

Z kinematics tilt cylinder Valid for:

L524 - 438 / from 0101

Description Piston diameter

Valid for:

Value Unit 120 mm

Rod diameter

70 mm

Stroke length

440 mm

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

Description Piston diameter

Value Unit 140 mm

Rod diameter

80 mm

Stroke length

440 mm

P kinematics tilt cylinder Valid for:

L524 - 438 / from 0101

Description

Valid for:

Piston diameter

80 mm

Rod diameter

50 mm

Stroke length

775 mm

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

Description

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

Value Unit

Value Unit

Piston diameter

90 mm

Rod diameter

50 mm

Stroke length

970 mm

MJFCIFSS

2.0-19 of 26

Product Description

Service Manual

Technical data

Return suction filter Description

Value Unit

Filtration grade

10 µm

Return strainer Description

Value Unit

Filtration grade

40 µm

Bleeder filter Description

Value Unit

Filtration grade

10 µm

Inlet opening pressure

0.03 bar

Outlet opening pressure

2.1.6

0.5 bar

Steering system Servostat Description

Value Unit

Displacement

462 cm³

Secondary pressure relief

285 ±10 bar

Volume flow boost

1 : 1.6

Steering cylinder Description

Value Unit

Piston diameter

90 mm

Rod diameter

40 mm

Stroke length

500 mm

Emergency steering pump Description

Value Unit

Capacity

11 cm² 55 ±5 bar

Pressure relief valve

Emergency steering pump pressure switch Description Switch type

Value Unit Normally open 10 ±1 bar

Switch point, rising

Emergency steering check pressure switch Description Switch type Switch point, rising

2.0-20 of 26

MJFCIFSS

Value Unit Normally open 5 ±0.5 bar L524 - 438 / from 0101 L534 - 434 / from 0101 L538 - 432 / from 0101

Service Manual

Product Description Technical data

2.1.7

Brake system Brake system gear pump

Valid for:

L524 - 438 / to 6316

Description

Valid for:

Flow rate at rated speed

32.5 l/min

Speed at rated speed

2322 min -1

L524 - 438 / from 6317; L534 - 434 / from 0101

Description

Valid for:

Value Unit

Value Unit

Flow rate at rated speed

37.2 l/min

Speed at rated speed

2322 min -1

L538 - 432 / from 0101

Description

Value Unit

Flow rate at rated speed

35.7 l/min

Speed at rated speed

2550 min -1

Compact brake valve Description

Value Unit

Accumulator charge valve activation pressure

145 ±5 bar

Accumulator charge valve deactivation pressure

175 ±5 bar

Maximum service brake pressure

65 ±5 bar

Service brake hydro accumulator Description Hydro accumulator volume Preload pressure (nitrogen filling)

Value Unit 750 cm³ 50 bar

Brake light pressure switch Description Switch type Switching point, falling

Value Unit Normally open 90 ±5 bar

Disc brake

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

Description

Value Unit

Brake pad gap

1.0 ±0.5 mm

Brake lining thickness, new

4.5 mm

Minimum brake lining thickness

1.0 mm

MJFCIFSS

2.0-21 of 26

Product Description

Service Manual

Technical data

Parking brake hydro accumulator Description

Value Unit

Hydro accumulator volume

160 cmÂł

Preload pressure (nitrogen filling)

30 bar

Parking brake pressure switch Description Switch type

Value Unit Change-over switch 100 Âą5 bar

Switching point, falling

2.1.8

Electrical system Electrical system with circuit diagrams Description

Value Unit

System voltage

24 V

Battery Valid for:

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

Description Battery voltage

12 V

Battery capacity

100 Ah

Acid density of charged battery Valid for:

Value Unit

1.26 - 1.28 kg/l

L538 - 432 / from 0101

Description Battery voltage

12 V

Battery capacity

110 Ah

Acid density of charged battery

2.1.9

Value Unit

1.26 - 1.28 kg/l

Transfer gear Transfer gear

Valid for:

L524 - 438 / from 0101

Description

Value Unit

Variable displacement motor 1 transmission

1.829 -

Variable displacement motor 2 transmission

1.641 -

Cardan speed at 34 km/h

2640 min-1

Speed sensor Valid for:

2.0-22 of 26

Inductive

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

Description

Value Unit

Variable displacement motor 1 transmission

1.641 -

Variable displacement motor 2 transmission

1.641 -

MJFCIFSS

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

Service Manual

Product Description Technical data

Description Cardan speed at 34 km/h Speed sensor

Value Unit 2895 min -1 Inductive

Speed sensor Description Type

Inductive sensor -

Distance to spur gear A

2.1.10

Value Unit min. 1.2 mm max. 1.8 mm

Axles and tyres Front axle

Valid for:

L524 - 438 / from 0101

Description Self-locking differential level Width

45 % 1900 mm

Wheel lug tightening torque Wheel lug spanner size Weight Valid for:

Value Unit

650 Nm 30 mm 490 kg

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

Description Self-locking differential level Width

Value Unit 45 % 1900 mm

Wheel lug tightening torque Wheel lug spanner size Weight

650 Nm 30 mm 600 kg

Rear axle Valid for:

L524 - 438 / from 0101

Description Self-locking differential level Swing angle (to each side) Width Wheel lug spanner size Weight

6 ° 650 Nm 30 mm 600 kg

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

Description Self-locking differential level Swing angle (to each side) Width

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

45 % 1900 mm

Wheel lug tightening torque

Valid for:

Value Unit

Value Unit 45 % 6 ° 1900 mm

MJFCIFSS

2.0-23 of 26

Product Description

Service Manual

Technical data

Description Wheel lug tightening torque Wheel lug spanner size Weight

2.1.11

Value Unit 650 Nm 30 mm 680 kg

Machine frame and ballast weight Ballast weight

Valid for:

L524 - 438 / from 0101

Description

Valid for:

Left ballast weight

570 kg

Right ballast weight

650 kg

L534 - 434 / from 0101

Description

Valid for:

Value Unit

Left ballast weight

825 kg

Right ballast weight

975 kg

L538 - 432 / from 0101

Description

2.1.12

Value Unit

Value Unit

Left ballast weight

740 kg

Right ballast weight

810 kg

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

Value Unit 3 4.0 kW

Blower Description Air flow Blower speeds Voltage

Value Unit 630 m³/h 3 24 V

Current consumption (max) free blowing

10.5 A

Power consumption (min) free blowing

245 W

Air filter Description Filter class

2.0-24 of 26

Value Unit EU3

Filtration grade

10 µ

Filter surface (effective)

1.8 m²

MJFCIFSS

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

Service Manual

Product Description Technical data

Air-conditioning system Description Coolant oil

2.1.13

Value Unit ZXL 100PG

Cooling power

4.8 kW

Coolant filling quantities

1,4 kg

Temperature switch activation temperature

4 ±1 °C

Temperature switch deactivation temperature

1 ±1 °C

Low pressure switch OFF

1.5 bar

Low pressure switch ON

2.9 bar

High pressure switch OFF

25.0 bar

High pressure switch ON

19.0 bar

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

Valid for:

L524 - 438 / from 0101

Description L - length Valid for:

Value Unit 2400 mm

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

Description L - length

Value Unit 2500 mm

Lift arms with P kinematics Valid for:

L524 - 438 / from 0101

Description L - length Valid for:

Value Unit 2400 mm

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

Description L - length

Value Unit 2600 mm

Hydraulic quick-change device for Z lift arms (hydraulic actuation) Description A system connection size Weight

Value Unit 1000 mm 300 kg

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

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

Value Unit 1000 mm 300 kg

MJFCIFSS

2.0-25 of 27

Product Description

Service Manual

Technical data

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

2.1.14

Value Unit 1000 mm 230 kg

Equipment and accessories Bucket

Valid for:

L524 - 438 / from 0101

Description B bucket width

Valid for:

2500 mm

Specific material weight

1.8 t/m³

Heaped bucket capacity (ISO 7546)

2.0 m³

L534 - 434 / from 0101

Description B bucket width

Valid for:

Value Unit

Value Unit 2500 mm

Specific material weight

1.8 t/m³

Heaped bucket capacity (ISO 7546)

2.4 m³

L538 - 432 / from 0101

Description B bucket width

Value Unit 2500 mm

Specific material weight

1.8 t/m³

Heaped bucket capacity (ISO 7546)

2.5 m³

Forklift Description Fork carrier prong size Prong length

Value Unit FEM III 1200 mm

High dump bucket (optional) Description B bucket width

2.0-26 of 26

Value Unit 2700 mm

Specific material weight (L524-438 with P kinematics)

0.9 t/m³

Specific material weight (L534-434 with P kinematics)

1.0 t/m³

Specific material weight (L538-432 with P kinematics)

1.1 t/m³

Bucket capacity as per ISO 7546

3.0 m³

Maximum operating pressure for attachment hydraulics

250 bar

MJFCIFSS

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

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 (L524) ...........................................3.4-1

3.4.2

Table of filling quantities (L534) ...........................................3.4-1

3.4.3

Table of filling quantities (L538) ...........................................3.4-2

3.4.4

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

3.5

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

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

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

3.5.2

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

3.5.3

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

3.5.4

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

3.5.5

Checking the engine oil level (L524, L534) ..........................3.5-7

3.5.6

Changing the engine oil (L524, L534) ..................................3.5-8

3.5.7

Changing the engine oil filter (L524, L534) ........................3.5-10

3.5.8

Changing the engine oil filter (L538) ..................................3.5-11

3.5.9

Checking the V-ribbed belt (L524, L534)............................3.5-11

3.5.10

Checking the V-ribbed belt (L538)......................................3.5-12

3.5.11

Checking the engine valve play (L524, L534) ....................3.5-15

3.5.12

Checking the engine valve play (L538) ..............................3.5-18

3.5.13

Checking the flame glow system (L538) ............................3.5-19

3.5.14

Greasing the ring gear on the engine flywheel (L538) .......3.5-20

3.5.15

Changing the diesel engine oil separator (L538) ...............3.5-20

3.5.16

Bleeding the fuel system (L524, L534)...............................3.5-21

3.5.17

Bleeding the fuel system (L538).........................................3.5-22

3.5.18

Bleeding the fuel system (L538).........................................3.5-23

3.5.19

Replacing the fuel pre-filter (L524, L534) ...........................3.5-24

3.5.20

Replacing the fuel pre-filter (L538) .....................................3.5-25

3.5.21

Replacing the filter insert in the fuel separator (L538) .......3.5-26

MJFCIFSS

3.0-1 of 4

Maintenance

3.0-2 of 4

Service Manual 3.5.22

Replacing the fuel fine filter (L524, L534).......................... 3.5-27

3.5.23

Changing the fuel fine filter (L538) .................................... 3.5-29

3.5.24

Draining off condensate from the fuel filter (L524, L534 fine filter) ............................................................................ 3.5-30

3.5.25

Draining off condensate from the fuel filter (L538) ............ 3.5-32

3.5.26

Draining off condensate from the fuel separator (L538).... 3.5-33

3.5.27

Draining off condensate and sediment from the fuel tank .................................................................................... 3.5-33

3.5.28

Checking the air suction hoses for leaks and tight fitting .. 3.5-34

3.5.29

Cleaning the air filter service cap and dust extraction valve................................................................................... 3.5-34

3.5.30

Checking that the air filter vacuum switch works............... 3.5-35

3.5.31

Changing the air filter main element when indicated by the vacuum switch ............................................................. 3.5-36

3.5.32

Checking the exhaust lines for leaks and tight fitting (L524)................................................................................. 3.5-37

3.5.33

Checking the exhaust lines for leaks and tight fitting (L534)................................................................................. 3.5-38

3.5.34

Checking the exhaust lines for leaks and tight fitting (L538)................................................................................. 3.5-39

3.5.35

Checking the coolant level................................................. 3.5-40

3.5.36

Changing the coolant filter (L538) ..................................... 3.5-40

3.5.37

Checking the coolant antifreeze concentration (L524, L534).................................................................................. 3.5-41

3.5.38

Checking the coolant antifreeze and DCA 4 concentration (L538).......................................................... 3.5-45

3.5.39

Cleaning the cooling system.............................................. 3.5-49

3.5.40

Changing coolant with antifreeze (L524, L534) ................ 3.5-50

3.5.41

Changing the coolant with anti-freeze and DCA 4 (L538)................................................................................. 3.5-51

3.5.42

Lubricating the pilot control unit, cleaning the magnets and lubricating the universal joint (L524)........................... 3.5-52

3.5.43

Lubricating the pilot control unit, cleaning the magnets and lubricating the universal joint (L534, L538)................. 3.5-53

3.5.44

Checking the oil level in the hydraulic tank........................ 3.5-53

3.5.45

Draining water and sediment from the hydraulic tank ....... 3.5-54

3.5.46

Changing the hydraulic oil ................................................. 3.5-54

3.5.47

Checking and cleaning the magnetic rod on the hydraulic tank..................................................................... 3.5-55

3.5.48

Changing the hydraulic tank return suction filter ............... 3.5-55

3.5.49

Changing the hydraulic tank bleeder filter ......................... 3.5-56

3.5.50

Checking the steering ........................................................ 3.5-56

3.5.51

Lubricating the bearing points on the steering cylinders ... 3.5-56

3.5.52

Checking the service brake and parking brake ................. 3.5-57

3.5.53

Checking the gap and wear on the parking brake linings.. 3.5-57

MJFCIFSS

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

Service Manual

Maintenance 3.5.54

Checking the indicator lamps and lighting..........................3.5-58

3.5.55

Checking the batteries, fluid level and terminals................3.5-59

3.5.56

Checking the transfer gear oil level ....................................3.5-60

3.5.57

Changing the transfer gear oil ............................................3.5-60

3.5.58

Checking the axle oil levels ................................................3.5-61

3.5.59

Changing the axle gear oil..................................................3.5-62

3.5.60

Checking the tightness of the wheels (once after 50, 100 and 250 h) ...................................................................3.5-63

3.5.61

Checking and lubricating the drive shaft ............................3.5-64

3.5.62

Checking and adjusting the tyre pressure ..........................3.5-64

3.5.63

Lubricating the articulation bearing and rear oscillating bearing................................................................................3.5-65

3.5.64

Greasing the cab door hinges ............................................3.5-65

3.5.65

Cleaning or replacing the fresh air and recirculated air filter .....................................................................................3.5-65

3.5.66

Checking the indicator and filling level beads in the dryer-collector unit of the air conditioner ............................3.5-66

3.5.67

Checking and lubricating the bearings and lubrication points on Z lift arms ............................................................3.5-67

3.5.68

Checking and lubricating the bearings and lubrication points on P lift arms ............................................................3.5-68

3.5.69

Checking and lubricating the bucket bearing on Z lift arms....................................................................................3.5-70

3.5.70

Checking and lubricating the bucket bearing on P lift arms....................................................................................3.5-71

3.5.71

Checking the bucket stops on Z lift arms ...........................3.5-72

3.6

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

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

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

3.6.2

Checking the engine speed L524, L534...............................3.6-2

3.6.3

Checking the engine speed L538.........................................3.6-3

3.6.4

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

3.6.5

Checking the travel hydraulics blocked condition ................3.6-6

3.6.6

Checking the travel pump replenishing pressure .................3.6-7

3.6.7

Checking the start of regulation of the variable displacement pump ..............................................................3.6-7

3.6.8

Checking the output of the travel pump................................3.6-8

3.6.9

Checking the pressure relief and replenishing valve of the travel pump.....................................................................3.6-9

3.6.10

Checking the pressure cut-off of the travel pump ..............3.6-10

3.6.11

Checking the variable displacement motor 1 in the control range.......................................................................3.6-11

3.6.12

Checking the servo pressure regulation of variable displacement motor 2 .........................................................3.6-12

MJFCIFSS

3.0-3 of 4

Maintenance

Service Manual 3.6.13

Checking the pressure regulation of variable displacement motor 2 ........................................................ 3.6-12

3.6.14

Checking the working hydraulics pump flow controller...... 3.6-13

3.6.15

Checking the secondary pressure relief valves on the control block L524.............................................................. 3.6-14

3.6.16

Checking the secondary pressure relief valves on the control block L534, L538.................................................... 3.6-14

3.6.17

Checking the LS pressure cut-off on the control block L524 ................................................................................... 3.6-15

3.6.18

Checking the LS pressure cut-off on the control block L534, L538 ......................................................................... 3.6-15

3.6.19

Checking the P kinematics pre-tension valve on the control block L534, L538.................................................... 3.6-16

3.6.20

Checking the opening and closing pressure of the compact brake valve.......................................................... 3.6-16

3.6.21

Checking the accumulator charge pressure ...................... 3.6-17

3.6.22

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

3.6.23

Checking the brake light pressure switch .......................... 3.6-18

3.6.24

Checking the capacity of the brake accumulator............... 3.6-19

3.6.25

Checking the inch/brake system overlap........................... 3.6-19

3.7

3.0-4 of 4

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

Handling lubricants and fuels............................................... 3.7-1

3.7.2

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

3.7.3

Diesel fuels .......................................................................... 3.7-4

3.7.4

Engine coolants (L524, L534).............................................. 3.7-5

3.7.5

Coolants for diesel engines (L538) ...................................... 3.7-6

3.7.6

Hydraulic oils........................................................................ 3.7-9

3.7.7

Lubricating oils for the transmission .................................. 3.7-10

3.7.8

Grease for general lubrication points................................. 3.7-11

MJFCIFSS

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

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