Liebherr L524 L534 L538 Wheel Loader Service Repair Manual – PDF Download by www.heydownloads.com

Service Manual (20

Wheel Loader (10 points)

L524 / L534 / L538(10

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 â&#x20AC;&#x153;General Informationâ&#x20AC;? 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

Product description

Maintenance

Diesel engine

Cooling system

Travel hydraulics

Working hydraulics

Steering system

Brake system

Electrical system

Transfer gear

Axles and cardan shaft

Machine frame and ballast weight

Central lubrication system

Coverings and access

Cab, heating and air-conditioning

Lift arms and quick-change device

Equipment and accessories

Repairs and troubleshooting

Options

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

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1.0-1 of 2

General Information

1.0-2 of 2

Service Manual

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

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: â&#x20AC;&#x201C; The safety rules in force at the operating site â&#x20AC;&#x201C; Legally enforceable road traffic regulations â&#x20AC;&#x201C; Guidelines issued by trade associations

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

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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

Introduction

General safety regulations

Proper use

Decals on the machine

Instructions on preventing crushing injuries and burns

Instructions on preventing fires and explosions

Safety instructions for start-up

Safety precautions during start-up

Instructions for safe working

Safety instructions for driving on slopes

Parking safely

Transporting the machine safely

Towing the machine safely

Measures for ensuring safe maintenance

Safety instructions for working on machines with hydro accumulators

Safety instructions for welding work on the machine

Instructions for working safely on the working attachment

Safety instructions for transporting the machine by crane

Safe maintenance of hydraulic hoses and hose lines

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

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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

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Product Description

2.0-2 of 2

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

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

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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

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

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

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

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

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:

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

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

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:

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

Maximum capacity

90 cm³

Flow rate at rated speed Power Weight

19.6 cm³ 60 kg

Pressure cut-off

430

bar

L534 - 434 / from 0101

Description

Value Unit

Control type

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

bar

2.0-15 of 26

Product Description

Service Manual

Technical data

Valid for:

L538 - 432 / from 0101

Description

Value Unit

Control type

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

bar

Variable displacement motor 1 Valid for:

L524 - 438 / from 0101

Description Control type

Maximum displacement

107 cm³

Minimum displacement

43 cm³

Maximum speed Torque (Dp 400 bar) Weight

230

bar

Value Unit

Control type

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

bar

L538 - 432 / from 0101

Description

Value Unit

Control type

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

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

bar

High pressure start of regulation

260

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

bar

290

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

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

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:

bar

215

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

bar

215

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

bar

210

bar

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

Description Piston diameter LS pressure relief valve

Value Unit 18 mm 305

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

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

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

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

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

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

Service Manual

Maintenance Maintenance and inspection schedule

3.1 Maintenance and inspection schedule The following abbreviations are used in this section: – h = service hours – OM = operating manual – SM = service manual Various symbols (solid or empty circles, boxes and stars) are used to indicate the maintenance tasks, which fall into two main types. The symbols have the following meanings: Example 1 - printed documentation Table with solid circle, box or star

Example

Example 2 - online documentation Table with symbol on dark grey field – 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: Example 1 - printed documentation Table with empty circle, box or star, or service hours (h)

Example

Example 2 - online documentation Table with symbol or service hours on yellow field – The maintenance and inspection work must be performed or supervised by authorised engineers from LIEBHERR or its authorised dealers. This affects the maintenance intervals on delivery, every 500, 1000, 2000 service hours (h), and at unscheduled times. You will find a list of the spare parts needed for maintenance and inspection work in the service package of the spare parts list.

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

MJFCIFSS

3.1-1 of 4

Maintenance

Service Manual

Maintenance and inspection schedule

Customer: ………………………………….. Machine type: ………...…

Maintenance / inspection after service hours

Ser. no.: ……....…… 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

Complete machine Have the driver lubricate the machine in accordance with the lubrication chart and instruct him on proper maintenance Instruct the driver in the operation of all functions Check the machine for external damage Make sure the bolted connections are tight Seal any leaks Check the hydraulic pressure according to the testing and adjustment plan Diesel engine Check the engine oil level Change the engine oil (note: the operating hours stated here only apply to the appropriate engine oil quality / for complicating factors see the lubricants and fuels section) Change the diesel engine oil filter Check the V-ribbed belt Check the engine valve play Check the flame glow system (L538 only) Lightly grease the ring gear on the engine flywheel (L538 only) 3000h Replace the engine oil separator (or every 2 years) (L538 only) Replace the fuel pre-filter (L524, L534) Replace the filter insert in the fuel separator (L538) Change the fuel fine filter Drain off condensate from the fuel filter (L524, L534) Drain off condensate from the fuel separator (L538) Drain off condensate and sediment from the fuel tank Clean the air filter service cap and dust extraction valve Check that the air filter vacuum switch works Replace the air filter primary element if indicated by the vacuum switch (replace the secondary element after having replaced the primary element 3 times) Check the air suction hoses for leaks and tight fitting Check the exhaust lines for leaks and tight fitting Soot particle filter (optional) Check the soot particle filter pressure monitor for function, leaks and blockages Check and drain the soot particle filter condensate separator Change the soot particle filter condensate separator Clean the soot particle filter

3.1-2 of 4

MJFCIFSS

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

Service Manual

Maintenance Maintenance and inspection schedule

Customer: ………………………………….. Machine type: ………...…

Maintenance / inspection after service hours

Ser. no.: ……....…… 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

Cooling system Check the coolant level Change the coolant filter (L538 only) Check the coolant antifreeze concentration (L538 with DCA 4 component) Clean the cooling system 3000h Change the coolant and antifreeze (L538 with DCA 4 component) (or every 2 years) Working hydraulics Check the hydraulic tank oil level (take an oil sample every 500 hours for bio oil) Drain off condensate and sediment from the hydraulic tank Change the oil in the hydraulic tank and check the return strainer 250h Check and clean the magnetic rod on the hydraulic tank Change the hydraulic tank return suction filter Change the hydraulic tank bleeder filter Lubricate the pilot control device solenoids, universal joints and tappets Steering system Check that the steering is working Lubricate the bearing points on the steering cylinders Brake system Check 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 Transfer gear Check the transfer gear oil level Change the transfer gear oil 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 Check and lubricate the cardan shaft(s) Check the tyre pressure

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

MJFCIFSS

3.1-3 of 4

Maintenance

Service Manual

Maintenance and inspection schedule

Customer: ………………………………….. Machine type: ………...…

Maintenance / inspection after service hours

Ser. no.: ……....…… 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

Machine frame and ballast weight Lubricate the articulation bearing and rear oscillating bearing Lubrication system (optional) Check whether metered quantities are adequate at the bearing points (grease collars) of the central lubrication system Check the pipes, hoses and lubrication points of the lubrication system Cab, heating and air-conditioning Grease the cab door hinges Clean or replace the fresh air and recirculated air filter Check the indicator and filling level beads in the dryer-collector unit (optional) of the air conditioner Lift arms and quick-change device Lubricate the lift arms and attachment Check the lift arm bearing bushings Check the lift arms bucket stops (Z kinematics) Lubricate and test the quick-change device

3.1-4 of 4

MJFCIFSS

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

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.

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

MJFCIFSS

3.2-1 of 2

Maintenance

Service Manual

Testing and adjustment plan

Customer: ……………………………………..

Maintenance / inspection after service hours

Machine type: ………...…

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

TASKS TO BE PERFORMED By authorised specialist staff Once-only activity Repeat interval As necessary

Diesel engine Check the diesel engine speed Cooling system Check the fan motor and fan control pressure relief valve Travel hydraulics Check the replenishing pressure of the variable displacement pump Check the start of regulation of the variable displacement pump Check the output of the variable displacement pump Check the pressure relief and replenishing valve of the variable displacement pump Check the pressure cut-off of the variable displacement pump Check the variable displacement motor in control range 1 Check the control pressure regulation of variable displacement motor 2 Check the pressure regulation of variable displacement motor 2 Working hydraulics Check the flow controller of the working hydraulics pump Check the secondary pressure relief valves on the control block Check the LS pressure cut-off on the control block Check the pre-tension valve on the control block Brake system Check the activation and deactivation pressure on 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 Check the inch/brake system overlap

3.2-2 of 2

MJFCIFSS

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

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.

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

MJFCIFSS

3.3-1 of 1ĂŞ

Maintenance

Service Manual

Testing and adjustment checklists

3.3-2 of 1ĂŞ

MJFCIFSS

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

Costumer:

L 524 ÍñÒæ ìíè Ñ°»®¿¬·²¹ ¸±«®æ Ì§°» ±º ¿°°´·½¿¬·±²æ

Job site:

Ý¸»½µ»¼ ¾§æ Ý¸»½µ»¼ ±² ¼¿¬»æ

Check / Adjustment

Unit

Adjust. values

Value before adjust

Value after adjust

Adjust. point

Test point

Diesel engine Diesel engine RPM Ô±© ·¼´» ÎÐÓ Ø·¹¸ ·²¼´» ÎÐÓ

³·²

óï

³·²

óï

ëð

õèð

èëðo îëëð

Cooling system Cooling System øº¿² ½±²¬®±´÷ Ø§¼®¿«´·½ ±·´ íï ó ëë pÝ Ý±±´¿²¬ ¾»´±© éè pÝ Ú¿² ¿¬ ¸·¹¸ Ü·»»´ »²¹·²» ÎÐÓñ Í»²±® «²°´«¹¹»¼

¾¿®

ïéëo

Ú¿² ¿¬ ¸·¹¸ Ü·»»´ »²¹·²» ÎÐÓ

¾¿®

êëo

Ú¿² ¿¬ ´±© Ü·»»´ »²¹·²» ÎÐÓ

¾¿®

íð

ïð

oïð

Travel hydraulic Replenisihing pressure ß¬ ¸·¹¸ ·¼´» ÎÐÓ

¾¿®

íðo

Ø·¹¸ °®»«®»

¾¿®

ëð

Ü·»»´ »²¹·²» ÎÐÓ Ý±²¬®±´ °®»«®»

³·²

óï

ëð

ïðëð

ëð

Óß øÓÞ÷

oëð

¾¿®

êo

¾¿®

íèð

ÐÍÌ

Pump performance at 380 bar Ø·¹¸ °®»«®» Ü·»»´ »²¹·²» ÎÐÓ Ý±²¬®±´ °®»«®»

³·²

óï

îððð

íèð

Óß øÓÞ÷

oïðð î

¾¿®

ïéo

¾¿®

ìéðo

ÐÍÌ

High pressure relief valves Ú±®©¿®¼ Î»ª»®»

ïð

Óß

oïð

ÓÞ

Óß øÓÞ÷

¾¿®

ìéð

¾¿®

ìíðo

Pressure cut off Ø·¹¸ °®»«®» Û²¹·²» °»»¼ ¼®±°ô ³¿¨ò ¼·ºº»®»²½» ¬± ¸·¹¸ ·¼´» ÎÐÓ

³·²

óï

ëð î

¾¿®

îîo

Ø·¹¸ °®»«®» ©¸»² ¬®¿ª»´´·²¹ ¿¬ ê ó é µ³ñ¸

¾¿®

îíðo

ßµ¬·ª¿¬·²¹ °®»«®»

¾¿®

ïîð

Óï

¾¿®

Óî

Ý±²¬®±´ °®»«®»

ÐÍÌ

Variable displ. motor 1 in regulating range ë

Óß

Variable displ. motor 2 Control pressure regulating ßµ¬·ª¿¬·²¹ °®»«®» Ý±²¬®±´ °®»«®»

¾¿®

oï

ÐÍÌ

Óß

Pressure regulating ßµ¬·ª¿¬·²¹ °®»«®»

¾¿®

ëð

Ø·¹¸ °®»«®»

¾¿®

îêðo

ëð

Óî

ëð

ã Þ´±½µ»¼ Ó¿½¸·²»

3.3

L524 ó ìíè ñ ðïðï ó èéçë

MJFCIFSS

Check / Adjustment

Unit

Adjust. values

Value before adjust

Value after Adjust. adjust

point

Test point

Ð ñ ÔÍ

Working hydraulic Working hydraulic pump Ú´±© ®»¹«´¿¬±® ó °®»«®» ¼·ºº»®»²¦

¾¿®

îèo

¾¿®

íìðo

Control valve block Z - bar linkage Í»½±²¼¿®§ °®»«®» ®»´·»º ª¿´ª»ô ´·º¬ Í»½±²¼¿®§ °®»«®» ®»´·»º ª¿´ª»ô ¬·´¬ ·² Í»½±²¼¿®§ °®»«®» ®»´·»º ª¿´ª»ô ¬·´¬ ±«¬

¾¿®

oë

íìð

¾¿®

íìð

¾¿®

íìðo

P – bar linkage Í»½±²¼¿®§ °®»«®» ®»´·»º ª¿´ª»ô ´·º¬

oë

Í»½±²¼¿®§ °®»«®» ®»´·»º ª¿´ª»ô ¬·´¬ ·²

¾¿®

íìð

Í»½±²¼¿®§ °®»«®» ®»´·»º ª¿´ª»ô ¬·´¬ ±«¬

¾¿®

ïëðo

Í»½±²¼¿®§ °®»«®» ®»´·»º ª¿´ª»ô ¿¼¼·¬·±²¿´ »¯«·°³»²¬

¾¿®

îëðo

ïñê

¾¿®

íðëo

¾¿®

îëðo

Óí

Control valve block ÔÍ ó Ð®»«®» ®»´·»º ª¿´ª» ñ ßØ Quick change device Ð®»«®» ®»´·»º ª¿´ª»

ïð

Steering system Pressure relief valve / steering ÔÍ ó Ð®»«®» ®»´·»º ª¿´ª» ñ ¬»»®·²¹

¾¿®

îïðo

Brake system Compact brake valve Ý«¬ ·² °®»«®»

¾¿®

oë

Óí

Óï ñ Óî

ïìëo

Ý«¬ ±«¬ °®»«®»

¾¿®

ïéë

Þ®¿µ» °®»«®» ·² ¿¨´»

¾¿®

êëo

¾¿®

â ëð

¾¿®

çðo

Accumulator ßº¬»® ç ¾®¿µ·²¹ ¿½¬·±²

¿¨´» Óï ñ Óî

Pressure switch – brake accumulator pressure Í©·¬½¸·²¹ °±·²¬

Óí

º®±²¬ ¿¨´» Óï

Óß

Pressure switch – brake light Í©·¬½¸·²¹ °±·²¬

oðôë

¾¿®

ïððo

Overlap / Inching - brake Ø·¹¸ °®»«®» ¬®¿ª»´ ¸§¼®¿«´·½

îð

Remarks:

Signature:

Attention: Ì¸» ©±®µ·²¹ ¸§¼®¿«´·½ °«³° ³«¬ ²±¬ ¾» ´±¿¼»¼ ©·¬¸ ³±®» ¬¸¿² íëð ¾¿®ò Þ» ½¿®»º«´ ©¸»² ¿¼¶«¬·²¹ ¬¸» »½±²¼¿®§ ª¿´ª» ·² ¬¸» ½±²¬®±´ ª¿´ª» ¾´±½µò Ý¸»½µ ¿²¼ ¿¼¶«¬ ±²´§ ·º ®»¯«·®»¼

3.3

L524 ó ìíè ñ ðïðï ó èéçë

MJFCIFSS

Costumer:

L 524 S/N: 438 Operating hours: Type of application:

Job site:

Checked by: Checked on date:

Check / Adjustment

Unit

Adjust. values

Value before adjust

Value after adjust

Adjust. point

Test point

Diesel engine Diesel engine RPM Low idle RPM High indle RPM

min

-1

min

-1

850

2550

+80

Cooling system Cooling System (fan control) Hydraulic oil 31 - 55 Â°C Coolant below 78 Â°C 5

Fan at high Diesel engine RPM/ Sensor unplugged

bar

175

Fan at high Diesel engine RPM

bar

Fan at low Diesel engine RPM

bar

Travel hydraulic Replenisihing pressure At high idle RPM

bar

MA (MB)

Regulation-begin-var. displ. pump High pressure Diesel engine RPM Control pressure

bar min

-1

1050 2

bar

PST

bar

380

Pump performance at 380 bar High pressure Diesel engine RPM Control pressure

min

-1

380

MA (MB)

100

2000

bar

PST

Forward

bar

470

Reverse

bar

470

bar

430

MA (MB)

High pressure relief valves

Pressure cut off High pressure Engine speed drop, max. difference to high idle RPM Control pressure

min

-1

50 2

bar

PST

High pressure when travelling at 6 - 7 km/h

bar

230

Aktivating pressure

bar

120

bar

Variable displ. motor 1 in regulating range 5

Variable displ. motor 2 Control pressure regulating Aktivating pressure Control pressure

bar

PST

Pressure regulating Aktivating pressure

bar

High pressure

bar

260

= Blocked Machine

3.3

L524 - 438 / from 8796

MJFCIFSS

Check / Adjustment

Unit

Adjust. values

Value before adjust

Value after Adjust. adjust

point

Test point

P / LS

Working hydraulic Working hydraulic pump Flow regulator - pressure differenz

bar

Secondary pressure relief valve, lift

bar

340

Secondary pressure relief valve, tilt in

bar

340

bar

340

Secondary pressure relief valve, lift

bar

340

Secondary pressure relief valve, tilt in

bar

340

Secondary pressure relief valve, tilt out

bar

150

Secondary pressure relief valve, additional equipment

bar

250

1/6

bar

305

bar

250

145

M1 / M2

Control valve block Z - bar linkage

Secondary pressure relief valve, tilt out P â&#x20AC;&#x201C; bar linkage

Control valve block LS - Pressure relief valve / AH Quick change device Pressure relief valve

Steering system Pressure relief valve / steering LS - Pressure relief valve / steering

bar

210

Brake system Compact brake valve Cut in pressure

bar

Cut out pressure

bar

175

Brake pressure in axles

bar

> 50

bar

Accumulator After 9 braking actions

axles M1 / M2

Pressure switch â&#x20AC;&#x201C; brake accumulator pressure Switching point

front axles M1

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

0,5

bar

100

Overlap / Inching - brake High pressure travel hydraulic

Remarks:

Signature:

Attention: The working hydraulic pump must not be loaded with more than 350 bar. Be careful when adjusting the secondary valves in the control valve block. Check and adjust only if required

3.3

L524 - 438 / from 8796

MJFCIFSS

Costumer:

L 534 ÍñÒæ ìíì ñ Ñ°»®¿¬·²¹ ¸±«®æ Ì§°» ±º ¿°°´·½¿¬·±²æ

Job site:

Ý¸»½µ»¼ ¾§æ Ý¸»½µ»¼ ±² ¼¿¬»æ

Check / Adjustment

Unit

Adjust. values

Value before adjust

Value after adjust

Adjust. point

Test point

Diesel engine Diesel engine RPM Ô±© ·¼´» ÎÐÓ Ø·¹¸ ·²¼´» ÎÐÓ

³·²

óï

³·²

óï

ëð

õèð

èëðo îëëð

¾¿®

ïéëo

Ú¿² ¿¬ ¸·¹¸ Ü·»»´ »²¹·²» ÎÐÓ

¾¿®

êëo

Ú¿² ¿¬ ´±© Ü·»»´ »²¹·²» ÎÐÓ

¾¿®

íð

ïð

oïð

Travel hydraulic Replenisihing pressure ß¬ ¸·¹¸ ·¼´» ÎÐÓ

¾¿®

íîo

Ø·¹¸ °®»«®»

¾¿®

ëð

Ü·»»´ »²¹·²» ÎÐÓ Ý±²¬®±´ °®»«®»

³·²

óï

ëð

ïðëð

ëð

Óß øÓÞ÷

oëð

¾¿®

êo

¾¿®

íèð

ÐÍÌ

Pump performance at 380 bar Ø·¹¸ °®»«®» Ü·»»´ »²¹·²» ÎÐÓ Ý±²¬®±´ °®»«®»

³·²

óï

ïçðð

íèð

Óß øÓÞ÷

oïðð î

¾¿®

ïêo

¾¿®

ìéðo

ÐÍÌ

High pressure relief valves Ú±®©¿®¼ Î»ª»®»

ïð

Óß

oïð

ÓÞ

Óß øÓÞ÷

¾¿®

ìéð

¾¿®

ìíðo

Pressure cut off Ø·¹¸ °®»«®» Û²¹·²» °»»¼ ¼®±°ô ³¿¨ò ¼·ºº»®»²½» ¬± ¸·¹¸ ·¼´» ÎÐÓ

³·²

óï

ëð î

¾¿®

îîo

Ø·¹¸ °®»«®» ©¸»² ¬®¿ª»´´·²¹ ¿¬ ê ó é µ³ñ¸

¾¿®

îêðo

ßµ¬·ª¿¬·²¹ °®»«®»

¾¿®

ïíð

Óï

¾¿®

Óî

Ý±²¬®±´ °®»«®»

ÐÍÌ

Variable displ. motor 1 in regulating range ë

Óß

Variable displ. motor 2 Control pressure regulating ßµ¬·ª¿¬·²¹ °®»«®» Ý±²¬®±´ °®»«®»

¾¿®

oï

ÐÍÌ

Óß

Pressure regulating ßµ¬·ª¿¬·²¹ °®»«®»

¾¿®

ëð

Ø·¹¸ °®»«®»

¾¿®

îçðo

ëð

Óî

ëð

ã Þ´±½µ»¼ Ó¿½¸·²»

3.3

L534 ó ìíì ñ ðïðï ó êçìí

MJFCIFSS

Check / Adjustment

Unit Adjust. values

Value before adjust

Value after adjust

Adjust. point

Test point

Ð ñ ÔÍ

Working hydraulic Working hydraulic pump Ú´±© ®»¹«´¿¬±® Š °®»«®» ¼·ºº»®»²¦

¾¿®

îëo

¾¿®

1) îëðo

Contol valve block Í»½±²¼¿®§ °®»«®» ®»´·»º ª¿´ª»ô ´·º¬

oë

Í»½±²¼¿®§ °®»«®» ®»´·»º ª¿´ª»ô ¬·´¬ ·²

¾¿®

1) îîð

Í»½±²¼¿®§ °®»«®» ®»´·»º ª¿´ª»ô ¬·´¬ ±«¬ ñ Z - bar linkage

¾¿®

1) îîðo

Í»½±²¼¿®§ °®»«®» ®»´·»º ª¿´ª»ô ¬·´¬ ±«¬ ñ P - bar linkage

¾¿®

ïëðo

Í»½±²¼¿®§ °®»«®» ®»´·»º ª¿´ª» ó ¿¼¼·¬·±²¿´ »¯«·°³»²¬

¾¿®

îëðo

íñë

¾¿®

íðëo

¾¿®

èëo

Íî

¾¿®

îëðo

Óí

oë

Óí

Óï ñ Óî

Control valve block ÔÍó Ð®»«®» ®»´·»º ª¿´ª» ñ ßØ Control valve block Ð®»¬»²·±² ª¿´ª» ñ Ð ó ¾¿® ´·²µ¿¹»

Quick change device Ð®»«®» ®»´·»º ª¿´ª»

ïð

Steering system Pressure relief valve / steering ÔÍó Ð®»«®» ®»´·»º ª¿´ª» ñ ¬»»®·²¹

¾¿®

îïðo

Brake system Compact brake valve Ý«¬ ·² °®»«®»

¾¿®

ïìëo

Ý«¬ ±«¬ °®»«®»

¾¿®

Þ®¿µ» °®»«®» ·² ¿¨´»

¾¿®

êë

¾¿®

â ëð

¾¿®

çðo

ïéë

oë

Accumulator ßº¬»® ç ¾®¿µ·²¹ ¿½¬·±²

¿¨´» Óï ñ Óî

Pressure switch – brake accumulator pressure Í©·¬½¸·²¹ °±·²¬

Óí

º®±²¬ ¿¨´» Óï

Óß

Pressure switch – brake light Í©·¬½¸·²¹ °±·²¬

oðôë

¾¿®

ïððo

Overlap / Inching - brake Ø·¹¸ °®»«®» ¬®¿ª»´ ¸§¼®¿«´·½

îð

Remarks:

Signature:

1) Ì¸» ©±®µ·²¹ ¸§¼®¿«´·½ °«³° ³«¬ ²±¬ ¾» ´±¿¼»¼ ©·¬¸ ³±®» ¬¸¿² 310 barò Ð®±½»¼«®» º±® ¬»¬·²¹ ¬¸» ®»´·»º ª¿´ª»æ ¬«®² ±«¬ ®»´·»º ª¿´ª» ¾§ ïñî ¬«®² ¿¼¶«¬ ¬¸» ®»´·»º ª¿´ª» ¬± ¬¸» ª¿´ª» ·² ¬¸» ¬¿¾´» ¬«®² ·² ®»´·»º ª¿´ª» ¾§ ïñî ¬«®² Ý¸»½µ ¿²¼ ¿¼¶«¬ ±²´§ ·º ®»¯«·®»¼

3.3

L534 ó ìíì ñ ðïðï ó êçìí

MJFCIFSS

Costumer:

L 534 S/N 434 / Operating hours: Type of application:

Job site:

Checked by: Checked on date:

Check / Adjustment

Unit

Adjust. values

Value before adjust

Value after adjust

Adjust. point

Test point

Diesel engine Diesel engine RPM Low idle RPM High indle RPM

min

-1

min

-1

850

2550

+80

Cooling system Cooling System (fan control) Hydraulic oil 31 - 55 Â°C Coolant below 78 Â°C 5

Fan at high Diesel engine RPM/ Sensor unplugged

bar

175

Fan at high Diesel engine RPM

bar

Fan at low Diesel engine RPM

bar

Travel hydraulic Replenisihing pressure At high idle RPM

bar

MA (MB)

Regulation-begin-var. Displ. pump High pressure Diesel engine RPM Control pressure

bar min

-1

1050 2

bar

PST

bar

380

Pump performance at 380 bar High pressure Diesel engine RPM Control pressure

min

-1

380

MA (MB)

100

1900

bar

PST

Forward

bar

470

Reverse

bar

470

bar

430

MA (MB)

High pressure relief valves

Pressure cut off High pressure Engine speed drop, max. difference to high idle RPM Control pressure

min

-1

50 2

bar

High pressure when travelling at 6 - 7 km/h

bar

260

Aktivating pressure

bar

130

Aktivating pressure

bar

Control pressure

bar

PST

Variable displ. motor 1 in regulating range 5

MA M1

Variable displ. motor 2 Control pressure regulating

M2 1

PST

Pressure regulating Aktivating pressure

bar

High pressure

bar

290

= Blocked Machine

3.3

L534 - 434 / 6944 - 8961

MJFCIFSS

Check / Adjustment

Unit

Adjust. values

Value before adjust

Value after adjust

Adjust. point

Test point

P / LS

Working hydraulic Working hydraulic pump Flow regulator â&#x20AC;&#x201C; pressure differenz

bar

Secondary pressure relief valve, lift

bar

1) 250

Secondary pressure relief valve, tilt in

bar

1) 220

Secondary pressure relief valve, tilt out / Z - bar linkage

bar

1) 220

Secondary pressure relief valve, tilt out / P - bar linkage

bar

150

Secondary pressure relief valve additional equipment

bar

250

1/8

bar

305

bar

250

Contol valve block

Control valve block LS- Pressure relief valve / AH Control valve block Pretension valve / P - bar linkage

Quick change device Pressure relief valve

Steering system Pressure relief valve / steering LS- Pressure relief valve / steering

bar

210

Brake system Compact brake valve Cut in pressure

bar

145

Cut out pressure

bar

175

Brake pressure in axles

bar

M1 / M2

bar

> 50

bar

Accumulator After 9 braking actions

axles M1 / M2

Pressure switch â&#x20AC;&#x201C; brake accumulator pressure Switching point

front axles M1

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

0,5

bar

100

Overlap / Inching - brake High pressure travel hydraulic

Remarks:

Signature:

1) The working hydraulic pump must not be loaded with more than 310 bar. Procedure for testing the relief valves: turn out relief valve by 1/2 turn adjust the relief valve to the valve in the table turn in relief valve by 1/2 turn Check and adjust only if required

3.3

L534 - 434 / 6944 - 8961

MJFCIFSS

Costumer:

L 534 S/N 434 / Operating hours: Type of application:

Job site:

Checked by: Checked on date:

Check / Adjustment

Unit

Adjust. values

Value before adjust

Value after adjust

Adjust. point

Test point

Diesel engine Diesel engine RPM Low idle RPM High indle RPM

min

-1

min

-1

850

2550

+80

Cooling system Cooling System (fan control) Hydraulic oil 31 - 55 Â°C Coolant below 78 Â°C 5

Fan at high Diesel engine RPM/ Sensor unplugged

bar

175

Fan at high Diesel engine RPM

bar

Fan at low Diesel engine RPM

bar

Travel hydraulic Replenisihing pressure At high idle RPM

bar

MA (MB)

Regulation-begin-var. Displ. pump High pressure Diesel engine RPM Control pressure

bar min

-1

1050 2

bar

PST

bar

380

Pump performance at 380 bar High pressure Diesel engine RPM Control pressure

min

-1

380

MA (MB)

100

1900

bar

PST

Forward

bar

470

Reverse

bar

470

bar

430

MA (MB)

High pressure relief valves

Pressure cut off High pressure Engine speed drop, max. difference to high idle RPM Control pressure

min

-1

50 2

bar

High pressure when travelling at 6 - 7 km/h

bar

260

Aktivating pressure

bar

130

Aktivating pressure

bar

Control pressure

bar

PST

Variable displ. motor 1 in regulating range 5

MA M1

Variable displ. motor 2 Control pressure regulating

M2 1

PST

Pressure regulating Aktivating pressure

bar

High pressure

bar

290

= Blocked Machine

3.3

L534 - 434 / from 8962

MJFCIFSS

Check / Adjustment

Unit

Adjust. values

Value before adjust

Value after adjust

Adjust. point

Test point

P / LS

Working hydraulic Working hydraulic pump Flow regulator â&#x20AC;&#x201C; pressure differenz

bar

Secondary pressure relief valve, lift

bar

1) 250

Secondary pressure relief valve, tilt in

bar

1) 220

Secondary pressure relief valve, tilt out / Z - bar linkage

bar

1) 220

Secondary pressure relief valve, tilt out / P - bar linkage

bar

150

Secondary pressure relief valve additional equipment

bar

250

1/8

bar

305

bar

250

Contol valve block

Control valve block LS- Pressure relief valve / AH Control valve block Pretension valve / P - bar linkage

Quick change device Pressure relief valve

Steering system Pressure relief valve / steering LS- Pressure relief valve / steering

bar

210

Brake system Compact brake valve Cut in pressure

bar

145

Cut out pressure

bar

175

Brake pressure in axles

bar

M1 / M2

bar

> 50

bar

Accumulator After 9 braking actions

axles M1 / M2

Pressure switch â&#x20AC;&#x201C; brake accumulator pressure Switching point

front axles M1

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

0,5

bar

100

Overlap / Inching - brake High pressure travel hydraulic

Remarks:

Signature:

3.3

L534 - 434 / from 8962

MJFCIFSS

Costumer:

L 538 S/N 432 / Operating hours: Type of application:

Job site:

Checked by: Checked on date:

Check / Adjustment

Unit

Adjust. values

Value before adjust

Value after adjust

Adjust. point

Test point

Diesel engine Diesel engine RPM Low idle RPM High indle RPM

min

-1

min

-1

850

2100

+80

Cooling system Cooling System (fan control) Hydraulic oil 31 - 55 Â°C Coolant below 78 Â°C 5

Fan at high Diesel engine RPM/ Sensor unplugged

bar

175

Fan at high Diesel engine RPM

bar

Fan at low Diesel engine RPM

bar

Travel hydraulic Replenisihing pressure At high idle RPM

bar

MA (MB)

Regulation-begin-var. Displ. pump High pressure Diesel engine RPM Control pressure

bar min

-1

1030 2

bar

PST

bar

380

Pump performance at 380 bar High pressure Diesel engine RPM Control pressure

min

-1

380

MA (MB)

100

1700

bar

PST

Forward

bar

470

Reverse

bar

470

bar

430

MA (MB)

High pressure relief valves

Pressure cut off High pressure Engine speed drop, max. difference to high idle RPM Control pressure

min

-1

50 2

bar

PST

High pressure when travelling at 6 - 7 km/h

bar

230

Aktivating pressure

bar

120

bar

Variable displ. motor 1 in regulating range 5

Variable displ. motor 2 Control pressure regulating Aktivating pressure Control pressure

bar

PST

Pressure regulating Aktivating pressure

bar

High pressure

bar

260

= Blocked Machine

3.3

L538 - 432 / 0101 - 6943

MJFCIFSS

Check / Adjustment

Unit

Adjust. values

Value before adjust.

Value after adjust.

Adjust. point

Test point

P / LS

Working hydraulic Working hydraulic pump Flow regulator - pressure differenz

bar

Secondary pressure relief valve, lift

bar

1) 250

Secondary pressure relief valve, tilt in

bar

1) 220

Secondary pressure relief valve, tilt out / Z - bar linkage

bar

1) 220

Secondary pressure relief valve, tilt out / P - bar linkage

bar

150

Secondary pressure relief valve additional equipment

bar

250

3/5

bar

305

bar

250

Contol valve block

Control valve block LS - Pressure relief valve / AH Control valve block Pretension valve / P - bar linkage

Quick change device Pressure relief valve

Steering system Pressure relief valve / steering LS - Pressure relief valve / steering

bar

210

Brake system Compact brake valve Cut in pressure

bar

145

Cut out pressure

bar

175

Brake pressure in axles

bar

M1 / M2

bar

> 50

bar

Accumulator After 9 braking actions

axles M1 / M2

Pressure switch â&#x20AC;&#x201C; brake accumulator pressure Switching point

front axles M1

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

0,5

bar

100

Overlap / Inching - brake High pressure travel hydraulic

Remarks:

Signature:

3.3

L538 - 432 / 0101 - 6943

MJFCIFSS

Costumer:

L 538 S/N 432 / Operating hours: Type of application:

Job site:

Checked by: Checked on date:

Check / Adjustment

Unit

Adjust. values

Value before adjust

Value after adjust

Adjust. point

Test point

Diesel engine Diesel engine RPM Low idle RPM High indle RPM

min

-1

min

-1

850

2100

+80

Cooling system Cooling System (fan control) Hydraulic oil 31 - 55 Â°C Coolant below 78 Â°C 5

Fan at high Diesel engine RPM/ Sensor unplugged

bar

175

Fan at high Diesel engine RPM

bar

Fan at low Diesel engine RPM

bar

Travel hydraulic Replenisihing pressure At high idle RPM

bar

MA (MB)

Regulation-begin-var. Displ. pump High pressure Diesel engine RPM Control pressure

bar min

-1

1030 2

bar

PST

bar

380

Pump performance at 380 bar High pressure Diesel engine RPM Control pressure

min

-1

380

MA (MB)

100

1700

bar

PST

Forward

bar

470

Reverse

bar

470

bar

430

MA (MB)

High pressure relief valves

Pressure cut off High pressure Engine speed drop, max. difference to high idle RPM Control pressure

min

-1

50 2

bar

PST

High pressure when travelling at 6 - 7 km/h

bar

230

Aktivating pressure

bar

120

bar

Variable displ. motor 1 in regulating range 5

Variable displ. motor 2 Control pressure regulating Aktivating pressure Control pressure

bar

PST

Pressure regulating Aktivating pressure

bar

High pressure

bar

260

= Blocked Machine

3.3

L538 - 432 / from 6944

MJFCIFSS

Check / Adjustment

Unit

Adjust. values

Value before adjust.

Value after adjust.

Adjust. point

Test point

P / LS

Working hydraulic Working hydraulic pump Flow regulator - pressure differenz

bar

Secondary pressure relief valve, lift

bar

1) 250

Secondary pressure relief valve, tilt in

bar

1) 220

Secondary pressure relief valve, tilt out / Z - bar linkage

bar

1) 220

Secondary pressure relief valve, tilt out / P - bar linkage

bar

150

Secondary pressure relief valve additional equipment

bar

250

1/8

bar

305

bar

250

Contol valve block

Control valve block LS - Pressure relief valve / AH Control valve block Pretension valve / P - bar linkage

Quick change device Pressure relief valve

Steering system Pressure relief valve / steering LS - Pressure relief valve / steering

bar

210

Brake system Compact brake valve Cut in pressure

bar

145

Cut out pressure

bar

175

Brake pressure in axles

bar

M1 / M2

bar

> 50

bar

Accumulator After 9 braking actions

axles M1 / M2

Pressure switch â&#x20AC;&#x201C; brake accumulator pressure Switching point

front axles M1

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

0,5

bar

100

Overlap / Inching - brake High pressure travel hydraulic

Remarks:

Signature:

3.3

L538 - 432 / from 6944

MJFCIFSS

Service Manual

Maintenance Lubrication chart and filling quantities

3.4 Lubrication chart and filling quantities 3.4.1 Valid for:

Table of filling quantities (L524) L524 - 438 / from 0101

Specifications in the medium column: The standard lubricants and fuels required for central European climate conditions are stated here. Before you change or top up the oil in the hydraulic system (hydraulic tank), always check if it is filled with petroleum or bio oil. For more detailed information about the required lubricants and service fuels, see the section on lubricants and fuels. Specifications in the dosage column: The values stated for the filling quantities in the table are only guidelines. The dipstick and level markings are always mandatory. Each time the oil is replaced or topped up, check the level in the unit in question. Description

Medium

Diesel engine cooling system total capacity Diesel engine (with filter change)

Coolant

24.5 l

Engine oil SAE 10W - 40

12.0 l

Transfer gear

Gear oil SAE 90 LS

2.1 l

Front axle differential

Gear oil SAE 90 LS Gear oil SAE 90 LS

12.2 l

Rear axle differential

Gear oil SAE 90 LS

12.7 l

Rear axle wheel hub (each)

Gear oil SAE 90 LS

2.5 l

Hydraulic tank

Engine oil SAE 20W - 20

100 l

Hydraulic system total capacity

Engine oil SAE 20W - 20

130 l

Air-conditioning system

Refrigerant R 134a

Front axle wheel hub (each)

3.4.2 Valid for:

Dosage

Unit

2.4 l

1400 g

Table of filling quantities (L534) L534 - 434 / from 0101

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

LIEBHERR

3.4-1 of 4

Maintenance

Service Manual

Lubrication chart and filling quantities

For more detailed information about the required lubricants and service fuels, see the section on lubricants and fuels. Specifications in the dosage column: The values stated for the filling quantities in the table are only guidelines. The dipstick and level markings are always mandatory. Each time the oil is replaced or topped up, check the level in the unit in question. Description

Medium

Diesel engine cooling system total capacity

Coolant

24.5 l

Diesel engine (with filter change)

Engine oil SAE 10W - 40

14.0 l

Transfer gear

Gear oil SAE 90 LS

2.5 l

Front axle differential

Gear oil SAE 90 LS

15.5 l

Front axle wheel hub (each)

Gear oil SAE 90 LS

2.5 l

Rear axle differential

Gear oil SAE 90 LS Gear oil SAE 90 LS

15.5 l

Hydraulic tank

Engine oil SAE 20W - 20

100 l

Hydraulic system total capacity

Engine oil SAE 20W - 20 Refrigerant R 134a

130 l

Rear axle wheel hub (each)

Air-conditioning system

3.4.3 Valid for:

Dosage

Unit

2.5 l

1400 g

Table of filling quantities (L538) L538 - 432 / from 0101

3.4-2 of 4

LIEBHERR

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

Service Manual

Maintenance Lubrication chart and filling quantities

3.4.4

Description

Medium

Dosage

Unit

Diesel engine cooling system total capacity

Coolant

30.5 l

Diesel engine (with filter change)

Engine oil SAE 10W - 40

19.0 l

Transfer gear

Gear oil SAE 90 LS

2.5 l

Front axle differential

Gear oil SAE 90 LS

15.5 l

Front axle wheel hub (each)

Gear oil SAE 90 LS

2.5 l

Rear axle differential

Gear oil SAE 90 LS

15.5 l

Rear axle wheel hub (each)

Gear oil SAE 90 LS

2.5 l

Hydraulic tank

Engine oil SAE 20W - 20

100 l

Hydraulic system total capacity

Engine oil SAE 20W - 20

130 l

Air-conditioning system

Refrigerant R 134a

1400 g

Lubrication chart The lubrication chart provides an overview of the location of the maintenance points on the machine and of the maintenance intervals. You will find detailed information in the maintenance and inspection schedule, as well as in the individual descriptions in the section on maintenance tasks. For more detailed information about the required lubricants and service fuels, see the section on lubricants and fuels. For information about the required filling quantities, see the tables of filling quantities.

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

LIEBHERR

3.4-3 of 4

Maintenance

Service Manual

Lubrication chart and filling quantities

Symbol

Description

Symbol

Description

General lubrication points

Lubrication

Check the oil level

Check the coolant level

Oil change

3.4-4 of 4

MJFCIFSS

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

Service Manual

Maintenance Maintenance tasks

3.5 Maintenance tasks On completion of servicing, the machine should be returned to the operating position. See the description of the operating position in the operation section of the operating manual.

3.5.1

Preparatory tasks for maintenance Before performing the various maintenance tasks, move the machine to maintenance position unless otherwise explicitly specified in the description. The various maintenance tasks include: – Lubricating the lift arms – Checking the oil level or changing the oil in the engine, gears, axles, hydraulic tank, etc. – Replacing filters as well as adjustment and repair work on the hydraulic system

Safety precautions for maintenance Always observe the accident prevention regulations during maintenance work. See the safety regulations section for measures to ensure safe maintenance. Make sure that visual contact between the operator in the cab and maintenance personnel is always maintained.

Visual contact

Danger

There is a risk of accidents for maintenance personnel. The presence of unauthorised persons on the machine can place the maintenance personnel in extreme danger.

! Never enter a dangerous area of the machine without making your presence known. Make sure you can be clearly seen before entering one of the machine’s danger areas. Secure the machine against rolling away with wheel wedges.

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

MJFCIFSS

3.5-1 of 72

Maintenance

Service Manual

Maintenance tasks

Maintenance positions The maintenance position depends on the maintenance task to be performed. The two basic maintenance positions 1 and 2 are described below. They enable you to access the individual maintenance points. Maintenance position 1

To move the machine into maintenance position 1 proceed as follows.

Maintenance position 1 Park the machine on level ground. Lower the lift arms. Set the bucket down flat on the ground. Turn off the engine. Take out the ignition key. Maintenance position 2

To move the machine into maintenance position 2 proceed as follows.

Maintenance position 2 Park the machine on level ground. Engage the articulation lock. Lower the lift arms. Tilt the bucket out and set it down on the ground on its teeth or cutting edge. Turn off the engine. Take out the ignition key.

3.5-2 of 72

MJFCIFSS

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

Service Manual

Maintenance Maintenance tasks

Opening the service doors and hoods Opening the engine compartment hood

When the hood is open, you can access the following units: – Diesel engine – Air filter – Hydraulic pumps – Cooling system – Batteries – Battery main switch

Engine compartment door 1 Engine compartment hood 2 Handle with lock Warning

3 Gas-filled springs

Engine parts which are in motion can cause injury. Rotating or moving engine parts, such as the fan blades or V-belts, can cause injury.

! Only open the engine compartment hood when the engine is shut down. Open the lock with the ignition key. Open the hood 1 with the handle 2 and lift it up as far as it will go. The hood is held in this position by two gas-filled springs 3. There is a risk of injuries if the hood falls shut. Warning

! Check that gas-filled spring holds it completely open. If not, rectify the problem immediately. Troubleshooting The function is not assured Contact LIEBHERR CUSTOMER SERVICE.

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

MJFCIFSS

3.5-3 of 72

Maintenance

Service Manual

Maintenance tasks

Opening the cooler flap 1 Cooler flap 2 Gas-filled spring When the flap is open, you can access the following units: â&#x20AC;&#x201C; Cooling system â&#x20AC;&#x201C; Hydraulic tank

Cooler flap

When opening or closing the flap, climb onto the machine via the cab access, making sure that you have secure footing.

Standing position

Pull up the flap 1 until it is fully open. The flap is held in this position by the gas-filled spring 2.

Cooler flap

3.5-4 of 72

MJFCIFSS

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

Service Manual

Maintenance Maintenance tasks

There is a risk of injury if the flap falls shut. Warning

! Check that the gas-filled springs securely hold it fully open. If not, rectify the problem immediately. Troubleshooting The function is not assured Contact LIEBHERR CUSTOMER SERVICE.

Turning off the battery main switch The battery main switch is located at the rear right of the engine compartment. For certain maintenance jobs, the battery main switch must first be turned off. Find out from the descriptions of the relevant maintenance tasks whether the battery main switch must be turned on or off. See the section on maintenance tasks. Switch on the battery main switch after completing these maintenance tasks.

Battery main switch 1 Battery main switch

Caution

2 Key

There is a risk of damaging the electrical system.

! Do not turn off the battery main switch while the engine is running. First turn off the engine and then turn off the battery main switch.

Danger

There is a risk of accidents for maintenance personnel. If unauthorised people are on the machine it can put the maintenance personnel in extreme danger. ! For safety reasons, it is essential that the battery main switch is turned off. ! Take out the key. To turn off the battery main switch 1, turn the key 2 to the 0 position.

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Maintenance tasks

3.5.2

Checking the machine for external damage Make sure that the machine is in maintenance position 1. Procedure Before starting up the machine, check for external damage which might impair safe operation. Immediately repair any damage which may impair safety.

3.5.3

Making sure the bolted connections are tight Make sure that: – The machine is in maintenance position 2. – The service doors and hoods are open. Procedure Tighten any loose screws or bolts with the required tightening torque.

3.5.4

Sealing leaks Make sure that: – The machine is in maintenance position 2. – The service doors and hoods are open. Procedure Check the entire hydraulic system for leaks. Replace any damaged hydraulic seals. Tighten any loose hydraulic couplings. See also the section on safe maintenance of hydraulic hoses and hose lines.

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Maintenance Maintenance tasks

3.5.5 Valid for:

Checking the engine oil level (L524, L534) L524 - 438 / 0101; L534 - 434 / 0101

The oil filler neck is on the top of the engine on the valve cover. Make sure that: – The machine is in maintenance position 1. – The engine compartment hood is open. – The engine is level and has not been running for 2 to 3 minutes. Procedure Pull out the dipstick 1, wipe it clean, and re-insert it. Pull out the dipstick 1 once again and read off the oil level. The oil level must be within the cross hatching 2.

Diesel engine dipstick If the oil level is in the range 3 or below: Top up with engine oil. For the oil quality, see the section on lubricants and fuels.

Checking the engine oil level (L538) Valid for:

L538 - 432 / 0101

The oil filler neck is on the top of the engine on the valve cover. Make sure that: – The machine is in maintenance position 1. – The engine compartment hood is open. – The engine is level and has not been running for 1 to 2 minutes. Procedure Pull out the dipstick 3, wipe it clean, and re-insert it. Pull out the dipstick 3 once again and read off the oil level. The oil level must be within the cross hatching 2. If the oil level is too low: Top up with oil. For the oil quality, see the section on lubricants and fuels.

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Maintenance tasks

LIEBHERR diesel engine Top up with oil via the oil filler neck 2. Clean the filler cap, place it on the filler neck 2 and tighten it.

3.5.6 Valid for:

Changing the engine oil (L524, L534) L524 - 438 / 0101; L534 - 434 / 0101

Changing the engine oil Unscrew the cap of the oil drain valve 1 on the bottom of the oil pan. Screw the oil drain hose 2 to the oil drain valve 1. Drain off the oil into the receptacle. Unscrew the oil drain hose 2 and unscrew the cap of the oil drain valve 1.

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Maintenance Maintenance tasks

When changing the engine oil and the oil filter: Change the filter as described in the section on changing the oil filter. Top up the oil via the oil filler neck 4 to the top marking 5 on the cross hatching of the dipstick 6 (for the oil quality, see the section on lubricants and fuels). Clean the filler cap 3, put it on the filler neck 4 and tighten it. Clean the filler cap, put it on the filler neck 1 and tighten it. Start the engine and check the oil pressure.

Diesel engine dipstick Turn off the engine and after 1 or 2 minutes check the oil level on the dipstick 1. If the oil level is in the range 3 or below: Correct the oil level.

Changing the engine oil (L538) Valid for:

L538 - 432 / 0101

Make sure that: – The machine is in maintenance position 1. – The engine compartment hood is open. – The engine is warm. – A suitable receptacle, an oil drain hose and the specified engine oil are at hand. See the table of filling quantities for the required capacity of the receptacle. Procedure Only change the oil when the engine is warm. Unscrew the cap 2 of the oil drain valve 3 on the oil pan. Screw the oil drain hose 1 onto the oil drain valve 3 and allow the oil to drain into the container. Unscrew the oil drain hose 1 and screw the cap 2 onto the oil drain valve 3.

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Service Manual

Maintenance tasks

When changing the engine oil and the oil filter: Change the filter as described in the section on changing the oil filter. Pour the new oil into the filler neck 2 up to the MAX marking on the dipstick 3. Clean the filler cap 1, place it on the filler neck 2 and tighten it. Start the engine and check the oil pressure. Turn off the engine and check the oil level on the dipstick 3. Top up with oil if necessary.

3.5.7 Valid for:

Changing the engine oil filter (L524, L534) L524 - 438 / from 0101; L534 - 434 / from 0101

Make sure that: – The machine is in maintenance position 1. – The engine oil has been drained. – You have a LIEBHERR oil filter cartridge ready. Procedure

Unscrewing the oil filter Release the oil filter cartridge 2 with a strap wrench 3 and unscrew the filter. Clean the seal surfaces of the filter bracket 1, if necessary remove the old filter seals and anything left of them. Lightly coat the rubber seal ring on the new oil filter cartridge 2 with engine oil.

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Maintenance Maintenance tasks

Screw the new oil filter cartridge onto the filter bracket 1 until the seal touches the filter bracket 1. Tighten it another half to three-quarter turn. Top up with oil as described in the section on engine oil.

3.5.8 Valid for:

Changing the engine oil filter (L538) L538 - 432 / from 0101

Make sure that: â&#x20AC;&#x201C; The machine is in maintenance position 1. â&#x20AC;&#x201C; The engine compartment hood is open. Procedure Release the filter cartridges 1 with a strap wrench and unscrew them. Clean the seals on the filter bracket. Lightly coat the rubber gaskets on the new oil filter cartridges with engine oil. Screw the new filter cartridges onto the filter bracket and tighten them by hand. Start up the engine and check the oil pressure on the engine oil pressure symbol field in the display unit. Turn off the engine. Check the seals on the oil filters and the oil level. Top up with oil if necessary.

3.5.9 Valid for:

Checking the V-ribbed belt (L524, L534) L524 - 438 / from 0101; L534 - 434 / from 0101

Access is from the right-hand side of the engine. The V-ribbed belt drive has an automatic tensioning device. The tensioning device cannot be repaired. The tensioning device is designed so that the lever moves within the tensioning limits 3 and the fixed limit stops 4. Checking the V-ribbed belt

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

Make sure that: The machine is in maintenance position 1. The engine compartment hood is open.

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Maintenance tasks

Procedure

V-ribbed belt tensioning device Visually inspect the limit stops 4 and 5. Check the V-ribbed belt for wear and damage. If the tension limit stop 3 on the swivel arm touches the fixed stop 4, check the brackets for the alternator, belt tensioner etc. and check the belt tightness. Replace the belt if necessary. Replacing the belt:

Make sure that: – The machine is in maintenance position 1 – The engine compartment hood is open – You have a new V-ribbed belt ready Procedure Take off the belt guard by removing the three screws 2. Relax the tensioner and replace the belt. Check the play between the tension stop 3 and the fixed stop 4. If there is no play between the tension stop 3 and the fixed stop 4, check the length of the belt and the bearing of the tensioning device. Fit the belt guard again.

3.5.10

Checking the V-ribbed belt (L538)

Valid for:

L538 - 432 / 0101 -

Access is from the rear right side. Check by hand. The V-ribbed belt is properly tensioned when it can be pushed at the test point M between the pulleys with a force of 120 N by 13 mm. Make sure that: – The machine is in maintenance position 1 – The engine compartment hood is open.

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Maintenance Maintenance tasks

1 Battery main switch 2 Counter nut 3 Clamp screw

Checking with the Krikit 2 tester

4 Key M Test position

Lower the indicator arm 2 all the way in the measuring device 1. Place the measuring device 1 in the middle of the belt at the test position M between the two pulleys. Using the button 3 gradually apply pressure to the belt until you hear and feel the spring in the measuring device 1 click. The indicator arm 2 then shows the belt tension on the scale. Carefully take off the measuring device 1 without moving the indicator arm 2. Read off the tension shown by the indicator arm “KG” on the scale (see arrow). Check the tension against the specified value and tighten or relax the belt if necessary. The value on the “KG” scale of the measuring device is slightly higher for new belts than for ones which have run in. For the specified tension see the technical data.

Krikit 2 belt tension tester

Adjusting the belt tension Version A

There are three different V-ribbed belt arrangements. The procedure for version “A” is described here (installed in series with alternator only). The alternator is fitted on a bracket which can be adjusted using the clamp screw 1.

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Service Manual

Maintenance tasks

Belt tensioning version “A” Loosen the fixing bolts 3, 4 and nut 2. Use the clamp screw 1 to raise the bracket with the alternator until the belt tension is correct. Tighten the fixing bolts 3, 4 and nut 2 again. Check the belt tension as described. Tighten the belt if necessary. Let the engine run for a short while, then check the belt tension again, tightening if necessary. Adjusting the belt tension Version B Valid for:

There are three different V-ribbed belt arrangements. The procedure for version “B” is described here (installed with air conditioning compressor and tension rollers). L538 - 432 / 0101 - 8507

The fixing bolts on the tension rollers 2 and 4 are hex bolts. The cams on each roller are set so that the bolt is positioned on the roller as shown. The position of the tension roller 2, with a 45° cam inclination as shown, is the basic setting. After all work on the belt, the tension roller 2 must first be returned to this original position. Loosen the hex bolt on the roller 4 with a 19 mm ring spanner or socket wrench. Turn the cam of the roller 4 anticlockwise using the square fitting of a ratchet wrench until the belt is correctly tightened, then tighten the hex bolt. Check the belt tension as described. Tighten the belt again if necessary.

Adjusting the belt tension Version B

3.5-14 of 72

Let the engine run for a short while, then check the belt tension again, tightening if necessary.

MJFCIFSS

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Service Manual

Maintenance Maintenance tasks

Checking the belt tension Version C Valid for:

There are three different V-ribbed belt arrangements. The procedure for version “C” is described here (installed with air conditioning compressor and automatic tensioning device). L538 - 432 / 8508

The V-ribbed belt drive has an automatic tensioning device. The tensioning device cannot be repaired.

V-ribbed belt installation with tensioning device Push a DIN 3122 D 12.5 (1/2”) ratchet into the square fitting of the tensioning device. Pull back the tensioning device against the spring force anticlockwise as far as it will go and take off the belt. Check that the tension roller and the pulleys are in perfect condition (for example the tension roller bearings are in place and the pulleys are not worn). If any parts are damaged, replace them. With the tensioning device swung back, put the new belt on the pulleys of the crankshaft, air conditioning compressor, alternator and deflector roller. Then return the tensioning device to the tensioning position.

3.5.11

Checking the engine valve play (L524, L534)

Valid for:

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

Check the valve play with the engine cold. Make sure that: – The machine is in maintenance position 1. – The engine compartment hood and door are open. – You have the special cranking device (ID no. 0541887), a feeler gauge and valve seals ready. – The engine is cold or has been allowed to cool for at least two hours. Conventions on the cylinder numbering, direction of rotation and position of the valves: – Cylinder 4 on flywheel side – Direction of rotation anticlockwise looking at the flywheel – Outlet valves on flywheel side

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Service Manual

Maintenance tasks

Valve play D504 NA/T Inlet valve

0.35 mm

Outlet valve

0.45 mm

Engine D 504 NA/T Cylinder Overlap

Adjust

Procedure

Remove the intake line 1 from the turbocharger to the manifold. Cover the opening of the manifold to stop anything falling in. Remove the plug 2 from the valve cover and remove the hex nut below. Carefully take off the valve cover, so that the washers of the valve fastening screws are not lost. Dismantle the belt guard.

Turn the engine by the pulley 2 using the cranking device 3. (For the cranking device 3, use a ratchet 1 with a 16 mm socket).

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Maintenance Maintenance tasks

Valve layout S Flywheel end 2 Cylinder 2 A Outlet valve 3 Cylinder 3 E Inlet valve 4 Cylinder 4 1 Cylinder 1 Turn the crankshaft in the direction of rotation until the valves of the fourth cylinder overlap. Adjust the valves of the first cylinder.

Adjusting the valves Push a feeler gauge 6 between the valve 5 and the rocker arm 4 and check the valve play. If the valve play is not correct: Loosen the counter nut 3 of the adjusting screw for the rocker arm in question 4 using a 17 mm ring spanner 1, and correct the setting using a screwdriver 2. Tighten the counter nut again. Check the valve play again after you tighten the counter nut 3. Check the other cylinders and adjust them as necessary by turning the crankshaft until the valves overlap as shown in the table. After checking and adjusting the valves, put on the valve cover with new seals. Put the belt guard and intake line back on.

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Service Manual

Maintenance tasks

3.5.12

Checking the engine valve play (L538)

Valid for:

L538 - 432 / from 0101

Check the valve play with the engine cold. Make sure that: – The machine is in maintenance position 1. – The engine compartment hood is open. – You have the special cranking device, a feeler gauge and cylinder head seals ready. – The engine is cold or has been allowed to cool for at least two hours. Conventions on the cylinder numbering, direction of rotation and position of the valves: – Cylinder 1 on flywheel side – Direction of rotation anticlockwise looking at the flywheel – Outlet valves on flywheel side Valve play D504 NA/T Inlet valve

0.25 mm

Outlet valve

0.30 mm Engine D 924 Cylinder Overlap

Adjust

Procedure Take off the cylinder head covers. Attach the cranking device (ID no. 0524045) to the flywheel housing. For reasons of space, use extensions on the cranking device to the rear towards the ratchet. Turn the crankshaft in the direction of rotation until the valves of the cylinder to be adjusted. See the table for specifications.

Push a feeler gauge between the valve and the rocker arm and check the valve play.

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Service Manual

Maintenance Maintenance tasks

If the valve play is not correct: Loosen the nut on the adjusting bolt for the rocker arm, adjust it and tighten the nut again. Check the valve play again after you tighten the counter nut. After checking and adjusting, put on the cylinder head covers with new seals.

3.5.13

Checking the flame glow system (L538)

Valid for:

L538 - 432 / from 0101

The test is restricted to checking the solenoid valve Y1 and the flame glow plug R3. The preglow relay controls the preglow time until the engine is ready, which can take anything from 0.5 to 2.0 minutes, depending on temperature. Make sure that: â&#x20AC;&#x201C; The machine is in maintenance position 1. â&#x20AC;&#x201C; The engine compartment hood is open.

Procedure for checking the solenoid valve Unscrew the fuel line on the flame glow plug R3. Crank the engine with the starter. To do this, remove the fuse F8B. Fuel must flow out of the fuel line to the flame glow plug R3. Put the fuse F8B back in and start the engine. The fuel must stop flowing when the engine is running. If no fuel flows when the engine is cranked, or if the fuel flow will not stop flowing when the motor is running: Replace the solenoid valve Y1. When installing it, note the flow direction indicated by the arrow. Procedure for checking the flame glow plug Remove the flame glow plug R3. Re-attach the fuel line and the electrical lead to the flame glow plug R3. Set the starter switch S1 to the preglow position (position 1). The heating coil in the flame glow plug R3 should glow red when the preglow process has finished. Crank the engine with the starter. To do this, remove the fuse F8B. The fuel delivered to the glowing heating coil in the flame glow plug R3 should evaporate.

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Service Manual

Maintenance tasks

Troubleshooting If the heating coil in the flame glow plug R3 does not start glowing, or if no fuel is delivered to the heating coil when the engine is turning over: Replace the flame glow plug R3.

3.5.14

Greasing the ring gear on the engine flywheel (L538)

Valid for:

L538 - 432 / from 0101

Make sure that: – The machine is in maintenance position 1. – The engine compartment hood is open. Procedure Unscrew the service cap 1 from the flywheel housing. Check the sprocket 2 and apply a light coating of standard grease if necessary. Briefly run the engine and turn it off again. Apply more grease if necessary.

3.5.15

Changing the diesel engine oil separator (L538)

Valid for:

L538 - 432 / from 0101

The oil separator must be replaced if: – It is damaged – Oil fumes come out of the vent in the cover Make sure that: – The machine is in maintenance position 1. – The engine compartment hood is open. Procedure Loosen the clips on the oil separator 1 and the hose, and take off the oil separator. Put a new O-ring in the oil separator. Put on the new oil separator 1 and tighten the clips. Push on the hose and tighten the hose clip.

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Maintenance Maintenance tasks

3.5.16

Bleeding the fuel system (L524, L534)

Valid for:

L524 - 438 / from 010; L534 - 434 / from 0101

Make sure that: â&#x20AC;&#x201C; The machine is in maintenance position 1. â&#x20AC;&#x201C; The engine compartment hood is open. Procedure for bleeding the fuel system

Place a receptacle under the fuel fine filter. Unscrew the bleeder screw 1 on the fuel fine filter by two or three turns. Push the hand pump lever 2 until bubble-free fuel comes out of the bleeder screw 1. Tighten the bleeder screw 1 again. Push the hand pump lever 2 until the pump resistance subsides. Carry on pumping and undo the bleeder screw 1 (the remaining air escapes under pressure and the pump resistance increases again). Close the drain plug 1 and push the hand pump lever 2 until the pump resistance subsides. If you can feel no resistance accumulate while pushing the hand pump lever 2 or if no fuel comes out of the bleeder screw 1: Briefly turn over the diesel engine with the starter, because the lever of the fuel pump is probably at the top of the cam.

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Service Manual

Maintenance tasks

3.5.17

Bleeding the fuel system (L538)

Valid for:

L538 - 432 / 0101 - 8507

Make sure that: â&#x20AC;&#x201C; The machine is in maintenance position 1. â&#x20AC;&#x201C; The engine compartment hood is open. Procedure for bleeding the fuel system

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Maintenance Maintenance tasks

3.5.18

Bleeding the fuel system (L538)

Valid for:

L538 - 432 / from 8508

Make sure that: â&#x20AC;&#x201C; The machine is in maintenance position 1. â&#x20AC;&#x201C; The engine compartment hood is open. Procedure for bleeding the fuel system

Place a receptacle under the fuel fine filter. Unscrew the bleeder screws 1 and 2 on the fuel fine filters by two or three turns. Push the hand pump lever 3 until bubble-free fuel comes out of the bleeder screws 1 and 2. Tighten the bleeder screws 1 and 2 again. Push the hand pump lever 3 until the pump resistance subsides. Carry on pumping and undo the bleeder screws 1 and 2 (the remaining air escapes under pressure and the pump resistance increases again). Close the bleeder screws 1 and 2 and push the hand pump lever 3 until the pump resistance subsides. If you can feel no resistance accumulate while pushing the hand pump lever 3 or if no fuel comes out of the bleeder screws 1 and 2: Briefly turn over the diesel engine with the starter, because the lever of the fuel pump is probably at the top of the cam.

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Maintenance

Service Manual

Maintenance tasks

3.5.19

Replacing the fuel pre-filter (L524, L534)

Valid for:

L524 - 438 / 0101 - 8795; L534 - 434 / 0101 - 8961

Release the hose clips and remove the fuel pre-filter 1. Fit a new fuel pre-filter 1. Bleed the fuel system. Bleeding the fuel system

Procedure: see the section on bleeding the fuel system.

Changing the fuel pre-filter Valid for:

L524 - 438 / from 8796; L534 - 434 / from 8962

Make sure that: – The machine is in maintenance position 1. – The engine compartment hood is open. – You have a LIEBHERR fuel pre-filter cartridge ready. Procedure for changing the fuel pre-filter Carefully clean the fuel pre-filter and the area around it. Place the receptacle under the fuel pre-filter (possibly attaching a suitably sized hose to the drain valve 7). Open the drain plug 7 and bleeder screw 2 on the fuel pre-filter by two or three turns and drain the condensate into a suitable receptacle. Turn the retaining ring 3 on the pre-filter anticlockwise, (possibly using a strap wrench), take off the retaining ring and pull out the filter cartridge 4. Unscrew the water separator 6 from the filter cartridge. Dispose of the old filter cartridge.

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Service Manual

Maintenance Maintenance tasks

Fitting the new fuel fine filter Wash the water separator 6 and dry it with compressed air. Unscrew the old drain valve and dispose of it. Unscrew the drain valve from the new filter cartridge and screw it into the clean water separator. Screw in and tighten the water separator 6 on the new filter cartridge. Check the filter base and seal ring, clean them and replace them if necessary. Clean the seal on the filter head. Oil the seal on the new filter cartridge. Fit a new filter cartridge 4 on the filter base. Make sure that the slots 8 in the filter base and the lugs 9 on the filter cartridge are lined up. Fit the snap ring 3 and tighten it by 1/3 turn clockwise. The snap ring clicks into the notch. Bleed the fuel system. Bleeding the fuel system

Procedure: see the section on bleeding the fuel system.

3.5.20

Replacing the fuel pre-filter (L538)

Valid for:

L538 - 432 / 0101 - 8507

Make sure that: – The machine is in maintenance position 1. – The engine compartment hood is open. – You have a LIEBHERR fuel pre-filter cartridge ready. Procedure for changing the fuel pre-filter Open the drain plug 4 on the fuel pre-filter by two or three turns and drain the condensate into a suitable receptacle. Turn the retaining ring 1 on the pre-filter 90° anticlockwise (possibly using a strap wrench), take off the retaining ring and pull out the filter cartridge 2. Clean the seal on the filter head. Oil the seal on the new filter cartridge.

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Maintenance tasks

Align the stud 2 on the filter cartridge with the filter head 1, put it in the filter head and fasten it with the retaining ring (turn the ring clockwise until you feel it catch).

Bleed the fuel system. Bleeding the fuel system

Procedure: see the section on bleeding the fuel system.

3.5.21

Replacing the filter insert in the fuel separator (L538)

Valid for:

L538 - 432 / from 8508

Make sure that: – The machine is in maintenance position 1. – The engine compartment hood is open. – You have a LIEBHERR filter insert ready. Procedure for replacing the filter insert in the fuel separator

1 2 3 4 5

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Filter insert seal 6 Bleeder screw with seal Filter insert 7 Cover fixing screws Spring cartridge 8 Filter housing Cover seal 9 Sight glass Cover 10 Drain valve Carefully clean the fuel separator and the area around it. Place the receptacle under the fuel separator (possibly attaching a suitably sized hose to the drain valve 10).

MJFCIFSS

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

Service Manual

Maintenance Maintenance tasks

Open the bleeder screw 6. Push in the stop cock on the drain valve 10 and open it anticlockwise. Drain the condensate into a suitable receptacle. Release the fixing screws 7 and take off the cover. Take out the filter insert 2 along with the spring cartridge 3. Dispose of the filter insert 2. Clean the filter housing and the seal faces. Put in a new filter insert 2. Check the seal 4, replacing it if necessary, and assemble it in the reverse order. Bleed the fuel system. Bleeding the fuel system

Procedure: see the section on bleeding the fuel system.

3.5.22

Replacing the fuel fine filter (L524, L534)

Valid for:

L524 - 438 / 0101 - 8795; L534 - 434 / 0101 - 8961

Make sure that: â&#x20AC;&#x201C; The machine is in maintenance position 1. â&#x20AC;&#x201C; The engine compartment rear hatch is open. Procedure for changing the fuel fine filter

Carefully clean the fuel fine filter and the area around it. Place the receptacle under the fuel fine filter (possibly attaching a suitably sized hose to the drain valve 4). Open the drain valve 4 and drain off the fuel. Push up the snap ring 1 and turn it a quarter turn anticlockwise. Pull down the filter cartridge 2 and the snap ring 1. Unscrew the water separator 3 from the filter cartridge. Dispose of the old filter cartridge.

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Service Manual

Maintenance tasks

Fitting the new fuel fine filter Wash the water separator 3 and dry it with compressed air. Unscrew the (old) drain plug and dispose of it. Unscrew the drain valve from the new filter cartridge and screw it into the clean water separator. Screw in and tighten the water separator 3 on the new filter cartridge. Check the filter base and seal ring, clean them and replace them if necessary. Fit a new filter cartridge 2 on the filter base. Make sure that the slot in the filter base and the lug on the filter cartridge are lined up. Fit the snap ring 1 and tighten it by 1/3 turn clockwise. The snap ring clicks into the notch. Bleed the fuel system. Bleeding the fuel system

Procedure: see the section on bleeding the fuel system.

Changing the fuel fine filter Valid for:

L524 - 438 / from 8796; L534 - 434 / from 8962

Make sure that: â&#x20AC;&#x201C; The machine is in maintenance position 1. â&#x20AC;&#x201C; The engine compartment hood is open. Procedure for changing the fuel fine filter Carefully clean the fuel fine filter and the area around it. Place the receptacle under the fuel fine filter (possibly attaching a suitably sized hose to the drain valve 5). Open the drain plug 5 on the fuel fine filter by two or three turns and drain the condensate into a suitable receptacle. Turn the retaining ring 3 on the fine filter to the left, (possibly using a strap wrench), take off the retaining ring and pull out the filter cartridge 4. Clean the seal on the filter head. Oil the seal on the new filter cartridge.

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Maintenance Maintenance tasks

Fit a new filter cartridge 4 on the filter base. Make sure that the slot 8 in the filter base and the lugs 9 on the filter cartridge are lined up. Fit the snap ring 3 and tighten it by 1/3 turn clockwise. The snap ring clicks into the notch.

Bleed the fuel system. Bleeding the fuel system

Procedure: see the section on bleeding the fuel system.

3.5.23

Changing the fuel fine filter (L538)

Valid for:

L538 - 432 / 0101 - 8507

Make sure that: â&#x20AC;&#x201C; The machine is in maintenance position 1 â&#x20AC;&#x201C; The engine compartment hood is open. Procedure for changing the fuel fine filter Open the drain plug 3 on the fuel fine filter by two or three turns and drain the condensate into a suitable receptacle. Turn the retaining ring 1 on the pre-filter 90Â° anticlockwise (possibly using a strap wrench), take off the retaining ring 1 and pull out the filter cartridge 2.

Clean the seal on the filter head. Oil the seal on the new filter cartridge. Align the stud 2 on the filter cartridge with the filter head 1, put it in the filter head and fasten it with the retaining ring (turn the ring clockwise until you feel it catch).

Bleed the fuel system. Bleeding the fuel system

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

Procedure: see the section on bleeding the fuel system.

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Service Manual

Maintenance tasks

Changing the fuel fine filter Valid for:

L538 - 432 / from 8508

Make sure that: – The machine is in maintenance position 1. – The engine compartment hood is open. Procedure for changing the fuel fine filter Carefully clean the fuel fine filter and the area around it. Place the receptacle under the fuel fine filter (possibly attaching a suitably sized hose to the drain valve 1). Open the drain plug 1 and bleeder screw 4 on the fuel fine filters by two or three turns and drain the condensate into a suitable receptacle. Turn the retaining rings 3 and 5 on the fine filters anticlockwise (possibly using a strap wrench), take off the retaining rings and pull out the filter cartridges.

Clean the seals on the filter heads. Oil the seals on the new filter cartridges. Fit the new filter cartridges on the filter base: Make sure that the slots 1 in the filter base and the lugs 2 on the filter cartridges are lined up. Fit the snap rings and tighten them by 1/3 turn clockwise. The snap ring clicks into the notch.

Bleed the fuel system. Bleeding the fuel system

Procedure: see the section on bleeding the fuel system.

3.5.24

Draining off condensate from the fuel filter (L524, L534 fine filter)

Valid for:

L524 - 438 / 0101 - 8795; L534 - 434 / 0101 - 8961

Make sure that: – The machine is in maintenance position 1. – The engine compartment hood is open.

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Maintenance Maintenance tasks

Procedure for draining off condensate from the fuel fine filter

Place a receptacle under the fuel filter. Unscrew the drain plug 1 and drain the condensate into the receptacle until clean fuel starts to flow. Tighten the drain plug 1 again. Bleed the fuel system. Bleeding the fuel system

Procedure: see the section on bleeding the fuel system.

Draining off condensate from the fuel filter (L524, L534) Valid for:

L524 - 438 / from 8796; L534 - 434 / from 8962

Place the receptacle under the fuel filter (possibly attaching a suitably sized hose to the drain valve). Loosen the bleeder screws 3 and 4. Open the drain plug 1 by two or three turns and drain the condensate into a suitable receptacle until clear fuel flows. Tighten the drain plug 1 again. Open the drain plug 6 by two or three turns and drain the condensate into a suitable receptacle until clear fuel flows. Tighten the drain plug 6 again.

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Tighten the bleeder screws 3 and 4 again. Bleed the fuel system. Bleeding the fuel system

Procedure: see the section on bleeding the fuel system.

3.5.25

Draining off condensate from the fuel filter (L538)

Valid for:

L538 - 432 / 0101 - 8507

Make sure that: â&#x20AC;&#x201C; The machine is in maintenance position 1. â&#x20AC;&#x201C; The engine compartment hood is open. Procedure for draining condensate from the fuel filter

Carefully clean the fuel filter and the area around it. Place the receptacle under the fuel filter (possibly attaching a suitably sized hose to the drain valve). Open the drain plug 1 by two or three turns and drain the condensate into a suitable receptacle until clear fuel flows. Tighten the drain plug 1 again. Open the drain plug 2 by two or three turns and drain the condensate into a suitable receptacle until clear fuel flows. Tighten the drain plug 2 again. Bleed the fuel system. Bleeding the fuel system

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Procedure: see the section on bleeding the fuel system.

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Maintenance Maintenance tasks

3.5.26

Draining off condensate from the fuel separator (L538)

Valid for:

L538 - 432 / from 8508

Make sure that: â&#x20AC;&#x201C; The machine is in maintenance position 1. â&#x20AC;&#x201C; The engine compartment hood is open. Procedure for draining condensate from the fuel separator Carefully clean the fuel separator and the area around it. Place the receptacle under the fuel separator (possibly attaching a suitably sized hose to the drain valve 3). Open the bleeder screw 1 on the filter cover by two or three turns. Push in the stop cock 2 on the drain valve 3 and open it anticlockwise. Drain off the condensate into a suitable receptacle. Close the stop cock 2 and the bleeder screw 1 again.

Bleed the fuel system. Bleeding the fuel system

3.5.27

Procedure: see the section on bleeding the fuel system.

Draining off condensate and sediment from the fuel tank Make sure that the machine is in maintenance position 1. Procedure Unscrew the sealing cap 1 on the drain valve 2 on the bottom of the fuel tank. Screw the drain hose onto the drain valve 2. Drain the condensation and sediment into a suitable receptacle until clean fuel begins to flow. Unscrew the drain hose and screw the sealing cap 1 onto the drain valve 2 and tighten it.

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3.5.28

Checking the air suction hoses for leaks and tight fitting Make sure that: – The machine is in maintenance position 1. – The engine compartment hood is open. Procedure

Checking the air suction hoses for leaks and tight fitting Check the following hoses and clips for looseness, damage and cracks: – The intake hose 4 between the air intake pipe 2 and the filter housing 5 – The turbo hose 7 between the filter housing 5 and the turbocharger – Check that the hose clips 3 and 6 on these hoses are tight.

3.5.29

Cleaning the air filter service cap and dust extraction valve Important: With the engine running at lower idle speed, you should clearly feel air pulsating at the dust extraction valve. If the valve is damaged, the dust extraction function is impaired and the filters become clogged more quickly. Make sure that: – The machine is in maintenance position 1. – The engine compartment door is open.

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Maintenance Maintenance tasks

Procedure for cleaning the dust extraction valve

Air filter 1 Secondary element 4 Fixing clips 2 Primary element 5 Dust extraction valve 3 Service cap 6 Air filter housing Press the rubber seal on the dust extraction valve 5 several times to remove the dust from the service cap 3. When working in dusty conditions, check and empty the dust extraction valve 5 more often. If the dust extraction valve is damaged or stays open: Replace the dust extraction valve. Procedure for cleaning the service cap Open the fixing clips 4 on the service cap 3 and take the cap off. Clean the service cap. Put the service cap back on the filter housing. The dust extraction valve 5 must face down. Only when the lid completely covers the filter housing can you close the fixing clips without excessive force. Close the fixing clips 4.

3.5.30

Checking that the air filter vacuum switch works Make sure that: â&#x20AC;&#x201C; The machine is in maintenance position 1. â&#x20AC;&#x201C; You have a big enough plate available. Procedure

Testing the vacuum switch

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Take the rain cap 1 off the intake pipe 2. Starting the diesel engine. Slowly and carefully push the plate over the opening of the intake pipe 2. At the same time, check whether the indicator lamp in the cab lights up or the warning buzzer sounds. If you hear or see no warning signal when the intake pipe is just sealed, check the vacuum switch and the wiring, and replace it if necessary.

3.5.31

Changing the air filter main element when indicated by the vacuum switch The primary element 2 should be replaced when the air filter contamination symbol field on the display unit lights up. If the air filter contamination symbol field remains lit after the primary element 2 has been serviced then the secondary element 1 must also be replaced. Make sure that: â&#x20AC;&#x201C; The machine is in maintenance position 1. â&#x20AC;&#x201C; The engine compartment door is open. Procedure

Air filter 1 Secondary element 4 Fixing clips 2 Primary element 5 Dust extraction valve 3 Service cap 6 Air filter housing Open the fixing clips 4 on the service cap 3 and take the cap off. Remove the primary element 2 and the secondary element 1. To do this pull or turn the elements gently upwards, downwards or to the side in order to release the seal. Ensure that all dirt is removed from the filter housing before inserting a new filter cartridge. The secondary element 1 should be replaced every third time the main filter element 2 is replaced. Lightly oil the seal surfaces before installing the filter cartridges (for the primary element 2 this is on the inside, for the secondary element 1 on the outside). Re-insert the filter elements 1 and 2 and make sure that they are correctly fitted. Clean the service cap 3 and put it on the filter housing with the dust extraction valve 5 facing down. Only when the lid completely covers the filter housing can you close the fixing clips without excessive force. Close the fixing clips 4.

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3.5.32

Checking the exhaust lines for leaks and tight fitting (L524)

Valid for:

L524 - 438 / from 0101

Make sure that: â&#x20AC;&#x201C; The machine is in maintenance position 1. â&#x20AC;&#x201C; The engine compartment door is open. Procedure

Check that the clip 5, nuts 4 and seal 6 on the exhaust pipe between the turbocharger and the silencer are tightly fastened and do not leak. Check that the clip 2, tailpipe bolts 1 and silencer bolts 3 are tight. Also check that the flexible pipe is flush B (along both axes) and the length is balanced A (the effective length must be between the maximum and minimum lengths of the flexible section).

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3.5.33

Checking the exhaust lines for leaks and tight fitting (L534)

Valid for:

L534 - 434 / from 0101

Make sure that: â&#x20AC;&#x201C; The machine is in maintenance position 1. â&#x20AC;&#x201C; The engine compartment door is open. Procedure

Check that the clip 6, nuts 4 and seal 5 on the exhaust pipe between the turbocharger and the silencer are tightly fastened and do not leak. Check that the clip 2, tailpipe bolts 1 and silencer bolts 3 are tight. Also check that the flexible pipe is flush B (along both axes) and the length is balanced A (the effective length must be between the maximum and minimum lengths of the flexible section).

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3.5.34

Checking the exhaust lines for leaks and tight fitting (L538)

Valid for:

L538 - 432 / from 0101

Make sure that: â&#x20AC;&#x201C; The machine is in maintenance position 1. â&#x20AC;&#x201C; The engine compartment door is open. Procedure

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3.5.35

Checking the coolant level Make sure that: – The machine is in maintenance position 1. – The engine compartment hood is open. Procedure

Check the coolant level in the sight glass 2 on the equalising reservoir. The coolant level should be visible in the sight glass 2. If you cannot see the coolant level in the sight glass 2: Top up the coolant via the filler neck 1 to the top of the sight glass.

3.5.36

Changing the coolant filter (L538)

Valid for:

L538 - 432 / from 0101

Regularly changing the filter ensures that the DCA 4 concentration in the coolant is maintained, because the new filter contains a quantity of DCA 4. Make sure that: – The machine is in maintenance position 1. – The engine compartment hood is open. – You have a coolant filter ready. Procedure Close the cut-off valve 1 on the filter housing (the handle on the valve points up). Release the water filter 2 with a strap wrench and unscrew it. Clean any pieces of seal off the seal faces on the bracket. Lightly coat the rubber seal ring on the water filter with engine oil. Screw the new water filter 2 onto the bracket, and tighten it a half to three-quarter turn. Open the cut-off valve 1 (the handle on the valve is horizontal).

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3.5.37

Checking the coolant antifreeze concentration (L524, L534)

Valid for:

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

All year round, the coolant must contain at least 50 % by volume of concentrated antifreeze, but not more than 60 % by volume. This protects against freezing down to around - 37 °C. Make sure that: – The machine is in maintenance position 1. – The engine compartment hood is open. – You have the optical density tester kit or antifreeze tester ready. Procedure for checking the antifreeze concentration Caution

There is a danger of scalding due to coolant escaping under pressure.

! Only open the sealing cap on the filler neck when the engine has cooled down - the coolant temperature indicator in the indicator unit should be in the lower third of the segment field. Carefully open the sealing cap on the filler neck. Take a sample of the coolant and check the antifreeze concentration using the test tool. If the antifreeze concentration is too low: Refill with pure antifreeze until the required value is attained. Procedure for correcting the antifreeze concentration If the antifreeze concentration is too low: Drain off the coolant and top up with pure antifreeze according to the following diagram. Caution

There is a risk of damage to the diesel engine. Too much antifreeze and corrosion inhibitor impairs the cooling effect. This eventually causes damage to the diesel engine.

! Never use more than 60 % antifreeze and corrosion inhibitor.

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Selection for antifreeze concentration 1 Amount of pure antifreeze to be added in litres 2 Guidelines

3 Example -15 °C 5 Total capacity of cooling system 4 Measured coolant freezing in litres point in °C Procedure for the example -15 °C: If the total capacity is 25 litres and you measure a temperature of -15 °C in the cooling system, follow the guideline 3 (starting from the measured temperature) to the left down to the vertical line indicating the filling quantity for the cooling system 5 and from this point horizontally to the left edge. This gives you the topping up quantity of pure antifreeze and corrosion inhibitor 1 to be added in order to achieve protection down to -37 °C. To restore the correct mixture ratio, you must drain off at least the previously calculated quantity from the cooling system. Top up with the correct quantity of pure antifreeze and corrosion inhibitor. The coolant previously drained off can be used if necessary to restore the required coolant level.

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Using coolant without antifreeze

Using anti-corrosion agent without antifreeze In exceptional cases and when outside temperatures never fall below freezing, such as tropical zones, where it is demonstrable that no approved antifreeze and corrosion protection agent is available, corrosion inhibitors may be used. The coolant must be replaced once a year. The mixing ratio must consist of 7.5 % corrosion inhibitor and 92.5 % water. The Gefo 2710 refractometer is recommended for testing.

Procedure for checking the coolant corrosion inhibitor concentration Caution

There is a danger of scalding due to coolant escaping under pressure

Checking the mixing ratio with a refractometer

Gefo refractometer no. 2710 Refractometer – Screw for adjusting to zero line (water line) – The focus is set by turning the eyepiece – Soft eyepiece flap – Sturdy metal housing – Reinforced rubber grip Measuring procedure – Clean the cover and the prism carefully – Place 1 or 2 drops of test fluid on the prism – The fluid is distributed by closing the prism – Look through the eyepiece against a light background and focus the scale – Read off the values on the blue line

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Conversion table from Brix to corrosion inhibitor concentration (%vol) If the concentrations are not correct: Refill with corrosion inhibitor until the required value is attained. Procedure for correcting the coolant corrosion inhibitor concentration Drain off coolant Add the required quantity of corrosion inhibitor. Approved water-soluble corrosion inhibitors (concentrate) Product designation

Manufacturer

Caltex CL Corrosion Inhibitor Concentrate Chevron Texaco Heavy Duty Extended Life Corrosion Inhibitor Nitrite Free Havoline Extended Life Corrosion Inhibitor (XLI) Total WT Supra

Caltex Chevron Texaco ARTECO Total

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3.5.38

Checking the coolant antifreeze and DCA 4 concentration (L538)

Valid for:

L538 - 432 / from 0101

The coolant must contain at least 50 % by volume of antifreeze and corrosion inhibitor. This protects against freezing down to around -37 °C. Furthermore, the coolant must contain between 0.3 and 0.8 units of DCA 4 per litre. Make sure that: – The machine is in maintenance position 1. – The engine compartment hood is open. – The Fleetguard CC 2602 M test kit for the DCA 4 and anti-freeze concentration is ready. Procedure for checking the coolant antifreeze and DCA 4 concentration Caution

There is a danger of scalding due to coolant escaping under pressure.

! Only open the sealing cap on the filler neck when the engine has cooled down - the coolant temperature indicator in the indicator unit should be in the lower third of the segment field. Carefully open the sealing cap on the filler neck. Test the anti-freeze and DCA 4 concentrations with the Fleetguard CC 2602 M test kit. If the concentrations are not correct: Top up with anti-freeze and DCA 4 to the correct levels. Procedure for correcting the coolant antifreeze and DCA 4 concentration If the antifreeze concentration is too low: Drain off the coolant and top up with pure antifreeze according to the following diagram. Along with the calculated amount of pure antifreeze to be topped up, add around 5 units (5 %) of DCA 4. Caution

There is a risk of damage to the diesel engine. Too much antifreeze and corrosion inhibitor impairs the cooling effect. This eventually causes damage to the diesel engine.

! Never use more than 60 % antifreeze and corrosion inhibitor.

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Selection for antifreeze concentration 1 Amount of pure antifreeze to be added in litres 2 Guidelines

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Using coolant without antifreeze

Using DCA 4 without antifreeze and corrosion inhibitor In exceptional cases and when outside temperatures never fall below freezing, such as tropical zones, where it is demonstrable that no approved antifreeze and corrosion inhibitor is available, the coolant may be composed solely of water and DCA 4. In order to protect the cooling system from corrosion in this case: – About twice as much DCA 4 must be used in relation to the mixing ratio of antifreeze and corrosion inhibitor and DCA 4. – The DCA 4 concentration must be between 0.6 - 1.06 units per litre. – The coolant must be replaced once a year. The Fleetguard CC 2602 M test kit is recommended for testing.

Procedure for checking the coolant corrosion inhibitor concentration Caution

There is a danger of scalding due to coolant escaping under pressure

Checking the mixing ratio with a refractometer

GEFO refractometer no. 2710 Refractometer – Screw for adjusting to zero line (water line) – The focus is set by turning the eyepiece – Soft eyepiece flap – Sturdy metal housing – Reinforced rubber grip Measuring procedure – Clean the cover and the prism carefully – Place 1 or 2 drops of test fluid on the prism

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– The fluid is distributed by closing the prism – Look through the eyepiece against a light background and focus the scale – Read off the values on the blue line

Approved water-soluble corrosion inhibitors (concentrate) Product designation

Manufacturer

DCA 4 Diesel Coolant Additives Caltex CL Corrosion Inhibitor Concentrate Chevron Texaco Heavy Duty Extended Life Corrosion Inhibitor Nitrite Free Havoline Extended Life Corrosion Inhibitor (XLI) Total WT Supra

Fleetguard Caltex Chevron Texaco ARTECO Total

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3.5.39

Cleaning the cooling system Clean the cooler whenever necessary in order to ensure proper cooling. In dusty environments, check the cooler every day and clean it if necessary. Dust and other contaminants can be removed from the cooling fins with water jets, steam or compressed air. Compressed air is preferable. Make sure that: – The machine is in maintenance position 1. – The engine compartment hood is open. – The cooler flap is open. – The air conditioning condenser (optional) is pulled forward. Procedure

Caution

The cooler fins may be damaged if they are not treated with due care.

! Do not use hard objects or excessive water pressure for cleaning. Clean the cooler units 2 and air conditioning condenser (optional) 1 with compressed air, steam or water. Compressed air is preferable.

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3.5.40

Changing coolant with antifreeze (L524, L534)

Valid for:

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

Use clean, fresh water with a Ph value between 6.5 and 8.5 and a low sulphate / chlorine content for preparing the coolant. The coolant must be prepared outside the cooling system. Make sure the mixing ratio of the new coolant is correct. See the section on checking the antifreeze. Always dispose of any coolant which you have drained off but no longer need according to the applicable regulations. Make sure that: – The machine is in maintenance position 1. – The engine compartment hood is open. – You have a suitable receptacle and drain hose (on-board tools) ready. Procedure

Caution

There is a danger of scalding due to coolant escaping under pressure

! Only open the sealing cap on the filler neck when the engine has cooled down - the coolant temperature indicator in the indicator unit should be in the lower third of the segment field. Set the cab heater to warm. Open the cap A on the filler neck of the equalising reservoir. Unscrew the plug 2 on the drain valve, screw on the drain hose and catch the coolant in the receptacle. To completely drain and flush the engine, remove the plug 1. If the coolant is very dirty or corrosive, flush out the cooling system several times. Close the plugs 2 and 1. Dispose of the drained coolant.

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Caution

There is a risk of damage to the diesel engine. Never top up the cooling system when the engine is still hot. If the proportion of antifreeze and corrosion protection agent is too high, the cooling effect is reduced, causing damage to the engine.

! The coolant must contain at least 50 % but no more than 60 % by volume of concentrated antifreeze. Top up the coolant via the filler neck of the equalising reservoir to the top of the sight glass 2. Place the sealing cap A on the filler neck and tighten it. Start the engine and bring it to operating temperature. Turn the heater to warm and then check the coolant level again.

3.5.41

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

Valid for:

L538 - 432 / from 0101

Use clean, fresh water with a Ph value between 6.5 and 8.5 and a low sulphate / chlorine content for preparing the coolant. The coolant must be prepared outside the cooling system. Make sure the mixing ratio of the coolant to be added is correct. See the section on checking the anti-freeze and DCA 4 concentration of the coolant. Always dispose of any coolant which you have drained off but no longer need according to the applicable regulations. Make sure that: â&#x20AC;&#x201C; The machine is in maintenance position 1. â&#x20AC;&#x201C; The engine compartment hood is open. â&#x20AC;&#x201C; You have a suitable receptacle ready. Procedure

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Caution

There is a danger of scalding due to coolant escaping under pressure.

! Only open the sealing cap A on the filler neck when the engine has cooled down - the coolant temperature indicator in the indicator unit should be in the lower third of the segment field. Set the cab heater to warm. Open the cap A on the filler neck of the equalising reservoir. Open the drain plug 2 on the oil cooler housing 1 and let the coolant flow into the receptacle. Screw the drain plug 2 back in and tighten it. Top up the coolant via the filler neck of the equalising reservoir to the top of the sight glass B. Place the sealing cap A on the filler neck and tighten it. Start the engine and bring it to operating temperature. Turn the heater to warm and then check the coolant level again.

3.5.42

Lubricating the pilot control unit, cleaning the magnets and lubricating the universal joint (L524)

Valid for:

L524 - 438 / from 0101

Make sure that the machine is in maintenance position 1. Procedure The bucket return-to-dig retaining solenoid is fitted inside the actuation ring 3. The float position/lift kick-out retaining solenoid is fitted under the universal joint 5 in the pilot control device. Turn off the ignition and take out the key. This prevents inadvertent activation of the working attachment. Take the rubber sleeve 1 off the covering. If necessary clean the mechanical components, including the solenoids, using compressed air. Move the control lever in the appropriate direction for better access. Lubricate the tappet 4, universal joint 5 and the joint 6 with a brush. Fit the rubber sleeve 1 on the covering.

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3.5.43

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

Valid for:

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

Make sure that the machine is in maintenance position 1. Procedure Take the rubber sleeve 5 of the control lever off the retaining plate 4. Move the control lever in the appropriate direction for better access. Clean the retaining solenoids 1 with a brush. Lubricate the universal joints 2 and the discs 3 with a brush. Start the machine and check the retaining function of the solenoids. Fit the rubber sleeve of the control lever on the retaining plate.

3.5.44

Checking the oil level in the hydraulic tank – – – –

Make sure that: The machine is cold. The machine is in maintenance position 1. The cooling system flap is open.

Procedure for checking the hydraulic oil level The red maximum oil level marking shows the correct oil level. Check the oil level in the sight glass 1. If the oil level is too low: Top up with hydraulic oil.

Procedure for topping up with hydraulic oil Release the tank pre-pressure: Unscrew the bleeder filter 1 on the hydraulic tank. The hydraulic oil may only be poured in through the return strainer. Open the cover of the return strainer. Top up the hydraulic oil to the red oil level mark (see the sticker). Put the cover on the housing with the spring and tighten it up. Screw on the bleeder filter.

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3.5.45

Draining water and sediment from the hydraulic tank Make sure that: – The machine has not been used for at least 3 hours. – The machine is in maintenance position 1. – The engine compartment door is open. – You have a receptacle ready for water and oil. Procedure Unscrew the plug from the drain valve 1. Connect the drain hose and let the water and sediment flow into the receptacle. Take off the drain hose and screw the plug into the drain valve 1.

3.5.46

Changing the hydraulic oil Make sure that: – The machine is at operating temperature. – The machine is in maintenance position 1. – The engine compartment hood and door are open. – You have a receptacle of around 100 l capacity for the used oil. Procedure Release the tank pre-pressure: Unscrew the bleeder filter 1. Unscrew the plug from the drain valve 2. Connect the drain hose and let the oil flow into the receptacle. Take off the drain hose and screw the plug into the drain valve. The hydraulic oil may only be poured in through the return strainer 2. Open the cover of the return strainer 2. Top up the hydraulic oil to the red oil level mark in the sight glass 3 (see the sticker). Put the cover on the housing with the spring and tighten it up. Screw on the bleeder filter 1.

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3.5.47

Checking and cleaning the magnetic rod on the hydraulic tank Make sure that: – The machine is in maintenance position 1. – The cooling system flap is open. Procedure Release the tank pre-pressure: Unscrew the bleeder filter 1 on the hydraulic tank by two turns. Release the bolts on the lid and slowly lift the lid with the magnetic rod 2.

Troubleshooting Serious contamination or large metal fragments on the magnetic rod may indicate damage to the hydraulic system. In this event, locate the problem and rectify it. Carefully clean the magnetic rod. Place the O-ring and cover with the magnetic rod on the housing. Tighten the screws on the cover. Screw on the bleeder filter 1.

3.5.48

Changing the hydraulic tank return suction filter Make sure that: – The machine is in maintenance position 1. – The engine compartment hood is open. Procedure Release the tank pre-pressure: Unscrew the bleeder filter 1 on the hydraulic tank by two turns. Release the bolts on the lid and slowly lift the lid with the magnetic rod 2. Take out the filter element 3.

Troubleshooting Serious contamination or large metal fragments in the filter element or on the magnetic rod may indicate damage to the hydraulic system. In this event, locate the problem and rectify it. Put in a new filter element. Carefully clean the magnetic rod. Place the O-ring and cover with the magnetic rod on the housing and tighten the screws on the cover. Screw in the plug 4. Screw on the bleeder filter 1.

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3.5.49

Changing the hydraulic tank bleeder filter Make sure that: – The machine is in maintenance position 1. – The engine compartment hood is open. Procedure You cannot clean the bleeder filter. The bleeder filter 1 and its plastic housing must be changed at the intervals in the maintenance schedule. Unscrew the old bleeder filter. Screw on the new bleeder filter.

3.5.50

Checking the steering Procedure Start the diesel engine. Without moving the machine, turn the steering in both directions and check that it is functioning properly.

3.5.51

Lubricating the bearing points on the steering cylinders Make sure that: – The machine is in maintenance position 1. – The articulation lock is engaged. Procedure Lubricate the rod-end bearing point 1 of the steering cylinder. Lubricate the base-end bearing point 2 of the steering cylinder.

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Maintenance Maintenance tasks

3.5.52

Checking the service brake and parking brake Procedure for checking the service brake Make sure that there is enough room to check the service brake.

There is a danger of driving into bystanders or obstacles.

Warning

! Do not allow anyone into the danger area while these tests are being conducted. Start the machine, and drive it forwards in travel range 1 at around 8 km/h. Push the inch/brake pedal 1 all the way down. The machine must come to an abrupt stop. Troubleshooting If the braking effect is too slight or entirely absent: Contact LIEBHERR CUSTOMER SERVICE. Procedure for checking the parking brake Make sure that there is enough room to check the parking brake. There is a danger of driving into bystanders or obstacles.

Warning

! Do not allow anyone into the danger area while these tests are be!

ing conducted. Perform the test on level ground with no obstacles. Start the machine, select travel range 1 and forward travel direction. Drive the machine forwards at around 3 km/h and press the parking brake switch.

The symbol field 1 for the parking brake lights up. The machine must come to an abrupt halt. Troubleshooting If the braking effect is too slight or entirely absent: Contact LIEBHERR CUSTOMER SERVICE.

3.5.53

Checking the gap and wear on the parking brake linings Wear on the brake pads can increase the gap between them and the brake disc. If the gap is too wide, it must be adjusted. Make sure that: â&#x20AC;&#x201C; The machine is in maintenance position 2. â&#x20AC;&#x201C; Wedges are in place to secure the machine against rolling away. Procedure for checking the wear on the brake linings Visually check the thickness of the lining on both pads 8. If the lining is less than 1 mm, change the pads as follows. Start the engine and press the parking brake switch (the brake is open, under oil pressure). Unscrew the cap 7, loosen the nut 5 and unscrew the adjusting screw 6. Take out the cotter pin 4 and unscrew the castle nut 3. Remove the guide pin 1 and swing out the entire brake caliper. Replace the worn brake pads 2 with new ones. Fit the brake caliper and the guide pin 1 in the reverse order.

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Maintenance tasks

Adjust the brake pad gap as described below. Procedure for checking the brake pad gap Start the engine and press the parking brake switch (the brake is open, under oil pressure). Check the gap X with a feeler gauge (it should be 1 Âą 0.5 mm). If the gap is not correct, adjust it to the minimum 0.5 mm. Unscrew the cap 7 and loosen the lock nut 5. Tighten the adjusting screw 6 until the gap X is 0.5 mm. Tighten the lock nut 5. Engage the parking brake several times and check the gap again. Screw on the cap 7 and tighten it.

3.5.54

Checking the indicator lamps and lighting For the layout of the lighting components and symbol fields on the display, see the section on operation in the chapter on operation and handling in the operating manual. Procedure Start the diesel engine and check that the lighting components and symbol fields light up.

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Maintenance Maintenance tasks

3.5.55

Checking the batteries, fluid level and terminals The batteries are housed in the right ballast weight and can be accessed by opening the engine hood. The batteries must always be in perfect condition in order for the machine to work reliably. Make sure that: â&#x20AC;&#x201C; The machine is in maintenance position 1. â&#x20AC;&#x201C; The battery main switch is switched off and the main switch key is taken out.

Warning

Batteries give off explosive gases. Battery acid is highly corrosive.

! Do not smoke. Avoid naked flames when handling, servicing or recharging batteries.

Caution

Beware of sparks and explosions!

! Use a special terminal brush. Wipe the battery with a clean cloth. Clean the terminals and the connectors. To guarantee a good connection, check that the connectors are tight on the terminals, and tighten them if necessary. Smear the terminals and connectors with acid-proof grease such as vaseline. At very high temperatures, the acid level in the individual cells can drop due to different rates of evaporation. Open the plugs on each cell and check the acid level. Check the charge using an acid density tester. If the charge is too low (acid density below 1.26 kg/l): Recharge the batteries. If there is a risk of frost, it is important that the batteries are not discharged. Otherwise the electrolyte can freeze and irreparably damage the battery. If the acid level is too low: Top up with distilled water to around 10 mm above the plates.

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Maintenance tasks

3.5.56

Checking the transfer gear oil level Procedure

Caution

Do not open the filling, drain and level plugs when the transfer gear is hot, as pressurised oil can cause scalding.

! Slowly unscrew the filling plug 2 to allow any excess pressure to subside. Remove the filling plug 2 on the axle transfer gear. The oil level must be visible in the opening. If you cannot see the oil level in the transfer gear or if it is much lower than the opening: Top up with gear oil using the same opening. If the oil level is too high: Drain the oil to the correct level and rectify the cause.

3.5.57

Changing the transfer gear oil Make sure that: – The machine is in maintenance position 2. – You have gear oil approved in the LH specifications ready. – The oil in the gearbox is warm. – You have a suitable oil receptacle ready for disposal. Procedure

Caution

Do not open the filling, drain and level plugs when the transfer gear is hot, as pressurised oil can cause scalding.

! Slowly unscrew the filling plug 2 to allow any excess pressure to subside. Remove the filling plug 2 on the axle transfer gear. Open the drain plug 1 on the gearbox and drain the oil into a suitable receptacle. After completely draining, screw the drain plug 1 back in. Using a suitable hand pump or filling hose with a funnel, top up oil via the filler plug opening 2 until the level is correct or oil comes out of the opening. Screw in the filling plug 2 on the axle transfer gear. Dispose of the used oil properly.

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Maintenance Maintenance tasks

3.5.58

Checking the axle oil levels Make sure that: â&#x20AC;&#x201C; The machine is in maintenance position 2.

Checking the oil level in the differential Procedure Caution

Do not open the filling, drain and level plugs when the differential or wheel hub is hot, as pressurised oil can cause scalding.

! Slowly unscrew the filling plug 1 to allow any excess pressure to subside.

Open the filling plug 1 and check the oil level. If you cannot see the oil level in the differential or if it is much lower than the opening: Top up with gear oil using the same opening. If the oil level is too high: Drain the oil to the correct level and rectify the cause. Close the filling plugs 1.

Checking the oil level in the wheel hub Procedure Caution

Do not open the filling, drain and level plugs when the differential or wheel hub is hot, as pressurised oil can cause scalding.

! Slowly unscrew the filling plug 1 to allow any excess pressure to subside.

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Maintenance tasks

Turn the wheel hubs until the filling plug 1 is horizontal. Open the filling plug 1 on the wheel hub and check the oil level. If you cannot see the oil level in the wheel hub or if it is much lower than the opening: Top up with gear oil using the same opening. If the oil level is too high: Drain the oil to the correct level and rectify the cause.

3.5.59

Changing the axle gear oil Make sure that: – The machine is in maintenance position 2. – You have gear oil approved in the LH specifications ready. – The oil in the gearbox is warm. – You have a suitable oil receptacle ready for disposal.

Changing the oil in the differential Procedure

Open the filling plugs 1. Remove the three drain plugs 2 and catch the oil in suitable receptacles. After completely draining (do not flush), screw the drain plugs 2 back in. Top up the oil in the differential to the filling opening (you can use both filling openings). Check the oil level after a few minutes and top up if necessary. Screw in the filling plugs 1.

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Maintenance Maintenance tasks

Changing the oil in the wheel hub Procedure

Turn the wheel hub until the filling plug 1 is at the top. Slowly unscrew the filling plug to let off any pressure. Turn the wheel hub until the filling plug 1 is right at the bottom. Open the filling plug 1 and drain the oil into a receptacle. After completely draining, turn the wheel hub until the mark on the filling plug 1 is horizontal. Top up the oil to the marking on the filling opening and screw in the plug.

3.5.60

Checking the tightness of the wheels (once after 50, 100 and 250 h) Make sure that: â&#x20AC;&#x201C; The machine is in maintenance position 1. â&#x20AC;&#x201C; A torque wrench with a measuring range of over 650 Nm is available. Procedure Note: This one-off maintenance tasks scheduled for 50, 100 and 250 service hours must be performed every time the wheels are changed. â&#x20AC;&#x201C; Check that the nuts on all four wheels have been tightened with the required torque. See the technical data section.

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Maintenance tasks

3.5.61

Checking and lubricating the drive shaft Make sure that the machine is in maintenance position 1. Procedure Lubricate the drive shaft at both universal joints. Check the play of the drive shaft in the bearings.

3.5.62

Checking and adjusting the tyre pressure Make sure the air pressure in the tyres on both axles is correct for the tyre type, the way the machine is used and the working attachments fitted. The reference values can be found in the operating manual, in the technical data section. Procedure The air pressure in the tyres has a significant influence on the overall performance of the machine.

Explosiรณn de neumรกtico

Warning

Exploding tyres can cause serious injury. If the tyre inflation equipment is incorrectly or carelessly used or if the tyre pressure is too high, the tyres may burst or the rims may come off, causing severe, or possibly even fatal injuries.

! Use a sufficiently long hose with a self-locking adapter for pumping the tyres.

! Always keep outside the danger zone when tyres are being pumped up. Check the air pressure in all tyres with a measuring gauge and adjust it if necessary.

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Maintenance Maintenance tasks

3.5.63

Lubricating the articulation bearing and rear oscillating bearing Make sure that: â&#x20AC;&#x201C; The machine is in maintenance position 1. â&#x20AC;&#x201C; The articulation lock is engaged. Procedure Lubrication points on the right-hand side of the central lubricating rail: 1 Front oscillating bearing lubrication point 2 Rear oscillating bearing lubrication point Lubricate the front oscillating bearing: lubrication point 1 on the right central lubrication rail. Lubricate the rear oscillating bearing: lubrication point 2 on the right central lubrication rail.

Articulation bearing lubrication points 1 Top articulation bearing lubrica2 Bottom articulation bearing lubrition point cation point Lubricate the top of the articulation bearing: lubrication point 1 on the articulation bearing. Lubricate the bottom of the articulation bearing: lubrication point 2 on the articulation bearing.

3.5.64

Greasing the cab door hinges Procedure Lubricate the door hinges with a grease gun.

3.5.65

Cleaning or replacing the fresh air and recirculated air filter The cab fresh air filter can be accessed from the right rear outside of the cab. Make sure that the machine is in maintenance position 1.

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Maintenance tasks

Procedure Remove the star grip screw 1 and take off the ventilation grille 2. Undo the hex screw 3 and take off the holder 4. Pull out the filter element 5 on the left and remove it. Clean the filter element 5 if necessary. Carefully remove any dust which has collected in the fresh air filter duct. (The area behind the filter must be completely clean.) Put in the new or clean filter element 5 and fasten it with the holder 4 and screw. The holder 4 must exert moderate pressure on the seal face of the filter element. Make sure it is correctly installed (the arrow shows the direction of air flow). Put in the ventilation grille 2 and fasten it with the star grip screw 1.

3.5.66

Checking the indicator and filling level beads in the dryercollector unit of the air conditioner The dryer-collector unit is located under the left cab access.

Sight glass on the dryer-collector unit (OLD and NEW) 1 Dryer sight glass on older ma4 Dryer sight glass on new machines chines (until 10.2005) (after 11.2005) 2 White filling level bead 5 White filling level bead 3 Indicator bead: 6 Indicator bead: Blue for dry coolant Orange for dry coolant Pink for damp coolant Colourless for damp coolant Check the blue/orange bead 2 (moisture indicator). If the blue/orange bead 2 has turned pink/white: There is moisture in the refrigerant circuit. You must replace the dryercollector and the compressor oil and refill the system. The white bead 1 shows the filling level of R134a refrigerant in the circuit and acts as an indicator during initial filling. The white bead 1 must be at the top of the sight glass.

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Maintenance Maintenance tasks

The filling level can vary due to temperature fluctuations. It also sinks in time due to natural leakage. This does not impair operation. If the cooling performance deteriorates, one of the causes can be a low refrigerant level. In normal circumstances, one filling lasts for three to five years.

3.5.67

Checking and lubricating the bearings and lubrication points on Z lift arms Make sure that the machine is in maintenance position 1.

Lift arm maintenance position If the lubrication points near the bucket coupling are poorly accessible, make sure the working attachment is detached.

Z lift arms without quick-change device Lubricating the lift arms and cylinders

Lubrication points on lift arms and lift cylinder 1 Front lift cylinder lubrication point 3 Top lift arm lubrication point 2 Rear lift cylinder lubrication point Lubricate the bearing at the top of the lift arms: lubrication point 3 on the left and point 3 on the right. Lubricate the two points 1 and 2 on the left lift cylinder. Lubricate the two points 1 and 2 on the right lift cylinder.

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Maintenance tasks

Lubricating the tilt cylinder, linkage and connecting link

Lubrication points on the tilt cylinder, linkage and connecting link 1 Linkage lubrication point 3 Rear tilt cylinder lubrication point 2 Front tilt cylinder lubrication point 4 Connecting link lubrication point Lubricate point 1 on the linkage. Lubricate the bearing on the tilt cylinder: lubrication point 2 on the front and point 3 on the rear. Grease a lubrication point 4 on the connecting link.

3.5.68

Checking and lubricating the bearings and lubrication points on P lift arms Make sure that the machine is in maintenance position 1.

Lift arm maintenance position If the lubrication points near the bucket coupling are poorly accessible, make sure the working attachment is detached.

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P lift arms with quick-change device Lubricating the lift arms and cylinders

Lubrication points on lift arms and lift cylinder 1 Bottom lift arm lubrication point 2 Front lift cylinder lubrication point

3 Rear lift cylinder lubrication point 4 Top lift arm lubrication point

Lubricate the bearing at the top of the lift arms: lubrication point 4 on the left and point 4 on the right. Lubricate the two points 2 and 3 on the left lift cylinder. Lubricate the two points 2 and 3 on the right lift cylinder. Lubricate the two points at the bottom of the lift arms 1. Lubricating the tilt cylinder and links

Lubrication points on the tilt cylinder, linkage and connecting links 1, 3 Front link lubrication points 5, 6 Rear linkage lubrication point 2 Front linkage lubrication point 7 Rear link lubrication pint 4 Front tilt cylinder lubrica8 Rear tilt cylinder lubrication point tion point Lubricate one point 2 on the front left and right linkage. Lubricate two points 1 and 3 on the left and right front link. Lubricate the bearing on the tilt cylinders: lubrication point 4 on the front and point 8 on the rear. Lubricate two points 5 and 6 on the rear left and right linkage. Lubricate one point 7 on the rear left and right connecting link.

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Maintenance tasks

3.5.69

Checking and lubricating the bucket bearing on Z lift arms The lower bucket bearings should be lubricated daily if necessary.

Z lift arms without quick-change device Checking the bucket bearing

Bucket bearing 1 Bucket arm bearing bushing 2 Connecting link bearing bushing 3 Radial seal

4 Bucket arm 5 Bucket bearing plate A-A section

Check the bearing bushings 1 on the bucket arm for wear and if necessary replace the radial seal rings 3. Check the bearing bushings 2 on the bucket arm for wear and if necessary replace the radial seal rings 3.

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Maintenance Maintenance tasks

Lubricating the bucket bearing

Bucket coupling lubrication points 1 Connecting link lubrication point

2 Bucket bearing lubrication point A-A section Grease a lubrication point 1 on the connecting link. Lubricate point 2 on the left/lower bucket bearing. Lubricate point 2 on the right/lower bucket bearing.

3.5.70

Checking and lubricating the bucket bearing on P lift arms The lower bucket bearings should be lubricated daily if necessary.

P lift arms with quick-change device

Quick-change device lubrication points Grease a lubrication point 1 on the right bearing. Grease a lubrication point 2 on the left bearing.

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Maintenance tasks

3.5.71

Checking the bucket stops on Z lift arms Check the buckets stops for wear. Make sure that the machine is in maintenance position 2. If the sequence is correct, there is play at stop 1 and no play at stop 2. The stop sequence is the same for lift arms with and without a quickchange device.

Lift arms with Z kinematics a Lift arms without quick-change device:

b Lift arms with quick-change 2 Linkage stop device: 1 Bucket stop Start the machine and raise the lift arms to about half way. Retract the tilt cylinder so that there is no play at the stop 2 on the linkage. Turn off the engine. Check that the gap 1 at the bucket stop is correct. Description Gap

Value

Unit

5 Âą3

If it is not correct: Contact LIEBHERR CUSTOMER SERVICE.

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Maintenance Testing and adjustment tasks

3.6 Testing and adjustment tasks 3.6.1

Preparing for testing and adjustment During the warranty period, only trained and authorised specialist staff may carry out adjustments on the machine. Make sure that: – The machine is in maintenance position 2. – The machine is at operating temperature (except when testing the air conditioning). – The adjustment data for the machine is available or known. – Seals and safety caps are at hand. – The following special tools are available. Special tools Number Description Manometer, 0 - 40 bar class 1.0 2

ID no. 7361 288

Manometer, 0 - 600 bar class 1.0

5002 866

4000 mm test leads

7009 134

1500 mm test leads

7002 475

Tachometer (Ono Sokki)

7009538

Temperature measuring device

7020 372

LMS (alternative)

Safety precautions for testing and adjustment Always observe the accident prevention regulations during maintenance work. See the safety regulations section for measures to ensure safe maintenance. Make sure that visual contact between the operator in the cab and maintenance personnel is always maintained.

Visual contact

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Testing and adjustment tasks

3.6.2 Valid for:

Checking the engine speed L524, L534 L524 - 438 / 0101 - 8795; L534 - 438 / 0101 - 8961

You can measure the engine speed using an electronic tachometer. An impulse signal is taken from the injection pump. Procedure Start the engine. Check that the top and bottom engine speeds are correct.

Adjusting the speed 1 Lower idle speed adjust2 Upper idle speed adjusting screw ing screw If it is not correct: Adjust the stops of the injection pump or the gas pedal.

Checking the engine speed L524, L534 Valid for:

L524 - 438 / from 8796; L534 - 438 / from 8962

When you check or adjust the diesel engine speed, the machine must be at operating temperature (the engine must be at least 50 Â°C). You can change the speed by adjusting the gas pedal. The engine speed can be measured using the following equipment: â&#x20AC;&#x201C; Electronic tachometer. An impulse signal is taken from the injection pump. â&#x20AC;&#x201C; MURPHYGAGE diagnostic device with a signal from the diagnostic interface. Procedure Start the engine and bring it to operating temperature. Check that the top and bottom engine speeds are correct.

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Maintenance Testing and adjustment tasks

Adjusting the speed 1 Nut for upper idle speed 3 Threaded rod for adjusting lower adjusting screw idle speed 2 Upper idle speed adjusting screw 4 Angle encoder fork If it is not correct: Adjust the lower idle speed by changing the length of the threaded rod using the fork 3 and 4. Adjust the upper idle speed using the screw 2.

3.6.3 Valid for:

Description

Value Unit

Lower idle speed

800Âą50 min-1

Upper idle speed

2550+80 min-1

Checking the engine speed L538 L538 - 432 / from 0101

Adjusting the speed L524 - 438 / from 0101 L534 - 434 / from 0101 L538 - 432 / from 0101

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Testing and adjustment tasks

1 Length adjustment mechanism 3 Lower idle speed adjust2 Upper idle speed adjusting screw ing screw If it is not correct: Adjust the stops of the injection pump or the gas pedal. Description

3.6.4

Value

Unit

Lower idle speed

800

±50

min-1

Upper idle speed

2100±80

min-1

Checking the fan motor and fan control pressure relief valve Make the following checks on the fan motor: – Check the pressure relief valve on the fan motor (proportional solenoid or one of the temperature sensors unplugged). – Check the fan at a hydraulic oil temperature between 31 and 55 °C and a cooling water temperature below 71 °C. This test must be performed at upper engine speed.

You can check the fan using the system pressure, measured at the test connection 2 of the fan motor 1.

The temperature must be tested in the ranges stated below. Make sure that: – The hydraulic oil temperature is between 31 and 55 °C – The coolant temperature is below 78 °C If the hydraulic temperature is over 55 °C or the coolant temperature is above 78 °C, the fan speeds up. This makes it impossible to test the fan control.

Checking the fan motor pressure relief valve Connect a manometer (250 bar) to the test connection 2 on the gear pump 1. Disconnect the plug 6 on the fan motor proportional valve 3 or one of the temperature sensors. Start the engine and bring it to top idle speed. Check whether the pressure is correct at top engine idle speed.

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Maintenance Testing and adjustment tasks

If it is not correct: Adjust the pressure relief valve on the proportional valve 3 (using the adjusting screw and a 5 mm open-end spanner - the lock nut is a round nut).

1 Fan pump

2 Hydraulic oil temperature sensor

Turn clockwise to increase the pressure and anticlockwise to reduce it. Remove the cap 5. Adjust the screw 4 on the proportional valve 3. Plug in the disconnected plug again. Description

Value Unit

Fan pressure

175 ±5 bar

Fan speed

2130 ±50 min-1

Checking the fan at a hydraulic oil temperature of 31 °C to 55 °C and coolant temperature below 71 °C The fan speed (system pressure) is tested here in the stated temperature range. Bring the hydraulic oil and coolant up to the required temperatures. Start the engine and bring it to top idle speed. Check whether the pressure is correct at top engine idle speed. If it is not correct: Find and rectify the fault. Description

Value Unit

Fan motor pressure

65 ±10 bar

Fan speed

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1200 ±100 min-1

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Testing and adjustment tasks

3.6.5

Checking the travel hydraulics blocked condition The blocked condition is required for the following tests: – Checking the start of regulation of the travel pump – Checking the travel pump output at 380 bar – Checking the pressure relief and replenishing valve of the travel pump – Checking the pressure cut-off of the travel pump – Checking the variable displacement motor It means that the machine is in a blocked condition. You hold the machine with the service brake and drive against an immobile object. If there is no immobile object available, you can adjust the start of delivery by tightening the adjusting screw on the variable displacement motor 1 by two turns. This restricts the motor 1 to a small swivel angle and the machine can be held with the service brake. The inching function must be deactivated for the blocked condition. The inching function is deactivated by energising the inching deactivation solenoid valve 1. The power supply can come from the pilot control solenoid valve 2. Procedure

Unplug the cable 4 of the inching deactivation solenoid valve 1. Unplug the cable 3 of the pilot control solenoid valve 2 and plug it into the inching deactivation solenoid valve 1. Start the machine and select forward or reverse travel direction. Drive the machine against firm resistance and fully actuate the service brake.

Danger

If you slip off the brake pedal the machine can quickly run away. Beware of running over bystanders or obstacles.

! Do not allow anyone into the danger area while these tests are being conducted. Increase the engine speed according to the test you are performing. After the tests, restore the plug connections to their previous condition.

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Maintenance Testing and adjustment tasks

3.6.6

Checking the travel pump replenishing pressure Procedure Measure the replenishing pressure at the test connection G. Connect a manometer (40 bar) to the test connection G. Start the machine and let the engine run at top idling speed. Check that the replenishing pressure is correct. If it is not correct: Turn the adjusting screw on the replenishing pressure relief valve 1 until the replenishing pressure is correct. Description Replenishing pressure

3.6.7

Value Unit 32 ±2 bar

Checking the start of regulation of the variable displacement pump When regulation of the variable displacement pump begins, it starts to pump oil. In the blocked condition, the pressure rises as the engine speed increases. When the start of regulation is correctly set, 50 bar high pressure is attained at a certain engine speed. Procedure Connect a manometer (600 bar) to the test connection MA. Put the machine in the blocked condition. In the blocked condition, slowly increase the engine speed until the manometer MA shows exactly 50 bar. Check that the engine speed is correct. If it is not correct: Turn the adjusting screw on the control valve 1 until the engine speed is correct. The control pressure must be within the specified range.

Valid for:

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

Description Engine speed Control pressure Valid for:

1050 ±50 min-1 6 ±2 bar

L538 - 432 / from 0101

Description Engine speed Control pressure

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

Value Unit

MJFCIFSS

Value Unit 1030 ±50 min-1 7 ±2 bar

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Testing and adjustment tasks

3.6.8

Checking the output of the travel pump The position of the control lens 1 determines the output of the variable displacement pump. When you adjust it, the hydraulic return force of the variable displacement pump changes. Adjust the control lens with the twist screw 2. The notch in the twist screw (which is an eccentric screw) indicates its widest point. Turn it by ±90° to set the highest or lowest return force. When the pump output is correctly set, 380 bar high pressure is attained at a certain speed.

Procedure Connect a manometer (600 bar) to the test connection MA. Put the machine in the blocked condition. In the blocked condition, slowly increase the engine speed until the manometer MA shows exactly 380 bar. Check that the engine speed is correct. If it is not correct: Turn the twist screw 2 until the engine speed is correct. The control pressure must be within the specified range.

Valid for:

L524 - 438 / from 0101

Description Engine speed Control pressure Valid for:

Engine speed Control pressure

17 ±2 bar

Value Unit 1900 ±100 min-1 16 ±2 bar

L538 - 432 / from 0101

Description Engine speed Control pressure

3.6-8 of 20

2000 ±100 min-1

L534 - 434 / from 0101

Description

Valid for:

Value Unit

MJFCIFSS

Value Unit 1700 ±100 min-1 21 ±2 bar

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Service Manual

Maintenance Testing and adjustment tasks

3.6.9

Checking the pressure relief and replenishing valve of the travel pump The pressure relief and replenishing valves protect the variable displacement pump from pressure peaks. These can occur when braking the machine. When a pressure peak occurs, oil flows from the high pressure side via the pressure relief and replenishing valve to the low pressure side in a closed circuit. Procedure To attain the set value for the pressure relief and replenishing valves, the pressure cut-off must be set to a higher value. Screw in the adjusting screw 1 on the pressure cut-off by two turns. Connect a manometer (600 bar) to the test connections MA and MB. Put the machine in the blocked condition. Check the pressure relief and replenishing valve 3 for forward travel on the manometer MA. Check the pressure relief and replenishing valve 2 for reverse travel on the manometer MB.

Caution

Heat is quickly generated when you test the pressure relief and replenishing valves. Excessive heat can irreparably damage the pump.

! Only test the pressure relief and replenishing valves for a short time. In the blocked condition, increase the engine speed to the maximum. Check that the high pressure at the two pressure relief and replenishing valves is correct. If it is not correct: Turn the adjusting screw on the pressure relief and replenishing valve until the high pressure is correct. Loosen the adjusting screw 1 on the pressure cut-off by two turns and check the pressure cut-off. Description High pressure

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

MJFCIFSS

Value Unit 470 Âą10 bar

3.6-9 of 20

Maintenance

Service Manual

Testing and adjustment tasks

3.6.10

Checking the pressure cut-off of the travel pump The pressure cut-off limits the maximum pressure of the variable displacement pump. When this pressure is reached, the pump flow is automatically reduced to the level required to maintain the pressure. This results in a certain engine suppression. A low engine suppression (around 20 min-1) means slight leakage in the closed circuit. Increased engine suppression may indicate more serious leakage, a pressure cut-off failure or another fault. Procedure Connect a manometer (600 bar) to the test connection MA. Put the machine in the blocked condition. In the blocked condition, increase the engine speed to the maximum. Check that the high pressure on the manometer MA is correct. If it is not correct: Turn the adjusting screw 1 on the pressure cut-off until the manometer MA reaches the correct value. The engine suppression must be within the specified range.

Valid for:

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

Description

Value Unit

High pressure

430 ±5 bar

Servo pressure

22 ±2 bar

Maximum engine suppression at top idle speed Valid for:

L538 - 432 / from 0101

Description

Value Unit

High pressure

430 ±5 bar

Servo pressure

27 ±2 bar

Maximum engine suppression at top idle speed

3.6-10 of 20

50 min-1

MJFCIFSS

50 min-1

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

Service Manual

Maintenance Testing and adjustment tasks

3.6.11

Checking the variable displacement motor 1 in the control range Perform this check in the blocked condition. Hold the machine with the service brake at full engine speed in travel range 1. Then gradually release the service brake until the machine reaches a speed of 7 to 8 km/h. The set value should be attained at this speed. Procedure Connect a manometer (600 bar) to the test connection MA on the variable displacement pump. Connect a manometer (600 bar) to the test connection M1 on the variable displacement motor 1. Start the engine, select forward travel direction and travel range 1. In the blocked condition, increase the engine speed to the maximum. Slowly release the service brake to allow the machine to move off. Release the brake pedal (7 to 8 km/h) until the servo pressure at the test connection M1 is correct. Check that the high pressure at the test connection MA is correct. If the high pressure in the control range is too high: Loosen the adjusting screw 1 If the high pressure in the control range is too low: Tighten the adjusting screw 1

Valid for:

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

Description

Value Unit

High pressure at MA

230 Âą5 bar

Servo pressure at M1 Valid for:

L534 - 434 / from 0101

Description

Value Unit

High pressure at MA

260 Âą5 bar

Servo pressure at M1

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

120 bar

MJFCIFSS

130 bar

3.6-11 of 20

Maintenance

Service Manual

Testing and adjustment tasks

3.6.12

Checking the servo pressure regulation of variable displacement motor 2 Procedure The servo pressure regulation reduces the swivel angle of the motor as the servo pressure increases. This check tests the start of regulation. A pressure increase can be seen at the test connection M2. Connect a manometer (40 bar) to the test connection PST on the variable displacement pump A4VG. Connect a manometer (600 bar) to the test connection M2 on the variable displacement motor 2. Start the engine, select forward travel direction and travel range 2. Slowly increase the engine speed until the indicator on the manometer (test connection M2) moves away from 0 bar. Check that the servo pressure at the test connection PST is correct. If the servo pressure at the start of regulation is too high: Tighten the adjusting screw 1 If the servo pressure at the start of regulation is too low: Loosen the adjusting screw 1 Description Servo pressure

3.6.13

Value Unit 6 Âą1 bar

Checking the pressure regulation of variable displacement motor 2 Procedure The pressure regulation reduces the swivel angle of the motor as the high pressure increases. This check tests the end of regulation. The motor has reached the maximum swivel angle and the pressure at the test connection M2 has fallen to around 50 bar. Connect a manometer (600 bar) to the test connection MA on the variable displacement pump A4VG. Connect a manometer (600 bar) to the test connection M2 on the variable displacement motor 2. Start the engine, select forward travel direction and travel range 2. In the blocked condition, increase the engine speed until the pressure at the test connection MA exceeds 300 bar. Then slowly reduce the engine speed until the pressure at the test connection M2 is 50 Âą20 bar. Check that the high pressure at the test connection MA is correct. If the high pressure at the end of regulation is too high: Loosen the adjusting screw 2 If the high pressure at the end of regulation is too low: Tighten the adjusting screw 2

3.6-12 of 20

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

Service Manual

Maintenance Testing and adjustment tasks

Valid for:

3.6.14

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

Description

Value Unit

High pressure at MA

260 ±5 bar

Servo pressure at M2

50 ±20 bar

L534 - 434 / from 0101

Description

Value Unit

High pressure at MA

290 ±5 bar

Servo pressure at M2

50 ±20 bar

Checking the working hydraulics pump flow controller Make sure you have a differential pressure gauge and two pressure sensors for the range up to 600 bar. Procedure Measure the difference in pressure between the test connections P and LS. You can only measure the differential pressure when the flow controller is activated. This is best done when slowly raising the lift arms. Connect 600 bar pressure sensors to test connections P and LS. Start the engine and let it run at low idling speed. Slowly raise the lift arms and check whether the differential pressure is correct. If it is not correct: Turn the adjusting screw on the flow controller 1 until the differential pressure is correct.

Valid for:

L524 - 438 / from 0101

Description Differential pressure Valid for:

28 ±1 bar

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

Description Differential pressure

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

Value Unit

MJFCIFSS

Value Unit 25 ±1 bar

3.6-13 of 20

Maintenance

Service Manual

Testing and adjustment tasks

3.6.15

Checking the secondary pressure relief valves on the control block L524

Valid for:

L524 - 438 / from 0101

Procedure Connect a manometer (600 bar) to the test connection P on the control block. Start the machine and let the engine run at lower idling speed. Raise the lift arms, tilt out the bucket, tilt in the bucket and operate the additional equipment, each to the limit. Check that the pressure at each secondary pressure relief valve is correct. If it is not correct: Turn the adjusting screw on the secondary pressure relief valve until it is correct. Description

Value Unit

Lifting function (3)

350 ±5 bar

Tilt-in function (4) Z kinematics

340 ±5 bar

Tilt-in function (2) P kinematics

340 ±5 bar

Tilt-out function (2) Z kinematics

340 ±5 bar

Tilt-out function (4) P kinematics

150 ±5 bar

Additional equipment function (1)

250 ±5 bar

3.6.16

Checking the secondary pressure relief valves on the control block L534, L538

Valid for:

L534 - 434 / 0101 - 6943; L538 - 432 / 0101 - 6943

Procedure Loosen the adjusting screws on the secondary pressure relief valves 1, 2 and 4 on the control block by half a turn. Caution: only unscrew 4 on Z lift arms. Connect a manometer (600 bar) to the test connection P on the control block. Start the machine and let the engine run at lower idling speed. Raise the lift arms, tilt out the bucket, tilt in the bucket and operate the additional equipment, each to the limit. Check that the pressure at each secondary pressure relief valve is correct. If it is not correct: Turn the adjusting screw on the secondary pressure relief valve until it is correct. After checking, tighten the secondary pressure relief valves 1, 2 and 4 on the by half a turn. Caution: only screw in 4 on Z lift arms.

3.6-14 of 20

Description

Value Unit

Lifting function (1)

250 ±5 bar

Tilt-in function (2)

220 ±5 bar

Additional equipment function (3)

250 ±5 bar

Tilt-out function (4) Z kinematics

220 ±5 bar

Tilt-out function (4) P kinematics

150 ±5 bar

MJFCIFSS

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

Service Manual

Maintenance Testing and adjustment tasks

3.6.17

Checking the LS pressure cut-off on the control block L524

Valid for:

L524 - 434 / from 0101

Procedure The LS pressure cut-off 2 for the working hydraulics and the LS pressure cut-off 1 for the steering take the form of a valve in the control block. Connect a manometer (600 bar) to the test connection P. Start the machine and let the engine run at lower idling speed. Raise the lift arms to the limit. Check that the pressure is correct. If it is not correct: Turn the adjusting screw on the LS pressure cut-off 2 (working hydraulics) until the pressure is correct. Turn the steering as far as it will go and continue moving the steering wheel. Check that the pressure is correct. If it is not correct: Turn the adjusting screw on the LS pressure cut-off 1 (steering) until the pressure is correct.

3.6.18

Description

Value Unit

LS working hydraulics pressure cut-off (2)

305 ±5 bar

LS steering pressure cut-off (1)

210 ±5 bar

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

Valid for:

L534 - 434 / 0101 - 6943; L538 - 432 / 0101 - 6943

Procedure The LS pressure cut-off 1 for the working hydraulics is a valve screwed into the control block. There is another LS pressure cut-off 2 on the control block for the steering. Connect a manometer (600 bar) to the test connection P. Start the machine and let the engine run at lower idling speed. Raise the lift arms to the limit. Check that the pressure is correct. If it is not correct: Turn the adjusting screw on the LS pressure cut-off 1 (working hydraulics) until the pressure is correct. Turn the steering as far as it will go and continue moving the steering wheel. Check that the pressure is correct. If it is not correct: Turn the adjusting screw on the LS pressure cut-off 2 (steering) until the pressure is correct.

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

Description

Value Unit

LS working hydraulics pressure cut-off (1)

305 ±5 bar

LS steering pressure cut-off (2)

210 ±5 bar

MJFCIFSS

3.6-15 of 20

Maintenance

Service Manual

Testing and adjustment tasks

3.6.19

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

Valid for:

L534 - 434 / 0101 - 6943; L538 - 432 / 0101 - 6943

The pre-tension valve for P kinematics has a boost pressure. This allows differential control while tilting out. This function is only assured if the pre-tension valve is correctly adjusted. Procedure Install a test connection in the hose line 1. Connect a manometer (600 bar) to the test connection. Start the machine and let the engine run at lower idling speed. Operate the tilt-out function and check that the pressure is correct. If it is not correct: Loosen the hose on the pre-tension valve. Loosen the lock nut 2 and turn the adjusting screw 3 on the pre-tension valve until the pressure is correct. After adjusting, tighten the lock nut 2 and the hose on the pretension valve. Take the test connection off the hose 1. Description Pre-tension valve (P kinematics)

3.6.20

Value Unit 85 Âą5 bar

Checking the opening and closing pressure of the compact brake valve The compact brake valve fills the brake accumulator until the shut-off pressure is reached. When you repeatedly press the inch-brake pedal, the pressure in the brake accumulators falls until the opening pressure is reached. The brake accumulator charging function then begins. Procedure

Connect a manometer (600 bar) to the test connection M3. Start the machine and let the engine run at lower idling speed. Push the inch/brake pedal all the way down several times. Look at the manometer M3 to check that the opening pressure is correct. When the opening pressure is reached, the pressure on the manometer begins to rise. The pressure then increases to the closing pressure. Check the test connection M3 to see if the closing pressure is correct. If the opening or closing pressure is not correct: Remove the cap nut 1, loosen the lock nut 3 and turn the adjusting screw 2 on the compact brake valve until the opening and closing pressure are correct.

3.6-16 of 20

MJFCIFSS

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

Service Manual

Maintenance Testing and adjustment tasks

3.6.21

Description

Value Unit

Opening pressure

145 ±5 bar

Closing pressure

175 ±5 bar

Checking the accumulator charge pressure The pressure switch generates a warning if the brake accumulator pressure is too low. Procedure You can check the switching point of the accumulator pressure switch 1 using the test connection M3 on the compact brake valve and the symbol field 2 on the display unit. Connect a manometer (200 bar) to the test connection M3. Push the inch/brake pedal all the way down several times to lower the brake accumulator pressure. Check that the symbol field 2 lights up when the correct pressure is shown on the manometer M3. If it is not correct: Replace the brake accumulator pressure switch 1. Description Pressure switch activation point

3.6.22

Value Unit 90 ±5 bar

Checking the brake pressure on the compact brake valve Procedure You can check the maximum brake pressure using the test connections M1 on the front axle 1 and M2 on the rear axle 2.

Connect manometers (600 bar) to the test connections M1 and M2. Start the engine and let it run at low idling speed. Push the inch/brake pedal all the way down. Check that the pressure on both manometers is correct. If the level is too low: Loosen the lock nut and tighten the adjusting screw 3 until the brake pressure is correct when the pedal is all the way down. Description Brake pressure with the pedal fully pressed

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

MJFCIFSS

Value Unit 65 ±5 bar

3.6-17 of 20

Maintenance

Service Manual

Testing and adjustment tasks

3.6.23

Checking the brake light pressure switch Procedure You can check the activation point of the brake light pressure switch 2 using the test connection M1 on the front axle 1.

Connect a manometer (40 bar) to the test connection M1 on the front axle 1. Start the engine and let it run at low idling speed. Slowly and gently press the inch/brake pedal and watch the manometer M1 and the brake lights. Check that the brake lights light up at the correct pressure. If it is not correct: Check the brake lights, replace the brake light pressure switch 2 if necessary. Description Activation point of the pressure switch

3.6-18 of 20

MJFCIFSS

Value Unit 5 Âą0.5 bar

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

Service Manual

Maintenance Testing and adjustment tasks

3.6.24

Checking the capacity of the brake accumulator Test the capacity of the brake accumulators 1 and 2 for the front and rear axles by pressing the inch/brake pedal nine times. Before the test, the pressure in the brake accumulators must be 150 bar. After pressing the inch/brake pedal nine times, the pressure should not be below the correct level. Procedure

Connect a manometer (600 bar) to the test connection M3 on the compact brake valve. Connect manometers (600 bar) to the test connections M1 on the front axle and M2 on the rear axle. Push the inch/brake pedal all the way down about five times to lower the brake accumulator pressure. Start the engine and let it run at low idling speed. Watch the pressure on the manometer M3 and turn off the engine when it reaches 150 bar. Press the inch/brake all the way down nine times, keeping it down the final time. Check that the correct pressure is reached on the manometers M1 and M2. If the brake pressure on either manometer falls below the correct level: Replace the affected brake accumulator and perform the brake accumulator test again. Description Lower brake pressure tolerance

3.6.25

Value Unit 50 bar

Checking the inch/brake system overlap The overlap must be correctly set to ensure that the inching and brake functions interact properly. Procedure

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

MJFCIFSS

3.6-19 of 20

Maintenance

Service Manual

Testing and adjustment tasks

Connect a manometer (600 bar) to the test connection MA on the travel hydraulics pump 4. Start the engine and select forward travel. Press the inch/brake pedal all the way down and then run the engine up to top speed. Very slowly release the inch/brake pedal until the machine starts moving. Check whether the pressure on the manometer MA is correct when the machine moves off. If the level is too low: Loosen the lock nut 2 on the inch valve and tighten the adjusting screw 1 until the pressure is correct. If the level is too high: Loosen the lock nut 2 on the inch valve and loosen the adjusting screw 1 until the pressure is correct. Description Travel hydraulics high pressure

3.6-20 of 20

MJFCIFSS

Value Unit 100 Âą20 bar

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

Service Manual

Maintenance Lubricants and fuels

3.7 Lubricants and fuels 3.7.1

Handling lubricants and fuels Conscientious observance of the regulations for handling lubricants and fuels will increase the reliability and service life of the machine. It is especially important that the specified lubricant qualities are observed. You can find the various specifications about the prescribed intervals in the maintenance and inspection schedule and the lubrication chart. You can find details on lubrication, checking the oil level and changing operating fluids in the maintenance section under maintenance tasks. Follow the rules on handling lubricants and fuels, especially the environmental regulations.

Environmental protection Always implement and observe environmental protection measures. Observe national regulations. Ensure that liquids can be properly disposed of before draining them.

Disposing of used materials This applies to the following types of used materials and hazardous waste: – Oils, lubricants, brake fluids, etc. – Coolant – Fuels – Filters, oil cartridges etc. – Rubber, tyres, insulating materials etc. – Batteries Observe the regulations for protecting the environment when disposing of used materials. Collect and store all used materials separately in suitable containers, and take them to the designated collection points for proper disposal. Observe national regulations.

Disposing

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

MJFCIFSS

3.7-1 of 12

Maintenance

Service Manual

Lubricants and fuels

Converting the hydraulic system from petroleum to environmentally compatible hydraulic fluids For the operation of LIEBHERR earth moving machines with environmentally compatible hydraulic fluids we recommend AVIA SYNTOFLUID. Caution

Beware of damaging the machine’s hydraulic system. Mixing environmentally harmless hydraulic fluids with mineral oils produces a vigorous reaction that can damage the hydraulic system.

! Do not mix environmentally harmless hydraulic fluids with mineral oil. If you intend to convert the machine to environmentally-compatible hydraulic fluid, you must first consult LIEBHERR CUSTOMER SERVICE. Ask LIEBHERR for the INSTRUCTION SHEET and CONVERSION GUIDELINES and be sure to follow them.

3.7.2 Lubricating oil quality

Lubricating oils for diesel engines Only high-alloy lubricating oils are used in modern diesel engines. They consist of basic oils blended with additives. The lubricating oil regulation for LIEBHERR diesel engines is based on the following specifications and regulations. Description

Specifications

ACEA classification (Association des Constructeurs Européens de l’automobile)

E3, E4, E5

API classification (American Petroleum Institute)

CI-4, CH-4

Specifications and regulations for diesel engine lubricating oils Lubricating oil viscosity

The lubricating oil viscosity is selected according to the SAE (Society of Automotive Engineers) classification. The decisive factor for the selection of the correct SAE class is the ambient temperature. The selection of the SAE classification does not affect the quality of a lubricant oil. If the viscosity is too high, starting can be difficult. If it is too low, lubricant efficiency may be impaired. The temperature ranges detailed in the following diagram are guidelines short-term deviations are permissible.

Selection of the SAE class according to temperature The following engine oil is recommended (for outside temperatures of -20 °C / 4 °F to +45 °C / 113 °F):

3.7-2 of 12

MJFCIFSS

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

Service Manual

Maintenance Lubricants and fuels

LIEBHERR diesel engine oil – SAE 10W-40 / specification ACEA E4 – ID no. 8610049 20 – 20 litre drum Changing intervals

Changing intervals: – For the initial oil and filter change, using the original oil, see the maintenance and inspection schedule. – Change the oil according to climate zone, sulphur content in the fuel and oil quality as shown in the following table. Even if the specified number of service hours (h) is not reached in a given year, the engine oil and filter should be replaced at least once a year.

Complicating factors

Various complicating factors or harsh operating conditions can affect the maintenance intervals. Complicating factors or harsh operating conditions include: – Frequent cold starts – A sulphur content above 0.5 % in the fuel – Outside operating temperatures below -10 °C If working under difficult conditions, the oil change intervals defined in the maintenance and inspection schedule must be reduced by half, as shown in the table below. Complicating factor

Oil quality CI-4 CH-4 E4 E5

Operation conditions

Sulphur content in fuel

Normal climate, down to -10 °C

Up to 0.5 %

250 h

500 h

Above 0.5 %

125 h

250 h

Up to 0.5 %

125 h

250 h

Below -10 °C

Interval

Above 0.5 %

125 h

Oil change intervals in service hours (h)

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

MJFCIFSS

3.7-3 of 12

Maintenance

Service Manual

Lubricants and fuels

3.7.3 Specifications

Diesel fuels The diesel fuels must meet the minimum requirements in the fuel specifications listed below. Authorised fuel specifications: – DIN EN 590 – ASTM D 975 (89a) 1D and 2D Other specifications may only be used after consulting the engine developers. The sulphur content should not exceed 0.5 % by weight. Higher sulphur content affects the oil change intervals and the engine lifetime.

Lubricity

The reduction of the sulphur content in diesel fuels has raised the problem of lubricity. It has been found that diesel fuels which comply with the European limit of 0.05 % sulphur by weight can cause wear in injection systems, especially distributor injection pumps. Branded fuels (in Germany) contain these lubricant additives as part of their additives package. The fuel lubricity must be < 400 µm according to the HFRR (60°) test. The additives should be added by the supplier in his capacity as agent responsible for fuel quality. Addition of secondary lubricity additives by the customer is not recommended.

Diesel fuel at very low temperatures

When outside temperatures fall below 0 °C, the flow performance of summer diesel fuel may be insufficient as a result of paraffin separation. The same problem arises with winter diesel fuels below -15 °C. Diesel fuel containing additives for operating temperatures down to -20 °C is also often available. To avoid breakdowns, the diesel fuel must be mixed with two star petrol or paraffin at low temperatures. Blending in two star petrol must be viewed as an emergency remedy and it may not exceed 30 % by volume. Four star petrol may not be used for blending. The engine power can drop in relation to the additive mixture used for cold conditions. Blending in additives should therefore be kept to a minimum, taking into account the outside temperatures. For safety reasons, the fuel may only be mixed in a fuel container. When refuelling, pour in the fuel additive with lower specific gravity before the diesel fuel. The engine should then be run until the fuel mixture is circulating throughout the entire fuel system.

Diesel fuel mixing ratio (% vol)

Outside temperature °C

Summer diesel fuel %

Additive %

0 to -10

-10 to -15

50 *

Mixing ratio for summer diesel fuel * If an additive of 50 % is necessary, only paraffin may be used (not two-star petrol).

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MJFCIFSS

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

Service Manual

Maintenance Lubricants and fuels

Winter diesel fuel %

Outside temperature °C

Additive %

-15 °C

-20 °C

-15 °C

-20 °C

0 to -10

100

-10 to -15

100

-15 to -20

100

-20 to -25

50 *

Mixing ratio for winter diesel fuel * If an additive of 50 % is necessary, only paraffin may be used (not two-star petrol). Diesel fuel additives (flow improvers)

3.7.4 Valid for:

Coolant

Flow improvers available on the market will also improve the cold weather performance of the diesel fuel. Their use requires the observance of quantity and application recommendations stipulated by the manufacturer.

Engine coolants (L524, L534) L524 - 438 / from 0101; L534 - 434 / from 0101

The coolant must contain at least 50 % by volume of antifreeze and corrosion protection agent. This protects against freezing down to around -37 °C.

Mixing ratio of antifreeze and corrosion protection agent according to temperature G Frost protection to -10 °C

A Proportion in % of antifreeze

Fresh water quality when using corrosion inhibitor/antifreeze

Description

Value and unit

Water hardness

0.6 to 3.6 mmol/l (3 to 20° d)

pH value at 20 °C

6.5 to 8.5

Chloride ion content

max. 80 mg/l

Sulphate ion content

max. 100 mg/l Fresh water quality

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

MJFCIFSS

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Service Manual

Lubricants and fuels

3.7.5 Valid for:

General recommendations

Coolants for diesel engines (L538) L538 - 432 / from 0101

The cooling system only functions reliably when it is working in a pre-pressurised condition. Therefore it is essential that it is kept clean and leakproof, that the cooling plug and operating valves function properly and that the necessary coolant level is maintained. The antifreeze and corrosion protection agents approved by us ensure sufficient protection against cold, corrosion and cavitation, do not corrode seals and hoses and do not foam. Coolants which contain unsuitable antifreeze and corrosion protection or which have been insufficiently or incorrectly prepared can cause units or components in the coolant circuit to malfunction as a result of cavitation or corrosion damage. Also, heat-insulating deposits can occur on heat-conducting components which can result in overheating and cause the engine to break down. Fresh water regulations Drinking tap water is suitable with the following restrictions. Appearance: colourless, clear, free of visible impurities. Sea water, brackish water, salt water and industrial waste water are not suitable. Description Water hardness pH value at 20 Â°C Chloride ion content Sulphate ion content

Antifreeze/corrosion inhibitor

Fresh water quality Value and unit 0.6 to 2.7 mmol/l (3 to 15Â°d) 6.5 to 8.0 max. 80 mg/l max. 80 mg/l

To improve the quality of the coolant, water filter attachments have been introduced to LH earth mover engines. These filter the coolant in an auxiliary circuit, separating out dirt and rust particles which may cause leaks in coolant pumps. In addition, a chemical additive in the filter (DCA 4) prevent cavitation, corrosion, scaling and foaming in the cooling system and parts such as the coolant pump and cylinder bushings which come into contact with coolant. Because of the different volumes of cooling water and different water filter attachments on the engines and machinery, four different water filter attachments have been introduced.

Mixing ratio of coolant and DCA 4

DCA 4 stands for diesel coolant additive, and is manufactured by Fleetguard. The coolant must contain at least 50 % by volume of antifreeze and corrosion protection agent. This protects down to -37 Â°C. When coolant loss occurs, make sure that it does not fall below 50 % by volume.

Proportion in % of antifreeze and corrosion protection agent

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Service Manual

Maintenance Lubricants and fuels

There is a risk of damage to the diesel engine. Caution

! If the proportion of antifreeze and corrosion protection agent is too high, -

the cooling effect is reduced, causing damage to the engine. Do not use more than 60 % antifreeze and corrosion protection agent.

When carrying out maintenance work, check the mixing ratio of antifreeze/ corrosion inhibitor and the concentration of DCA 4, correcting it if necessary. The DCA 4 concentration must be between 0.3 and 0.8 units per litre. The Fleetguard CC2602 M test kit is recommended for testing the DCA 4 concentration. The prescribed interval for changing the coolant is 2 years. Filling the cooling system for the first time Before filling with new coolant, check that the cooling system is clean and flush it out if necessary. When the cooling system is filled for the first time or re-filled following repairs, additional fluid DCA 4 must be added to the DCA 4 concentration in the coolant filters for antifreeze and corrosion protection. DCA 4 is available in bottles (0.47 litres). Machine type

Filling

Water

L524, L534 L538 L544, L554 L564, L574, L580

24.5 30.5l 32.5l 38.0l

12.2 14.5l 15.5l 18.0l

Antifreeze/ corrosion inhibitor 12.2 14.5l 15.5l 18.0l

Fluid DCA 4 --1.5l 1.5l 2.0l

Approved antifreeze and corrosion protection agents Approved antifreeze and corrosion protection agent for diesel engine cooling systems (concentrate/undiluted) Product designation Agip Antifreeze Plus Aral Cooler Antifreeze AVIA Frostschutz APN (G48-00) Caltex Engine Coolant DB Caltex Extended Life Coolant Castrol Anti-Freeze O Chevron DEX-COOL Extended Life Anti-Freeze/Coolant DEUTZ KĂźhlschutzmittel 0101 1490 Esso KĂźhlerfrostschutz Frostschutz Motorex (G 48-00) Glysantin (G48-00) Havoline XLC Havoline DEX-COOL Extended Life Anti-Freeze/Coolant Organifreeze Total Antigel S-MB 486 Total Frostfrei

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

MJFCIFSS

Manufacturer Agip Aral AVIA Caltex Caltex Castrol Chevron Texaco DEUTZ Esso Bucher + Cie BASF ARTECO Chevron Texaco Total Total Total

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Lubricants and fuels

Approved antifreeze and corrosion protection agents (50: 50 premix) Product designation Manufacturer Liebherr Anti-Freeze APN Mix Id.Nr. 8611045 – 20 l drum LIEBHERR Caltex Extended Life Coolant Pre-Mixed 50/50 (ready-to-use-version) Caltex Chevron DEX-COOL Extended Life Prediluted 50/50 Antifreeze coolant Chevron Texaco Havoline XLC, 50/50 ARTECO Havoline DEX-COOL Extended Life Prediluted 50/50 Antifreeze coolant Havoline Organicool 50/50 Total Brands and manufacturers of antifreeze and corrosion inhibitors Using coolant without antifreeze

In exceptional cases and when outside temperatures never fall below freezing, such as tropical zones, where it is demonstrable that no approved antifreeze and corrosion inhibitor is available, the coolant may be composed solely of water and corrosion protection agent. The following products are approved: – Water with DCA 4 – the DCA 4 concentration must be between 0.6 and 1.06 units per litre. The Fleetguard CC2602 M test kit is recommended for testing the DCA 4 concentration. – Water with inhibitors – the mixing ratio must be 7.5% corrosion inhibitor and 92.5 % water. The GEFO 2710 refractometer is recommended for testing.

The coolant must be replaced once a year. Approved water-soluble corrosion inhibitors (concentrate) Product designation

Manufacturer

Fleetguard Caltex Chevron Texaco ARTECO Total

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Service Manual

Maintenance Lubricants and fuels

3.7.6

Specification

Hydraulic oils

Only engine oils (mineral oils) which meet the following Mercedes-Benz specifications are permitted. Mercedes-Benz sheet no.: 226.0 and 227.0 (single grade oils) 227.1 and 228.1 (multi grade oils)

Specifications: API- CC / SF, CD / SF, CE / SF CD / SF, CD / SF, CD+API- CC / SF (MIL-L-46152 B) CD / SF, CE / SF (MIL-L-2104 D), CD / SF (MIL-L-2104 D), CD / SF, CD+ (MIL-L-46152 B)

Mercedes-Benz oil specifications Viscosity

The viscosity is selected according to the SAE (Society of Automotive Engineers) classification. The decisive factor for the selection of the correct SAE class is the ambient temperature. The selection of the SAE classification has no bearing on the quality of a hydraulic oil. The temperature ranges presented in the diagram are merely guidelines.

Selection of the SAE class according to temperature For temperatures up to 10 °C below the specified limit: – Adjust the diesel engine to roughly half speed after starting. – Activate the hydraulic cylinders and engines and briefly move the cylinders to their stops. – Warming up takes roughly 10 minutes. At even lower temperatures: – Before starting the engine, prewarm the oil tank. Environmentally compatible hydraulic fluid

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

When operating LIEBHERR earth moving machines with environmentally compatible hydraulic fluids, we recommend AVIA SYNTOFLUID with the viscosity specified by LIEBHERR.

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Maintenance

Service Manual

Lubricants and fuels

Caution – Inexpert attempts to convert the hydraulic system to environmentally friendly hydraulic fluid can seriously damage the machine. See the section on conversion from mineral oils to environmentally harmless hydraulic fluids. Machines filled at factory with environmentally compatible hydraulic fluids have an appropriate sign (CAUTION) attached to the driver’s cab and hydraulic tank. Converting the hydraulic system – To convert the machine to environmentally compatible hydraulic fluid, see the corresponding section in this manual.

3.7.7

Axles

Lubricating oils for the transmission

Gear oils must comply with the API-GL-5-90 and MIL-L-2105 B, C or D specifications and the viscosity class SAE 90 LS *. * = Gear oil with limited slip additives for disc brakes and self-locking differentials. For the viscosity class SAE 90, an oil of the viscosity class SAE 80 W 90 LS can also be used.

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Service Manual

Maintenance Lubricants and fuels

Transfer gear

3.7.8

Oil as described in the section on axles should be used as lubricating oil for the axle transfer gear.

Grease for general lubrication points This grease must meet the KP2k specification – consistency 2 of the NL GI class according to DIN 51818 and DIN 51825 or EP 2 according to NF-T-60 132. The grease must be made of a lithium complex with a four ball tester (VKA) value of at least 2300 N according to DIN 51350 or ASTM D 2596. Application: – Grease for all lubrication points (according to the lubrication schedule) – Lubricant grease for bolt fitting – Lubricant grease for automatic central lubrication systems

Approved grease

LIEBHERR 9610 special grease is a milling-resistant, ageing-resistant lithium grease, providing protection against corrosion with excellent lubricity over a wide temperature range. Its molecular composition yields high degrees of shearing and milling stability and good flow properties in long pipes. Description

Grease for automatic central lubrication system

ID no.

Quantity

LH 9610 special grease 861302908

400 g (cartridge)

LH 9610 special grease 861301308

10 kg (drum)

LH 9610 special grease 861304508

25 kg (drum)

Greases with high-pressure additives (EP greases) are recommended. Only use greases with the same type of saponification. Note: Greases with solid lubricant particles such as graphite may not used.

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

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Maintenance

Service Manual

Lubricants and fuels

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4 Diesel Engine 4.0 Chapter contents 4

Diesel Engine ...................................................................... 4.0-1 4.1

Diesel engine (emissions stage I)...................................................4.1-1 4.1.1

Injection pump L524 .............................................................4.1-5

4.1.2

Injection pump L534 .............................................................4.1-6

4.1.3

Injection pump L538 .............................................................4.1-7

4.2

Diesel engine (emissions stage II)..................................................4.2-1 4.2.1

Injection pump L524, L534 ...................................................4.2-5

4.2.2

Electronic injection pump controller......................................4.2-6

4.2.3

Injection pump L538 .............................................................4.2-8

4.3

Fuel system (emissions stage I) .....................................................4.3-1 4.3.1

Fuel tank...............................................................................4.3-3

4.3.2

Fuel level sensor ..................................................................4.3-4

4.3.3

Fuel pre-filter (in-line filter) L524, L534 ................................4.3-5

4.3.4

Fuel fine filter (L524, L534) ..................................................4.3-6

4.3.5

Fuel pre-filter L538 ...............................................................4.3-7

4.3.6

Fuel fine filter L538 ...............................................................4.3-8

4.4

Fuel system (emissions stage II) ....................................................4.4-1 4.4.1

Fuel tank (see emissions stage I).........................................4.4-3

4.4.2

Fuel level sensor (see emissions stage I) ............................4.4-3

4.4.3

Fuel pre-filter L524, L534 .....................................................4.4-3

4.4.4

Fuel fine filter L524, L534 .....................................................4.4-5

4.4.5

Fuel pre-filter (separ filter) L538 ...........................................4.4-6

4.4.6

Fuel fine filter (tandem version) L538...................................4.4-7

4.5

Air filter system ...............................................................................4.5-1 4.5.1

Air filter .................................................................................4.5-2

4.5.2

Vacuum switch .....................................................................4.5-3

4.6

Exhaust system ..............................................................................4.6-1 4.6.1

4.7

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

Silencer.................................................................................4.6-2 Coupling..........................................................................................4.7-1

4.7.1

Coupling L524, L534 ............................................................4.7-1

4.7.2

Coupling (torsion absorber) L538.........................................4.7-2

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Diesel Engine

Service Manual

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Service Manual

Diesel Engine Diesel engine (emissions stage I)

4.1 Diesel engine (emissions stage I) (Id. Nr. 9739010, 9739011, 9880051 emissions stage 1)

Design Valid for:

L524 - 438 / 0101 - 8795; L534 - 434 / 0101 - 8961

The diesel engine is a water-cooled, four-stroke in-line engine with direct injection, turbocharger and charge air cooling (L534, L538). The engine is fitted transversely in the rear section and elastically supported on rubber elements. The flywheel end faces left. Cylinder 1 is at the water pump end and cylinder 4 is at the flywheel end.

Diesel engine components / starter view (front) 1 Engine oil drain valve 2 Flywheel-end flange for travel and working hydraulic pump 3 Dipstick 4 Starter 5 Auxiliary PTO gear pump 6 Fuel water separator 7 Fuel fine filter 8 Filter bleeder screw 9 Crankcase bleeder 10 Fuel pump

L524 - 438 / 0101 - 8795 L534 - 434 / 0101 - 8961 L538 - 432 / 0101 - 8507

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11 12 13 14 15 16 17 18 19 20 21

Intake manifold Air preheater 3-phase alternator V-belt tensioner Heat exchanger intake Water pump Coolant drain valve Water pump intake side Engine oil cooler Engine oil filter Oil pan

4.1-1 of 8

Diesel Engine

Service Manual

Diesel engine (emissions stage I)

Diesel engine components / starter view (rear) 1 Crankcase 10 Valve cover 2 Injection pump 11 Coolant temperature indicator 3 Cold start 50 °C thermo + thermostat B20 switch B20a 12 Cylinder head 4 Thermostat 13 Turbo lubricant supply 5 Exhaust manifold 14 Turbo return line 6 Water pump outlet 15 Oil pressure switch B7 7 Turbocharger 16 Flywheel 8 Filler neck 17 Engine bearing fastening 9 Injection nozzle Design features of the diesel engine: – Water-cooled four-stroke direct injection diesel engine – Turbocharger – Charge air cooling – Maintenance-free gear drive of lubricant pump and auxiliary power take-off for gear pump – Block cylinder head – Wet bushings – Oil-cooled light alloy pistons – Engine oil cooler – Engine oil filter – Tilt-proof oil pan – Fuel fine filter – Cast crankshaft on sliding bearing – Forged connecting rods on sliding bearing – Balance shafts

4.1-2 of 8

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L524 - 438 / 0101 - 8795 L534 - 434 / 0101 - 8961 L538 - 432 / 0101 - 8507

Service Manual

Diesel Engine Diesel engine (emissions stage I)

Valid for:

L538 - 432 / 0101 - 8507

The diesel engine is a water-cooled, four-stroke in-line engine with direct injection and turbocharger. The engine is fitted transversely in the rear section and elastically supported on rubber elements. The flywheel end faces left. Cylinder 1 is at the flywheel end and cylinder 4 is at the water pump end.

Diesel engine components / right view (front) 1 2 3 4

L524 - 438 / 0101 - 8795 L534 - 434 / 0101 - 8961 L538 - 432 / 0101 - 8507

Engine oil filter Fuel fine filter Distributor injection pump Fuel pre-filter with water separator

MJFCIFSS

5 6 7 8

Fuel pump Fan / brake system pump Motor scavenging pump Fan control oil temperature sensor B8

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Diesel Engine

Service Manual

Diesel engine (emissions stage I)

Diesel engine components / left view (rear) 1 Water filter 2 Water temperature encoder / switch B20

3 Fan control water temperature sensor B21 4 Lubrication pressure switch B7 5 Lubrication pressure adjusting screw

Design features of the diesel engine: – Water-cooled four-stroke direct injection diesel engine – Turbocharger – Charge air cooling – Maintenance-free gear drive of lubricant pump, coolant pump and auxiliary power take-off for gear pump – Single cylinder head – Wet bushings – Small number of parts due to lubricant and coolant lines integrated in crankcase – Oil-cooled light alloy pistons – Engine oil cooler – Double lube oil filter – Large, tilt-proof oil pan – Fuel fine filter – Forged steel crank shaft, connecting rods and cam shaft mounted on triple composite bearings.

Function description Basic function The diesel engine converts chemical energy in the fuel into mechanical energy, which it provides to the flywheel via the torsion absorber of the travel hydraulics and working hydraulics pump. A small portion of the power is taken off at the accessory PTO side of the engine to drive the hydraulic fan.

Technical data

4.1-4 of 8

MJFCIFSS

L524 - 438 / 0101 - 8795 L534 - 434 / 0101 - 8961 L538 - 432 / 0101 - 8507

Service Manual

Diesel Engine Diesel engine (emissions stage I)

4.1.1

Injection pump L524 (ID no. 7090481)

Design

1 2 3 4 5 6

Injection lines 8 Speed adjusting lever Maximum speed stop 9 Engine stop solenoid earth Diesel supply line from filter connection Injection pump 10 Engine stop solenoid positive Cold start solenoid valve connection Throttle cable length compensat- 11 Cold start 50 Â°C thermo switch ing spring plug B20a 7 Minimum speed stop Type: Distributor injection pump The point of injection can only be checked and adjusted using the special Time Trac tool. The engine stop solenoid is contained in the housing of the injection pump 4. The engine stop solenoid 9 is earthed to the housing of the injection pump 4.

Function description The injection pump is supplied by the fuel pump. The supply pressure is between 0.25 and 0.30 bar. The injection pump piston applies pressure to the fuel. The fuel is pumped under high pressure to the injection nozzles. When the ignition is on, the positive connection 10 of the engine stop solenoid is energised. When it is not energised, the diesel supply is interrupted. If the engine stop solenoid is defective, the entire injection pump 4 must be replaced. Up to a coolant temperature of 50Â°C, the cold start solenoid valve 5 adjusts the point of injection to ensure optimum combustion at all speeds and loads. The injection pump is fuel-lubricated.

L524 - 438 / 0101 - 8795 L534 - 434 / 0101 - 8961 L538 - 432 / 0101 - 8507

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Diesel Engine

Service Manual

Diesel engine (emissions stage I)

4.1.2

Injection pump L534 (ID no. 7090040)

Design

1 2 3 4 5 6 7 8

Injection adjuster solenoid Y4 Charge pressure adjuster LDA Injection pump Speed adjusting lever Minimum speed stop LDA line Maximum speed stop Cold start 50 Â°C thermo switch B20a

9 Throttle cable length compensating spring 10 Diesel supply line from filter 11 Injection lines 12 Engine stop solenoid positive connection Y5 13 Engine stop solenoid Y5 14 Injection adjuster solenoid positive connection Y4

Type: Distributor injection pump The point of injection can only be checked and adjusted using the special Time Trac tool. The engine stop solenoid is contained in the back of the housing of the injection pump 3.

Function description The injection pump is supplied by the fuel pump. The supply pressure is between 0.25 and 0.30 bar. The injection pump pistons apply pressure to the fuel. The fuel is pumped under high pressure to the injection nozzles. When the ignition is on, the positive connection 12 of the engine stop solenoid is energised. When it is not energised, the diesel supply is interrupted. Up to a coolant temperature of 50 Â°C, the injection adjuster solenoid 1 adjusts the point of injection to ensure optimum combustion at all speeds and loads. The injection pump is fuel-lubricated. At a certain charge pressure, the LDA 2 adjusts the injection quantity to the increased proportion of air.

4.1-6 of 8

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Service Manual

Diesel Engine Diesel engine (emissions stage I)

4.1.3

Injection pump L538 (ID no. 9881060)

Design

1 2 3 4 5 6

Injection lines Maximum speed stop Regulator screw Line to flame glow system Shutoff solenoid connection Pre-tension valve

7 Minimum speed stop 8 Fuel return 9 Throttle cable length compensating spring 10 Speed adjusting lever 11 Throttle holder

Type: Distributor injection pump The point of injection can only be checked and adjusted using the special dial gauge.

Function description The injection pump is supplied by the fuel pump. The supply pressure is between 0.25 and 0.30 bar. The injection pump pistons apply pressure to the fuel. The fuel is pumped under high pressure to the injection nozzles. When the ignition is on, the shutoff solenoid 5 is energised. When it is not energised, the diesel supply is interrupted. The injection pump is fuel-lubricated. The pre-tension valve 6 ensures that the diesel fuel is pumped to the flame glow solenoid valve.

L524 - 438 / 0101 - 8795 L534 - 434 / 0101 - 8961 L538 - 432 / 0101 - 8507

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4.1-7 of 8

Diesel Engine

Service Manual

Diesel engine (emissions stage I)

4.1-8 of 8

MJFCIFSS

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Service Manual

Diesel Engine Diesel engine (emissions stage II)

4.2 Diesel engine (emissions stage II) (ID no. 9739021, 9739022, 9076608)

Design Valid for:

L524 - 438 / from 8796; L534 - 434 / from 8962

The diesel engine is a water-cooled, four-stroke in-line engine with direct injection, turbocharger and charge air cooling. The engine is fitted transversely in the rear section and elastically supported on rubber elements. The flywheel end faces left. Cylinder 1 is at the water pump end and cylinder 4 is at the flywheel end.

Diesel engine components / starter view (front) 1 Engine bearing 2 Flywheel-end flange for travel and working hydraulic pump 3 Starter M1 4 Dipstick 5 Engine type plate 6 Fuel fine filter water drain valve 7 Fuel pump 8 Fuel fine filter 9 Filter bleeder screw 10 Fresh air intake pipe 11 Intake air temperature sensor B36

L524 - 438 / from 8796 L534 - 434 / from 8962 L538 - 432 / from 8508

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12 Three-phase alternator G1 13 Electrical connection to preglow coil R3 14 Preglow system power relay K4 15 Fuel pre-filter 16 V-belt tensioner 17 Fuel water separator 18 Coolant drain valve 19 Oil filter bracket with oil cooler 20 Oil filter 21 Crankcase bleeder 22 Oil pan drain valve

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Diesel Engine

Service Manual

Diesel engine (emissions stage II)

Diesel engine components / starter view (rear) 1 Engine speed encoder and crankshaft position sensor B37 2 Electronic injection controller 3 Solenoid valve-controlled injection pump 4 Fuel temperature sensor B35 5 Coolant temperature sensor / switch B20 6 Coolant temperature sensor B20a

7 8 9 10 11 12 13 14

Water pump outlet Injection nozzle Exhaust manifold Turbocharger Turbocharger lube oil supply Turbocharger lube oil return Oil pressure switch B7 Injection pump solenoid Y54

Design features of the diesel engine: – Water-cooled four-stroke direct injection diesel engine – Turbocharger – Charge air cooling – Electronic power and speed control – Maintenance-free gear drive of lubricant pump and auxiliary power take-off for gear pump – Block cylinder head – Wet bushings – Oil-cooled light alloy pistons – Engine oil cooler – Engine oil filter – Tilt-proof oil pan – Fuel fine filter – Cast crankshaft on sliding bearing – Forged connecting rods on sliding bearing – Balance shafts

4.2-2 of 8

MJFCIFSS

L524 - 438 / from 8796 L534 - 434 / from 8962 L538 - 432 / from 8508

Service Manual

Diesel Engine Diesel engine (emissions stage II)

Valid for:

L538 - 432 / from 8508

The diesel engine is a water-cooled, four-stroke in-line engine with direct injection, turbocharger and charge air cooling. The engine is fitted transversely in the rear section and elastically supported on rubber elements. The flywheel end faces left. Cylinder 1 is at the flywheel end and cylinder 4 is at the water pump end.

Diesel engine components / right view (front) 1 Coolant oil drain plug 2 Engine oil filter and cooler housing 3 Dipstick 4 Engine oil filter 5 Fuel fine filter 6 Air intake port

L524 - 438 / from 8796 L534 - 434 / from 8962 L538 - 432 / from 8508

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7 8 9 10

Oil filler neck Fuel pre-filter (Separ filter) Fuel pump Mechanically controlled distributor injection pump 11 Fuel pump bleeder hose 12 Oil drain valve

4.2-3 of 8

Diesel Engine

Service Manual

Diesel engine (emissions stage II)

Diesel engine components / left view (rear) 1 2 3 4 5

Alternator G1 Water pump cap Cooler return port V-belt tensioning screw Water filter

6 Water temperature sensor / switch B20 7 Turbocharger supply line 8 Turbocharger 9 Turbocharger return line 10 Starter

4.2-4 of 8

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L524 - 438 / from 8796 L534 - 434 / from 8962 L538 - 432 / from 8508

Service Manual

Diesel Engine Diesel engine (emissions stage II)

Technical data 4.2.1

Injection pump L524, L534 (ID no. 7090637)

Valid for:

L524 - 438 / from 8796; L534 - 434 / from 8962

Design

1 Solenoid valve-controlled injection pump 2 Distributor head position screw 3 Diesel supply line from filter 4 Leak oil line

5 Fuel temperature sensor B35 6 Injection lines 7 Injection pump solenoid valve Y54

Type: Solenoid valve-controlled distributor injection pump The injection pump solenoid valve Y54 stops the engine and controls the distributor injection pump. The moment of injection, injection quantity and engine speed are regulated by the ECU engine controller (A14) and the injection pump solenoid valve Y54.

Function description The injection pump is supplied by the fuel pump. The supply pressure is between 0.25 and 0.30 bar.

L524 - 438 / from 8796 L534 - 434 / from 8962 L538 - 432 / from 8508

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Diesel Engine

Service Manual

Diesel engine (emissions stage II)

Another pump in the distributor injection pump delivers the fuel to the pump pistons. The pump pressure is between 5 and 11 bar. An internal accumulator keeps the filling of the pump pistons precise. The pump pistons deliver the fuel to the distributor head and the solenoid valve. The fuel is directed from the distributor head to each injection nozzle. The solenoid valve controls the moment and quantity of injection. The injection pump is fuel-lubricated.

4.2.2 Valid for:

Electronic injection pump controller L524 - 438 / from 8796; L534 - 434 / from 8962

Design

Electronic controller with sensors 1 2 3 4

Injection pump solenoid Y54 Electronic controller A14 Gas pedal angle sensor R5 Crankshaft speed and position sensor B37 5 Fuel temperature sensor B35

6 Coolant temperature sensor B20a 7 Intake air temperature sensor B36 8 Diagnostic plug X141

Function description The electronic controller is powered when the ignition is on. As the engine turns, the crankshaft speed and position sensor 4 (B37) sends a frequency signal to the electronic controller. The gas pedal angle encoder 3 (R5) sends a voltage signal to the controller.

4.2-6 of 8

MJFCIFSS

L524 - 438 / from 8796 L534 - 434 / from 8962 L538 - 432 / from 8508

Service Manual

Diesel Engine Diesel engine (emissions stage II)

From these signals, the controller calculates the control impulses for the solenoid 1 (Y54) on the injection pump. The moment of injection (start and end of delivery) are programmed in the controller A14 and cannot be mechanically adjusted. See the detailed description in the section 10 on the electrical system.

L524 - 438 / from 8796 L534 - 434 / from 8962 L538 - 432 / from 8508

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Diesel Engine

Service Manual

Diesel engine (emissions stage II)

4.2.3

Injection pump L538 (ID no. 9076934)

Design

1 2 3 4 5 6 7

Injection lines Start of delivery adjusting point Line to flame glow system Shut-off solenoid Regulator screw Pre-tension valve Leak oil line

8 Charge pressure sensor 9 Charge pressure line 10 Throttle cable length compensating spring 11 Speed adjusting lever 12 Minimum speed stop 13 Pressure control valve

Type: Distributor injection pump The point of injection can only be checked and adjusted using the special dial gauge accessory.

Function description The injection pump is supplied by the fuel pump. The supply pressure is between 0.25 and 0.30 bar. Another pump in the distributor injection pump delivers the fuel to the pump pistons. The injection pump pistons apply pressure to the fuel. The fuel is pumped under high pressure from the distributor piston via pressurised lines to the injection nozzles. When the ignition is on, the shutoff solenoid 4 is energised. When it is not energised, the diesel supply is interrupted. The injection pump is fuel-lubricated. The pre-tension valve 6 ensures that the diesel fuel is pumped to the flame glow solenoid valve.

4.2-8 of 8

MJFCIFSS

L524 - 438 / from 8796 L534 - 434 / from 8962 L538 - 432 / from 8508

Service Manual

Diesel Engine Fuel system (emissions stage I)

4.3 Fuel system (emissions stage I) (ID 9658799, 9657769)

Design Valid for:

L524 - 438 / 0101 - 8795; ID 9658799 L534 â&#x20AC;&#x201C; 434 0101 -8961; ID 9658799

The fuel system consists of the fuel tank, fuel lines, the fuel pre-filter, the supply pump, the fuel fine filter, the injection pump and the injection nozzles.

Fuel system 1 2 3 4 5

Fuel tank Filler strainer Tank cap Fuel level sensor seal Fuel level sensor

L524 - 438 / 0101 - 8795 L534 - 434 / 0101 - 8961 L538 - 432 / 0101 - 8507

6 7 8 9 10

Filler pump plug Auxiliary heater plug Return line Intake line Fuel pre-filter

MJFCIFSS

11 12 13 14

Fuel fine filter Fuel pump Injection pump Drain valve

4.3-1 of 10

Diesel Engine

Service Manual

Fuel system (emissions stage I)

Valid for:

L538 - 432 / 0101 - 8507; ID 9657769

The fuel system consists of the fuel tank, the fuel lines, the fuel pre-filter, the supply pump, the fuel fine filter, the injection pump and the injection nozzles.

Fuel system 1 2 3 4 5

Fuel tank Filler strainer Tank cap Fuel level sensor seal Fuel level sensor

6 7 8 9 10

Filler pump plug Auxiliary heater plug Intake line Return line Fuel pre-filter

11 12 13 14

Fuel fine filter Fuel pump Injection pump Drain valve

Function description Valid for:

L524 - 438 / 0101-8795, ID 9658799; L534 - 434 / 0101-8961, ID 9658799

The pump draws fuel from the tank via the pre-filter and pumps it through the fine filter to the injection pump. The injection pump delivers the fuel via the high pressure lines to the injection nozzles. The injection nozzles spray aerosol fuel into the combustion chambers. On the underside of the fuel tank there is a valve for draining water (condensate) and sediment (fuel contamination). Use the drain hose supplied with the tool kit. Valid for:

L538 - 432 / 0101 - 8507; ID 9657769

4.3-2 of 10

MJFCIFSS

L524 - 438 / 0101 - 8795 L534 - 434 / 0101 - 8961 L538 - 432 / 0101 - 8507

Service Manual

Diesel Engine Fuel system (emissions stage I)

On the underside of the fuel tank there is a valve for draining water (condensate) and sediment (fuel contamination). Use the drain hose supplied with the tool kit.

4.3.1

Fuel tank (ID 7622943, 10014160)

Design The plastic fuel tank is located behind the right cab access.

Fuel tank 1 2 3 4 5

Tank Filler strainer Tank cap Fuel level sensor seal Fuel level sensor

6 7 8 9 10

Filler pump plug Auxiliary heater plug Supply Return Drain valve

Technical data

L524 - 438 / 0101 - 8795 L534 - 434 / 0101 - 8961 L538 - 432 / 0101 - 8507

MJFCIFSS

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Diesel Engine

Service Manual

Fuel system (emissions stage I)

4.3.2

Fuel level sensor Design The fuel level sensor is fitted vertically in the tank. It is connected via a lead and plugs to the display unit. The sensor tube contains two electrodes to transmit the fuel level in the tank.

Fuel level sensor 1 Sensor electronics 2 Fuel level sensor

3 Electrodes

Function description The fuel level sensor tube 2 contains electrodes 3 which measure the fuel level using a capacitive resistor. The electronics in the head of the fuel level sensor 2 transmit a corresponding voltage signal of 1V - 4V to the fuel level segment field on the display unit.

Fuel level bar display 1 Fuel level sensor 2 Fuel supply segment field 3 Display unit

4.3-4 of 10

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4 Fuel tank 5 Voltage 6 Quantity in litres

L524 - 438 / 0101 - 8795 L534 - 434 / 0101 - 8961 L538 - 432 / 0101 - 8507

Service Manual

Diesel Engine Fuel system (emissions stage I)

The diagram shows the voltages from the fuel level sensor 1 with reference to the contents of the tank. The lower the fuel level 6 the higher the voltage 5 and thus the level shown on the fuel level segment field 2. The first bar in the fuel level segment display 2 on the left shows that the fuel is a reserve level.

4.3.3

Fuel pre-filter (in-line filter) L524, L534 (ID 7090480) The fuel filter is an in-line filter between the fuel tank and the fuel pump. It must be replaced with each service.

Design

Fuel pre-filter installation The fuel pre-filter is an in-line filter in a transparent housing. The filter is clipped to the fuel feeder hose. A short section of hose connects the outlet to the fuel pump. The filter flow can be controlled in both directions. With this installation, the 90Â° port faces the pump.

Function description The fuel pump sucks the fuel through the fuel pre-filter. Any foreign particles are caught in the filter mesh. These can be seen through the transparent housing, indicating the degree of contamination. You can also observe the fuel flow. This is an advantage when servicing the fuel system, for example when it needs bleeding.

Technical data

L524 - 438 / 0101 - 8795 L534 - 434 / 0101 - 8961 L538 - 432 / 0101 - 8507

MJFCIFSS

4.3-5 of 10

Diesel Engine

Service Manual

Fuel system (emissions stage I)

4.3.4

Fuel fine filter (L524, L534) (ID 7090528) The filter has a snap fitting and can be serviced without any tools. The fixing ring, filter cartridge and water separator can be removed, taken apart and fitted by hand during maintenance.

Design

Fuel pre-filter installation 1 2 3 4 5 6

Water drain valve Water separator sight glass Sight glass fixing ring Fuel pump Filter insert Fuel hose

7 8 9 10 11

Filter outlet Bleeder screw For special functions Filter intake Filter fixing ring

The fuel filter is a pre-filter unit with a water separator and is fitted between the fuel pump and the injection pump. The filter element is a cartridge fixed to the filter head with a ring. This is a disposable filter cartridge which must be replaced each time it is serviced. The water separator is cleaned during maintenance and does not need to be replaced.

Function description The fuel pre-filter protects the fuel system from contamination. Also, any water which might be in the fuel system is caught in the water separator. The water separator below it is coaxially connected to the fine filter. The diesel fuel is pumped under pressure from the fuel pump through the filter intake into the filter insert. The pressure of the fuel pump forces the fuel through the filter membrane. The filtered fuel then flows through the outlet in the filter head via the fuel line to the fuel fine filter. The water in the fuel system settles in the water separator sight glass. The container can be emptied during maintenance by opening the drain valve.

4.3-6 of 10

MJFCIFSS

L524 - 438 / 0101 - 8795 L534 - 434 / 0101 - 8961 L538 - 432 / 0101 - 8507

Service Manual

Diesel Engine Fuel system (emissions stage I)

Technical data 4.3.5

Fuel pre-filter L538 (ID 7381876) The filter has a snap fitting and can be serviced without any tools. The filter and the water separator have a fixing ring and can be removed and replaced by hand during a service.

Design The fuel filter is designed as a pre-filter and is fitted between the fuel tank and the fuel pump. The filter element is a cartridge fixed to the filter head with a snap ring. This is a disposable filter cartridge which must be replaced each time it is serviced. The fuel pre-filter has a water separator sight glass. There is a tap on the sight glass to drain the water.

Fuel pre-filter 1 2 3 4 5

Filter base Filter intake Filter outlet Filter housing snap ring Water separator snap ring

6 7 8 9 10

Drain valve Water separator sight glass Filter insert Bleeder screw For special functions

Function description The fuel fine filter protects the fuel system from contamination. Also, any water which might be in the fuel system is caught in the water separator. The water separator below it is coaxially connected to the fine filter. The diesel fuel is pumped under pressure from the fuel pump through the filter intake into the filter insert.

L524 - 438 / 0101 - 8795 L534 - 434 / 0101 - 8961 L538 - 432 / 0101 - 8507

MJFCIFSS

4.3-7 of 10

Diesel Engine

Service Manual

Fuel system (emissions stage I)

The pressure of the fuel pump forces the fuel through the filter membrane. The filtered fuel then flows through the outlet in the filter head via the fuel line to the injection pump. The water in the fuel system is separated by the impregnation of the filter insert, and then settles in the water separator sight glass. The container can be emptied during maintenance by opening the drain valve.

Technical data 4.3.6

Fuel fine filter L538 (ID 7381643) The filter has a snap fitting and can be serviced without any tools. The filter can be removed with the snap ring and replaced by hand during a service.

Design The fuel filter is a fine filter and is fitted between the fuel pump and the injection pump. The filter element is a cartridge fixed to the filter head with a snap ring. This is a disposable filter cartridge which must be replaced each time it is serviced.

Fuel fine filter 1 2 3 4

Filter base Filter intake Filter outlet Drain valve

5 6 7 8

Filter insert Filter insert snap ring Bleeder screw For special functions

Function description The fuel fine filter protects the fuel system from contamination. Also, any water which might be in the fuel system is caught in the filter housing. The diesel fuel is pumped under pressure from the fuel pump through the filter intake 2 into the filter insert 5. The pressure of the fuel pump forces the fuel through the filter membrane.

4.3-8 of 10

MJFCIFSS

L524 - 438 / 0101 - 8795 L534 - 434 / 0101 - 8961 L538 - 432 / 0101 - 8507

Service Manual

Diesel Engine Fuel system (emissions stage I)

The filtered fuel then flows through the outlet in the filter head via the fuel line to the injection pump. The water in the fuel system is separated by the impregnation of the filter insert, and then settles in the filter housing at the bottom. The filter housing can be emptied during maintenance by opening the drain valve.

Technical data

L524 - 438 / 0101 - 8795 L534 - 434 / 0101 - 8961 L538 - 432 / 0101 - 8507

MJFCIFSS

4.3-9 of 10

Diesel Engine

Service Manual

Fuel system (emissions stage I)

4.3-10 of 10

MJFCIFSS

L524 - 438 / 0101 - 8795 L534 - 434 / 0101 - 8961 L538 - 432 / 0101 - 8507

Service Manual

Diesel Engine Fuel system (emissions stage II)

4.4 Fuel system (emissions stage II) Design Valid for:

L524 - 438 / 8796-; L534 - 434 / 8962-,

The fuel system consists of the fuel tank, fuel lines, the fuel pre-filter, the supply pump, the fuel fine filter, the injection pump and the injection nozzles.

Fuel system L524, L534 1 2 3 4

Drain valve Fuel tank Return line Intake line

5 Fuel line from fine filter to injection pump 6 Fuel fine filter

Valid for:

7 Fuel pump 8 Fuel pre-filter 9 Injection pump

L538 - 432 / 8508-,

The fuel system consists of the fuel tank, the fuel lines, the fuel pre-filter (separ filter), the supply pump, the fuel fine filter, the injection pump and the injection nozzles.

L524 - 438 / from 8796 L534 - 434 / from 8962 L538 - 432 / from 8508

MJFCIFSS

4.4-1 of 8

Diesel Engine

Service Manual

Fuel system (emissions stage II)

Fuel system L538 1 2 3 4 5

Drain valve Intake line Return line Fuel tank Fuel fine filter 2

6 7 8 9

Fine filter intake connection line Fine filter outlet connection line Fuel fine filter 1 Fine filter intake fuel line

10 11 12 13

Fine filter outlet fuel line Return line Fuel pre-filter (Separ filter) Fuel pump

Function description Valid for:

L524 - 438 / 8796-, L534 - 434 / 8962-,

The pump draws fuel from the tank via the pre-filter and pumps it through the fine filter to the injection pump. The excess fuel at the injection pump can flow back to the tank via the pretension valve. The injection pump delivers the fuel via the high pressure lines to the injection nozzles. The injection nozzles spray aerosol fuel into the combustion chambers. On the underside of the fuel tank there is a valve for draining water (condensate) and sediment (fuel contamination). Use the drain hose supplied with the tool kit. Valid for:

L538 - 432 / 8508-,

The pump draws fuel from the tank via the pre-filter (separ filter) and pumps it through the fine filters to the injection pump. The fuel fine filters are arranged as tandem filters. The fuel is divided between the two filters. The excess fuel at the injection pump can flow back to the tank via the pretension valve. The injection pump delivers the fuel via the high pressure lines to the injection nozzles.

4.4-2 of 8

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L524 - 438 / from 8796 L534 - 434 / from 8962 L538 - 432 / from 8508

Service Manual

Diesel Engine Fuel system (emissions stage II)

The injection nozzles spray aerosol fuel into the combustion chambers. On the underside of the fuel tank there is a valve for draining water (condensate) and sediment (fuel contamination). Use the drain hose supplied with the tool kit.

4.4.1

Fuel tank (see emissions stage I)

4.4.2

Fuel level sensor (see emissions stage I)

4.4.3

Fuel pre-filter L524, L534 (ID 7090562) The filter has a snap fitting and can be serviced without any tools. The fixing ring, filter cartridge and water separator can be removed, taken apart and fitted by hand during maintenance. The fuel filter is fitted between the fuel tank and the fuel pump. It must be replaced with each service. The sight glass can be used again after cleaning.

Design

Fuel pre-filter installation 1 2 3 4 5 6

Water drain valve Water separator sight glass Sight glass fixing ring Filter insert Fuel pump Fuel hose from tank

7 8 9 10 11

Filter outlet Filter head For special functions Bleeder screw Filter fixing ring

The fuel filter is a pre-filter unit with a water separator and is fitted between the fuel tank and the fuel pump. The filter element is a cartridge fixed to the filter head with a ring. This is a disposable filter cartridge which must be replaced each time it is serviced. The water separator is cleaned during maintenance and does not need to be replaced.

L524 - 438 / from 8796 L534 - 434 / from 8962 L538 - 432 / from 8508

MJFCIFSS

4.4-3 of 8

Diesel Engine

Service Manual

Fuel system (emissions stage II)

Function description The fuel pre-filter protects the fuel system from contamination. Also, any water which might be in the fuel system is caught in the water separator. The water separator below it is coaxially connected to the pre-filter. The fuel pump sucks the fuel through the fuel pre-filter. Any foreign particles are caught in the filter membrane. The water in the fuel system settles in the water separator sight glass. The container can be emptied during maintenance by opening the drain valve.

Technical data

4.4-4 of 8

MJFCIFSS

L524 - 438 / from 8796 L534 - 434 / from 8962 L538 - 432 / from 8508

Service Manual

Diesel Engine Fuel system (emissions stage II)

4.4.4

Fuel fine filter L524, L534 (ID 7090528) The filter has a snap fitting and can be serviced without any tools. The filter can be removed and replaced by hand during a service.

Design

Fuel fine filter installation 1 2 3 4

Water drain valve Filter insert Filter fixing ring Filter outlet

5 For special functions 6 Bleeder screw 7 Filter intake

The fuel fine filter is fitted between the fuel pump and the injection pump. The filter element is a cartridge fixed to the filter head with a ring. This is a disposable filter cartridge which must be replaced each time it is serviced.

Function description The fuel fine filter protects the fuel system from contamination. The diesel fuel is pumped under pressure from the fuel pump through the filter intake into the filter insert. The pressure of the fuel pump forces the fuel through the filter membrane. The filtered fuel then flows through the outlet in the filter head via the fuel line to the injection pump.

Technical data

L524 - 438 / from 8796 L534 - 434 / from 8962 L538 - 432 / from 8508

MJFCIFSS

4.4-5 of 8

Diesel Engine

Service Manual

Fuel system (emissions stage II)

4.4.5

Fuel pre-filter (separ filter) L538 (ID 7382133) The filter has an insert to pre-filter the diesel fuel. It also has a sight glass where water can settle. There are two contacts in the sight glass for a warning function.

Design The fuel filter is designed as a pre-filter and is fitted between the fuel tank and the fuel pump. The filter element is an insert which can be replaced by taking off the cover. This is a disposable filter insert which must be replaced each time it is serviced. The fuel pre-filter has a water separator sight glass. There is a tap on the sight glass to drain the water. Also, there are two contacts on the sight glass so that a warning lamp lights up if the water level is too high.

Fuel pre-filter (Separ filter) 1 2 3 4

Water drain pipe Drain valve Water level warning contacts Water separator sight glass

5 6 7 8

Filter housing Filter outlet Cover Filter intake

Function description The fuel pre-filter protects the fuel system from contamination. Also, any water which might be in the fuel system is caught in the water separator. The fuel pump sucks the fuel through the fuel pre-filter. Any foreign particles are caught in the filter insert. The water in the fuel system settles in the water separator sight glass. The container can be emptied during maintenance by opening the drain valve.

4.4-6 of 8

MJFCIFSS

L524 - 438 / from 8796 L534 - 434 / from 8962 L538 - 432 / from 8508

Service Manual

Diesel Engine Fuel system (emissions stage II)

The two contacts in the sight glass can be used to activate an optional warning lamp for the water level.

Technical data 4.4.6

Fuel fine filter (tandem version) L538 (ID 7382102) The filters have a snap fitting and can be serviced without any tools. The filter cartridges can be removed with the snap ring and replaced by hand during a service.

Design The fuel filters are fine filters and are fitted between the fuel pump and the injection pump. To achieve the required service life with this filtration grade, a tandem arrangement is used. The filter elements are cartridges fixed to the filter head with a snap ring. These are disposable filter cartridges which must be replaced each time they are serviced.

Fuel fine filter (tandem version) 1 2 3 4 5

Filter insert 1 Filter insert 2 Filter insert snap ring Bleeder screws Filter outlet connection line

6 7 8 9

Filter intake connection line For special functions Filter intake Filter outlet

Function description The fuel fine filters protect the fuel system from contamination. The fuel pump delivers the fuel under pressure through the line 8 to the filter insert 1 and the connecting line 6 to the filter insert 2. The fuel is divided between the two filters. The pressure of the fuel pump forces the fuel through the filter inserts. The fuel comes back together at the filter outlet and is delivered via the line 9 to the injection pump.

Technical data

L524 - 438 / from 8796 L534 - 434 / from 8962 L538 - 432 / from 8508

MJFCIFSS

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Diesel Engine

Service Manual

Fuel system (emissions stage II)

4.4-8 of 8

MJFCIFSS

L524 - 438 / from 8796 L534 - 434 / from 8962 L538 - 432 / from 8508

Service Manual

Diesel Engine Air filter system

4.5 Air filter system Design

Air filter system 1 2 3 4 5

Rain cap Air intake pipe Air hose clips Unfiltered air intake hose Air filter clips

6 7 8 9 10 11

Bracket Rear section Air filter Filtered air intake manifold Vacuum switch Diesel engine

Function description The engine takes in fresh air via the rain cap 1, the air hoses and the air filter 8. The filtered air is provided to the engine via the turbocharger.

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

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4.5-1 of 4

Diesel Engine

Service Manual

Air filter system

4.5.1

Air filter Design

Air filter arrangement 1 Secondary element 2 Primary element 3 Service cap

4 Fixing clips 5 Dust extraction valve 6 Filter housing

Function description The primary element 2 and the secondary element 1 of the dry air filter are designed to ensure maximum protection for the engine at very long service intervals. The primary element 2 with radial sealing at the filtered air connection in the filter housing 6 is subject to scheduled and non-scheduled maintenance. The secondary element 1 acts as a back-up if the primary element 1 is damaged. The secondary element 1 is not a service filter. It must be replaced if necessary. The dust extraction valve 5 automatically removes dust from the service cap 3. The tangential arrangement of the intake port sets the air into quick rotation, so that large dust particles are thrown by centrifugal force against the housing and accumulate in the service cap 3 due to the air flow. At idle speed, the accumulated dust particles in the service cap 3 are carried outside via the dust extraction valve 5 by the vibrations in the intake air. The service cap 3 must be fitted so that the dust extraction valve 5 faces down. With the engine running at lower idle speed, you should clearly feel air pulsating at the dust extraction valve 5.

4.5-2 of 4

MJFCIFSS

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Service Manual

Diesel Engine Air filter system

4.5.2

Vacuum switch (ID 6906001)

Design

Vacuum switch arrangement 1 Vacuum switch

2 Air filter

Function description The vacuum switch 1 monitors the pressure ratio between the turbocharger and the air filter 2. If the filters are dirty (excessive vacuum) it activates the air contamination symbol field on the display unit.

Technical data

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

MJFCIFSS

4.5-3 of 4

Diesel Engine

Service Manual

Air filter system

4.5-4 of 4

MJFCIFSS

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

Service Manual

Diesel Engine Exhaust system

4.6 Exhaust system Design

Exhaust system layout 1 2 3 4

Tail pipe Heat shield Silencer Turbocharger

5 6 7 8

Seals Exhaust pipe Flexible section of exhaust pipe Cooler support

Function description The exhaust gas passes from the turbocharger 4 through the exhaust pipe 6, the silencer 3 and the tail pipe 1 to the open air. The silencer 3 is fitted in the cooler support 8 and bolted to it. Movement between the turbocharger 4 on the engine and the silencer 3 is compensated by the flexible section of the exhaust pipe 7. The exhaust pipe 6 must be set so that the flexible section 7 is flush along both axes and is extended roughly half way. There are seals 5 between the turbocharger 4, exhaust pipe 6 and silencer 3. To keep radiated heat away from the cab, the tail pipe 1 is fitted with a heat shield 2.

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

MJFCIFSS

4.6-1 of 2

Diesel Engine

Service Manual

Exhaust system

4.6.1

Silencer Design The silencer is fitted in the cooler support and bolted to it.

Silencer 1 Fastening plate 2 Silencer outlet 3 Housing

4 Fastening point 5 Silencer intake

Function description The job of the silencer is to absorb sound energy. The silencer is a combined absorption/reflection silencer.

4.6-2 of 2

MJFCIFSS

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

Service Manual

Diesel Engine Coupling

4.7 Coupling 4.7.1

Coupling L524, L534 (ID 5717325, 10010559)

Design The coupling connects the flywheel on the diesel engine to the tandem pump.

Position of the coupling 1 2 3 4

Flywheel Fixing screw Elastic element Hub star

5 Hub star shoulder 6 Fixing screws 7 Elastic element

Installation position and instructions: – The elastic element 3 is fitted with its ribs facing the flywheel. The smooth side can be seen from the outside. – The hub star 4 is fitted with its shoulder 5 facing the travel hydraulics pump. – All screws are glued with LOCTITE 241.

Function description The coupling is an elastic connection between the diesel engine and the tandem pump.

Power transmission The following components transmit the engine torque to the tandem pump: – Flywheel 1 – Fixing screws 6 – Elastic element 3 – Hub star 4 – Hub

Technical data

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

MJFCIFSS

4.7-1 of 4

Diesel Engine

Service Manual

Coupling

4.7.2

Coupling (torsion absorber) L538 (ID 5607974)

Design The coupling (torsion absorber) is an elastic connection and vibration absorber between the flywheel on the engine and the tandem pump.

Location of the torsion absorber 1 Coupling (torsion absorber)

4.7-2 of 4

MJFCIFSS

2 Flywheel

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

Service Manual

Diesel Engine Coupling

Main components of the coupling (torsion absorber) 1 2 3 4

Coupling (torsion absorber) Hub Pressure springs Disc

5 6 7 8

Disc Fixing screw Flywheel housing Flywheel

The disc 5 is bolted to the flywheel 8 of the engine. The hub 2 is axially guided by circular discs riveted to the hub. The hub 2 can move radially on the disc 4. The springs 3 are arranged in a ring and form an elastic connection which transfers the torque between the disc 5 and the hub 2. The drive shaft of the tandem pump is connected to the hub 2 by spline shaft gearing.

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

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4.7-3 of 4

Diesel Engine

Service Manual

Coupling

Function description The coupling (torsion absorber) is an elastic connection between the diesel engine and the tandem pump. It transmits the engine torque to the pump while at the same time absorbing torque peaks between the two components.

Power transmission The following components transmit the engine torque to the tandem pump: – Flywheel 8 – Fixing screws 6 – Discs 4 and 5 – Pressure springs 3 – Hub 2

Damping The springs 3 absorb load fluctuations and torque peaks on the engine crankshaft. The vibrations of the crankshaft are greatly reduced as torque is transmitted to the tandem pump.

Technical data

4.7-4 of 4

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5 Cooling System 5.0 Chapter contents 5

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

Cooling System ................................................................... 5.0-1 5.0.1

Hydraulic cooling system......................................................5.0-2

5.0.2

Electric fan speed control .....................................................5.0-6

5.0.3

Engine coolant cooling system L524, L534..........................5.0-9

5.0.4

Engine coolant cooling system L538..................................5.0-10

5.0.5

Engine intake air cooling system........................................5.0-11

5.1

Gear pump ......................................................................................5.1-1

5.2

Gear motor......................................................................................5.2-1

5.3

Temperature sensor .......................................................................5.3-1

MJFCIFSS

5.0-1 of 2

Cooling System

5.0-2 of 2

Service Manual

MJFCIFSS

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

Service Manual

Cooling System

Design The cooling system is fitted on the rear section between the diesel engine and the driver's cab.

Cooler unit components 1 2 3 4 5 6

Cooler unit Equalising reservoir Fan blade Grille Fan motor Brake / fan pump

7 8 9 10 11

Air scoop Silencer chamber air hose Drain hose clips Cooler support Cooler for engine coolant

12 Charge air cooler (L524 from 8796 L538 from 8508) 13 Hydraulic oil cooler 14 Hydraulic oil scavenging cooler

Function description Basic function The fan takes in air from the outside of the cooler unit, and blows it over the cooling fins of the cooler unit, through the engine and out again. Also, hot air is drawn from the silencer chamber air hose. The speed of the hydrostatically driven fan depends on the engine speed and the coolant and hydraulic oil temperature.

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

MJFCIFSS

5.0-1 of 12

Cooling System

Service Manual The cooler system cools: – The motor scavenging hydraulic oil – The oil in the hydraulic system – The charge air of the engine (L524 - 438 / 8796-; L534 - 434 / 0101-; L538 - 432 / 8508-;) – The engine coolant – The air conditioning condenser (optional)

5.0.1

Hydraulic cooling system

Hydraulic cooling system components 1 2 3 4 5 6 7 8 9 10

Hydraulic system oil cooler Motor scavenging oil cooler Thermo valve Motor scavenging gear pump Brake / fan gear pump Hydraulic oil temperature sensor B8 Fan drive intake line Motor scavenging return line Motor scavenging intake line Compact brake valve pressure line

11 12 13 14 15 16 17 18 19 20 21

Gear motor tank line Fan gear motor Compact brake valve Gear motor proportional pressure relief valve Y13 Gear motor 200µ line filter Oil cooler collector pipe Compact brake valve gear motor pressure line Variable adjustment motor Flushing valve return line Gear motor leak oil line Variable displacement pump

22 Variable displacement pump return line 23 Hydraulic system cold return line 24 Return suction filter 25 Hydraulic cooler safety 2.5 bar return line 26 Hydraulic system hot return line 27 2.5 bar safety valve 28 Motor scavenging oil cooler return line 29 Return strainer 30 Hydraulic tank collector pipe

Cooling by the hydraulic system oil cooler 1 The following lines from the tank pass through the hydraulic system oil cooler 1: – Flushing valve return line 19 – Variable displacement pump return line 22 – Gear motor tank line 11

5.0-2 of 12

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Service Manual

Cooling System The leak oil of these components is pumped to the hydraulic tank collector pipe 16. From there in enters the left cooler box and at a temperature below 45°C it can flow directly through the thermo valve 3, the hydraulic system cold return line 23 and the return suction filter 24 to the hydraulic tank. If the temperature rises above 45 °C the thermo valve 3 closes and the oil has to flow through the hydraulic system oil cooler 1, the hydraulic system hot return line 26 and the return suction filter 24 to the hydraulic tank. The 2.5 bar safety valve 27 ensures that any pressure peaks for the system hydraulic oil cooler 1 are reduced.

Cooling by the motor scavenging oil cooler 2 The motor scavenging oil cooler 2 cools the oil for the variable displacement motors. The oil in the housing is drawn up by the motor scavenging gear pump 4 and pumped through the motor scavenging oil cooler 2 and the return strainer 29 into the hydraulic tank.

Hydraulic fan control

Hydraulic plan of fan drive 1 2 3 4 5 6 7 8 9

Hydraulic tank Return strainer Bleeder filter Return suction filter Replenishing valve with strainer Pre-tension valve Bypass valve 45 °C temperature valve Bypass valve (2.5 bar safety valve) 10 Compact brake block

11 Inching valve 12 Connection to accumulator charge valve 13 Flow distributor valve 14 Connection to hydro accumulator 15 Brake/fan gear pump 16 Scavenging gear pump 17 Hydraulic oil temperature sensor B8

18 Cooler unit 19 Proportional pressure relief valve assembly 20 Fan gear motor 21 Pressure relief valve 22 Restrictor 23 200µ line filter P System pressure test connection Y13 Proportional valve

The brake/fan pump 15 draws oil from the hydraulic tank 1 and pumps it to the compact brake valve, where the flow distributor valve directs most of the oil for charging the brake accumulator.

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5.0-3 of 12

Cooling System

Service Manual When the brake accumulators are full, the flow distributor valve supplies the oil to the fan motor 20. To protect the proportional pressure relief valve 19 from dirt, a 200Âľ in-line filter 23 is fitted at the motor intake. The proportional valve Y13 continuously regulates the integrated pressure relief valve 21 of the fan motor 20. At low temperature, the opening pressure of the pressure relief valve 21 is also low. Most of the oil flows through the pressure relief valve 21 to the tank. The fan turns at low speed (minimum speed = dragging speed). As the temperature increases the current to the proportional valve Y13 reduces, and the opening pressure of the pressure release valve 21 thus continuously increases. As a result, the fan motor 20 turns the fan at a higher speed. If the current fails at the proportional valve Y13, the opening pressure increases to the mechanically set level and the fan motor 20 turns at maximum speed, regardless of the engine speed (failsafe function).

Fan speed characteristics 1 Fan speed 2 Characteristics for fan speed with no current to proportional pressure relief valve Y13 or sensor failure B8, B21, cable rupture etc.

5.0-4 of 12

MJFCIFSS

3 Current to proportional valve (mA) 4 Engine speed 5 L524 - L534 fan speed at low temperature (minimum speed)

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

Service Manual

Cooling System Valid for:

L524 - 438 / 0101 -8795; L534 - 434 / 0101 -8961; L538 - 432 / 0101 -8507

Fan control at upper engine speed Hydraulic oil up to 31 °C Coolant up to 78 °C Hydraulic oil 31 - 55 °C Coolant up to 78 °C Hydraulic oil 55 - 73 °C Coolant 78 - 84 °C Hydraulic oil above 73 °C Coolant above 84 °C Hydraulic oil above 106 °C Coolant above 100 °C (L538) Coolant above 103 °C (L524, L534) Adjusting the pressure relief valve: Proportional solenoid deenergised or one of the two temperature sensors unplugged

System pressure

Current

Fan speed

20 ±10 bar

1350 mA

430 ±50 min -1

65 ±10 bar

880 mA

1200 ±50 min -1

65-125 ±10 bar

880 - 550 mA

1200-1740 min-1

125 ±10 bar

550 mA

1740 ±50 min -1

Warning lamp + buzzer + 1st gear

175 ±5 bar

0 mA

2130 ±50 min -1

Table of values for fan control Valid for:

L524 - 438 / 8796-; L534 - 434 / 8962-; L538 - 432 / 8508-;

Fan control at upper engine speed Hydraulic oil up to 30 °C Coolant up to 70 °C Hydraulic oil 31 - 64 °C Coolant 70 - 81.5°C Hydraulic oil 65 -73 °C Coolant 81.5 - 84 °C Hydraulic oil 73 - 90 °C Coolant 84 - 97 °C (L538) Coolant 84 - 100 °C (L524, L534) Hydraulic oil above 90 °C Coolant above 97 °C (L538) Coolant above 100 °C (L524, L534) Hydraulic oil above 95 °C Coolant above 100 °C (L538) Coolant above 103 °C (L524, L534) Adjusting the pressure relief valve: Proportional solenoid deenergised or one of the two temperature sensors unplugged

System pressure

Current

Fan speed

20 ±10 bar

1350 mA

430 ±50 min -1

65 ±10 bar

880 mA

1200 ±50 min -1

65-125 ±10 bar

880 -550 mA

1200-1740 min-1

125 ±10 bar

550 mA

1740 ±50 min -1

175 ±10 bar

0 mA

2130 ±50 min -1

Warning lamp + buzzer + 1st gear

175 ±5 bar

0 mA

2130 ±50 min -1

Table of values for fan control

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

MJFCIFSS

5.0-5 of 12

Cooling System

Service Manual 5.0.2 Valid for:

Electric fan speed control L524 - 438 / 0101 -12075; L534 - 434 / 12121 - 8961; L538 - 432 / 0101 -12096

Electric fan speed control A1 Electronic controller H13 Green hydraulic oil overheating LED H14 Red coolant overheating LED S1.1 Coding switch for normal/tropical version

5.0-6 of 12

S1.2

M1 Y13

Coding switch for temperature adjustment L524, L534 / L538 Fan motor Proportional pressure relief valve (fan speed)

MJFCIFSS

W B8 B21

Alternator terminal (engine speed) Hydraulic oil temperature sensor Coolant temperature sensor

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

Service Manual

Cooling System Valid for:

L524 - 438 / 12076-; L534 - 434 / 12122-; L538 - 432 / 12097-;

Electric fan speed control Kl.W Alternator terminal (engine speed) B8 Hydraulic oil temperature sensor B21 Coolant temperature sensor

1 Electronic controller A1 2 H14 red coolant overheating LED 3 H13 red hydraulic oil overheating LED 4 H12 red safety logic LED 5 S 2.1 Coding switch for joystick switch function (latch / push)

6 S 2.2 Coding switch with no function 7 S 1.1 Coding switch for normal/tropical version 8 S 1.2 Coding switch for temperature adjustment L524, L534 / L538 9 Fan motor M1 10 Proportional pressure relief valve Y13

The electronic controller A1 takes the readings from the temperature sensors for the hydraulic oil B8 and B21, as well as from the engine speed alternator terminal “W” and calculates an output current. This current controls the proportional pressure relief valve Y13 on the fan motor M1 and therefore the fan speed. The hotter the fluid, the higher the resistance on the temperature sensor and consequently the lower the current to the proportional pressure relief valve Y13. The resistance changes in almost linear proportion to the temperature of the fluid. If the hydraulic oil temperature exceeds a set value (see the table of fan control values), the following actions are taken: – The current is reduced to 0 mA. This turns the fan motor M1 at maximum speed. – The symbol field H23 for hydraulic oil overheating on the display unit lights up continuously.

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

MJFCIFSS

5.0-7 of 12

Cooling System

Service Manual – On the electronic controller A1 the red hydraulic oil overheating LED H13 lights up. – After 1 minute, the machine is switched down to travel range I until the temperature is reduced. – This is indicated by the travel range I and II symbol fields flashing alternately every 500ms. – In addition the warning buzzer B9 sounds (3 sec. on / 10 sec. off etc.). If the coolant oil temperature exceeds a set value (see the table of fan control values), the following actions are taken: – The current is reduced to 0 mA. This turns the fan motor M1 at maximum speed. – The symbol field H23 for hydraulic oil overheating on the display unit lights up continuously. – On the electronic controller A1 the red coolant overheating LED H14 lights up. – After 1 minute, the machine is switched down to travel range I until the temperature is reduced. This is indicated by the travel range I and II symbol fields flashing alternately every 500ms. – In addition the warning buzzer B9 sounds (3 sec. on / 10 sec. off etc.). The coding switch S1.1 allows you to switch between temperate and tropical operation mode. The coding switch S1.2 allows you to adjust the temperature on L524, L534 / L538 machines. For the temperatures see the table of values for fan control. The coding switch S2.1 allows you to set the switch function on the LH control lever (joystick). The coding switch S2.2 has no function. Version L524, L534 L538

Normal S1.1 ON ON

Tropics S1.2 ON OFF

S1.1 OFF OFF

S1.2 ON OFF

Latch joystick S2.1 S2.2 ON --ON ---

Push joystick S2.1 S2.2 OFF --OFF ---

Position of coding switches on electronic controller A1

5.0-8 of 12

MJFCIFSS

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

Service Manual

Cooling System 5.0.3 Valid for:

Engine coolant cooling system L524, L534 L524 - 438 / 0101; L534 - 434 / 0101

Coolant and charge air cooling circuit 1 2 3 4 5 6 7

Equalising reservoir Reservoir cap Coolant level sight glass Reservoir overflow pipe Dummy line Coolant cooler bleeder hose Connecting hose from cooling circuit to reservoir

8 Coolant hose from engine to cooler 9 Coolant hose from cooler to connector tube 10 Coolant outlet thermostat housing (hot) 11 Diesel engine

12 Coolant hose from connector tube to engine 13 Coolant temperature sensor B21 14 Connector tube from cooler to engine 15 Equalizing reservoir connection 16 Cooler unit 17 Cooler for diesel engine coolant

Depending on the temperature and controlled by the thermostat, the engine coolant is either cooled internally or pumped through the cooler 17. The coolant is pumped from the coolant outlet thermostat housing (hot) 10 through the hose 8 from the engine to the cooler. In the cooler, the coolant flows through the fins, which are cooled by circulating air, and then returns through the hose 9 to the connector pipe 12 and the hose 12 to the engine 11. The oil returning to the engine 11 flows past the coolant temperature sensor B21. The coolant temperature sensor B21 reports the current temperature to the controller A1, which regulates the fan speed. The coolant returns to the coolant circuit via the hose 7 connecting the coolant circuit and the equalising reservoir. The coolant circuit can be bled using the cooler bleeder line 6.

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

MJFCIFSS

5.0-9 of 12

Cooling System

Service Manual 5.0.4 Valid for:

Engine coolant cooling system L538 L538-432/0101-;

Cooling circuit for coolant 1 2 3 4 5

Equalising reservoir Reservoir cap Coolant level sight glass Reservoir overflow pipe Engine bleeder line

6 Hose from engine to cooler 7 Diesel engine 8 Coolant temperature sensor B21 9 Hose from cooler to engine

10 Cooler unit 11 Coolant cooler 12 Connecting hose from cooling circuit to reservoir 13 Cooler bleeder line

Depending on the temperature and controlled by the thermostat, the engine coolant is either cooled internally or pumped through the cooler 11. The coolant is pumped from the thermostat housing through the hose 6 from the engine to the cooler. In the cooler, the coolant flows through the fins, which are cooled by circulating air, and then returns through the hose 9 from the cooler to the engine 7. The oil returning to the engine 7 flows past the coolant temperature sensor B21 8. The coolant temperature sensor B21 8 reports the current temperature to the controller A1, which regulates the fan speed. The coolant returns to the coolant circuit via the hose 12 connecting the coolant circuit and the equalising reservoir. The coolant circuit can be bled using the engine and cooler bleeder lines 5 and 13.

5.0-10 of 12

MJFCIFSS

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

Service Manual

Cooling System

5.0.5 Valid for:

Engine intake air cooling system L524 - 438 / 8796-; L534 - 434 / 0101-; L538 - 432 / 8505-,

Charge air cooling circuit 1 Charge air cooler 2 Cooler unit 3 Charge air hose from cooler to engine

4 Engine air intake port 5 Turbocharger outlet 6 Charge air hose from engine to cooler

The air drawn in by the turbocharger and heater due to compression is pumped through the hose 6 from the engine to the charge air cooler 1. The charge air cooler 1 cools down the air and returns it via the hose 3 to the engine.

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

MJFCIFSS

5.0-11 of 12

Cooling System

5.0-12 of 12

Service Manual

MJFCIFSS

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

Service Manual

Cooling System Gear pump

5.1 Gear pump (ID 5717137, 5717323, 5716912)

Design

Gear pump arrangement 1 Oil motor scavenging gear pump 2 Oil motor scavenging return hose 3 Brake/fan gear pump 4 Fan motor pressure hose

5 Fan drive intake hose 6 Hydraulic oil temperature sensor 7 Oil motor scavenging intake hose

The fan gear pump 3 is fitted on the auxiliary drive of the engine and is driven by the engine at a specific transmission ratio via a spur gear. The fan pump 3 draws oil from the hydraulic tank and pumps it through the compact brake valve to the gear motor.

Function description Basic function

Gear pump components 1 2 3 4

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

Gear fixing nut Snap ring Shaft seal ring Flange

MJFCIFSS

7 8 9 10

Feather key Gears Housing Housing cover

5.1-1 of 2

Cooling System

Service Manual

Gear pump

5 Seals 6 Bearing bushings

11 Screw

The gear pump consists of two intermeshing gears 8 enclosed in a housing 9. One of the two gears 8 is driven via the outgoing shaft (driving gear), and the other driven by the gear teeth (driven gear). The fluid taken in is injected into the gaps between the teeth and pumped outside along the housing 9 from the intake port to the pressure port.

Pressure cut-off The cooling system gear pump pressure cut-off is performed by the pressure relief valve on the gear motor.

Technical data

5.1-2 of 1

MJFCIFSS

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

Service Manual

Cooling System Gear motor

5.2 Gear motor (ID 5717099) The gear motor 1 is attached to the fan grille. The motor 1 drives the fan blades via the fan drive shaft 2. The proportional pressure relief valve 3 attached to the gear motor 1 controls the fan speed.

Design

Gear motor with proportional pressure relief valve 1 Gear motor 2 Fan drive shaft

3 Proportional pressure relief valve

Gear motor with proportional pressure relief valve 1 2 3 4 5 6

Bearing cover Seal set Bearing bushings Gears Bearing bushings Motor housing

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

7 Seal set 8 Proportional pressure relief valve connecting housing 9 Proportional pressure relief valve 10 O-ring

MJFCIFSS

11 12 13 14 15

O-ring Shaft Roller bearing Shaft seal ring Bearing cover

5.2-1 of 4

Cooling System

Service Manual

Gear motor

Proportional pressure relief valve 1 2 3 4 5

Pressure relief adjusting screw Counter nut Cap Electromagnet Electromagnet connection

6 7 8 9

Secondary spring Housing Secondary piston Secondary restrictor

10 11 12 13

Housing Primary spring Main piston Primary restrictor

Function description Basic function The gear motor 1 is powered by the current from the gear pump. The gear motor 1 has a proportional pressure relief valve 3, which controls the speed of the gear motor and therefore the fan speed.

1 Gear motor 2 Proportional pressure relief valve assembly 3 Proportional pressure relief valve

5.2-2 of 4

MJFCIFSS

P Pump intake T1 Return to tank T2 Relief seal (return to tank)

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

Service Manual

Cooling System Gear motor

Pressure regulation by the proportional pressure relief valve

How the proportional pressure relief valve works When the solenoid 1 is not energised, the proportional pressure relief valve acts like a pilot-controlled pressure relief valve. The pressure acting at â&#x20AC;&#x153;Pâ&#x20AC;? passes through the primary restrictor 8 to the spring chamber of the main piston 7 and acts via the secondary restrictor 5 on the secondary piston 4. The pressure equalisation on the main piston 7 causes the primary spring 6 to close it. If the pressure on the secondary piston 4 becomes so high that the set force of the secondary spring 2 is exceeded, the secondary piston 4 opens, allowing oil to flow into the tank chamber. This gives rise to a difference in pressure in front of and behind the main piston 7, causing it to open. If the solenoid 1 is energised, a magnetic force is generated depending on the current. The magnetic force acts on the iron core 3, pulling it back according to the current strength. This magnetic force reduces the set spring force of the secondary spring 2 accordingly. This causes the proportional valve to open at a lower system pressure.

Fan speed regulation The proportional pressure relief valve acts as a bypass on the gear motor. At low temperature the bypass is almost fully open. Most of the pump flow goes through the bypass valve to the tank. The fan turns at low speed (minimum speed = dragging speed). As the temperature rises, the bypass valve closes proportionally. The gear motor turns the fan faster

Failsafe function The failsafe function is as follows: If the current fails at the proportional pressure relief valve, the bypass closed. The full flow of the gear pump drives the gear motor. The fan turns at maximum speed.

Technical data

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

MJFCIFSS

5.2-3 of 4

Cooling System

Service Manual

Gear motor

5.2-4 of 4

MJFCIFSS

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

Service Manual

Cooling System Temperature sensor

5.3 Temperature sensor (ID 10043264) The temperature sensor is used for measuring the temperature of the coolant and the hydraulic oil.

Design The sensor element of the temperature sensor consists of a thin-layer nickel resistor encapsulated in epoxy resin.

Function description Temperature measurement

Temperature/resistance curve The resistance in the sensor rises along with the temperature. The resistance curve of the temperature sensor is almost linear.

Technical data

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

MJFCIFSS

5.3-1 of 2

Cooling System

Service Manual

Temperature sensor

5.3-2 of 2

MJFCIFSS

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

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10 Electrical System 10.0 Chapter contents 10

Electrical System............................................................... 10.0-1 10.0.1

Electrical system with circuit diagrams (emissions tier I) ...10.0-1

10.0.2

Electrical system with circuit diagrams (emissions tier II) ..10.0-1

10.1

Fuse and relay board A4 ..............................................................10.1-1

10.2

Electronic controller A1.................................................................10.2-1 10.2.1

Electronic controller A1 version I........................................10.2-1

10.2.2

Electronic controller A1 version II.......................................10.2-8

10.3

Electronic controller A14 (diesel engine) ......................................10.3-1

10.4

Battery installation ........................................................................10.4-1 10.4.1

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

Battery ................................................................................10.4-1

MJFCIFSS

10.0-1 of 2

Electrical System

10.0-2 of 2

Service Manual

MJFCIFSS

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

Service Manual

Electrical System

10.0.1

Electrical system with circuit diagrams (emissions tier I)

Valid for:

L524-438/from 0101 – 8795; L534-434/from 0101 – 8961; L538-432/from 0101 – 8507

Design Components of the electrical system

The table below lists all the components of the electrical system. The entry in the step column helps you locate the component in the circuit diagrams. Abbreviations: – WH = Wiring harness – SV = Solenoid valve

Code

Description

Step

A1 A3 A4 A5 A13 B1 B3 B3a B4 B5 B7 B8 B9 B10 B11 B12 B13 B15 B16 B17 B19 B20 B21 B25 B26 B27 B28 B29 B30 B31 B32 CN1 CN2 CN5 CN8 CN11 CN12 CN13 CN14 D2 D3 D5

Electronic controller Radio (optional) Fuse and relay board Travel speed, service hours and clock LCD Display unit Rear axle power take-off speed sensor Emergency steering pressure switch Emergency steering check pressure switch Air filter contamination vacuum switch Parking brake pressure switch Engine oil pressure switch Hydraulic oil temperature sensor (fan control) Warning buzzer board Klaxon Speaker Brake light pressure switch Warning buzzer 1 Bucket return-to-dig proximity switch Reverse warning system Lift kick-out proximity switch Brake accumulator pressure 90 bar switch Coolant temperature indicator + thermostat Coolant temperature sensor (fan control) Fuel level sensor Air conditioning thermostat (optional) Air conditioning pressure switch (optional) Ride control off pressure switch (optional) Injection pump proximity switch Quick-change device buzzer (optional) Injection adjuster SV thermo switch L524, L534 Float position pressure switch (L534, L538) MATE-N-LOK connector, 9-pin, green MATE-N-LOK connector, 9-pin, yellow MATE-N-LOK connector, 15-pin, green MATE-N-LOK connector, 4-pin, white MATE-N-LOK connector, 12-pin, purple MATE-N-LOK connector, 12-pin, white MATE-N-LOK connector, 12-pin, red MATE-N-LOK connector, 14-pin, purple Diode 1N4007 Diode 1N4007 Diode 1N4007

4, 9, 10, 11 8/G 1 - 8, 10 3/A-B 3/A-B-C 9/G-H 10/G-H 10/G-H 3/H 4/E 3/H 9/G-H 2/D 6/A 8/H 8/C 9/H 5/E 4/H 5/E 3/H 3/H 9/G-H 3/H 7/C 7/D 5/F-G 9/G-H 5/H 1/G-H 5/F 1 - 11 1 - 11 1 - 11 1 - 11 1 - 11 1 - 11 1 - 11 1 - 11 1/C 6/D-E 2/B

L524 - 438 / 0101 - 8795 L534 - 434 / 0101 - 8961 L538 - 432 / 0101 - 8507

MJFCIFSS

Machine view 1 -1 --1 3 3 3 2 2 3 -1 -2 -2 3 2 2 1 1 1 ---3 -3 1 ------------

10.0-1 of 54

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Service Manual

Code

Description

Step

D6 D7 D8 D11 D12 D14 D15 D17 D18 D19 D20 D21 D23 D24 D25 D31 D32 D50 D69 D79 D89 D99 E1 E2 E3 E4 E5 E6 E7 E8 E9 E10 E11 E12 E13 E14 F01 F02 F03 F04 F1A

Diode 1N4007 Diode 1N4007 Diode 1N4007 Diode 1N4007 Diode 1N4007 Diode 1N4007 Diode 1N4007 Diode 1N4007 Diode P600 Diode P600 Diode 1N4007 Diode P600 Diode 1N4007 Diode 1N4007 Diode 1N4007 Diode 1N4007 Diode P300 Diode P600 Diode P600 Diode P600 Diode P600 Diode P600 Left reversing light 24 V - 21 W Cab light with switch 24 V - 10 W Left headlight 24 V - 70/75 W Right headlight 24 V - 70/75 W Left reversing light 24 V - 21 W Left tail light 24 V - 10 W Right tail light 24 V - 10 W Right profile light 24 V - 4 W Left profile light 24 V - 4 W Front left working floodlight 24 V - 70 W Front right working floodlight 24 V - 70 W Rear left working floodlight 24 V - 70 W (optional) Rear right working floodlight 24 V - 70 W (optional) Left/right number plate light 24 V - 10/10 W 100A main fuse (MEGA Fuse) 200A emergency steering pump fuse (MEGA Fuse) 60A preglow fuse (MEGA Fuse) 60A starter fuse (MEGA Fuse) 7.5A brake light fuse 10A fuse for interior lighting, socket, radio (optional), compressor seat (optional) 7.5A fuse for working attachment, fuel sensor, inductive sensor B29 15A fuse for lighting, switch lighting 15A fuse for front wiper, horn 7.5A fuse for right driving light 10A fuse for hazard warning system, working attachment, flashing beacon (optional) 15A fuse for front working floodlight 15A fuse for rear working floodlight (optional) 7.5A fuse for right high beam 3A fuse for left parking light, registration lighting 7.5A fuse for rear wiper 3A fuse for right parking light, monitor background lighting 7.5A fuse for ride control system (optional) 7.5A fuse for left driving light

1/E 5/E 5/F 4/F 1/C 7/F 5/F 6/E 6/C 2/F 6/E 6/C 5/F 4/F 5/F 1/E 2/E 1/G 5/F 5/F 6/E 6/E 4/H 8/G-H 6/G 6/G 4/H 6/G 6/G 6/G 6/G 8/G - H 8/G - H 8/G - H 8/G - H 6/G 1/E 10/G 2/C 1/C 8/A

Machine view ----------------------3 -3 3 3 3 3 3 3 3 3 --3 3 3 1 1 --

8/A

1/A 5/A 6/A 6/E

-----

6/A

8/A 8/A 6/E 6/E 7/A 6/E 5/A 6/E

---------

F1B F1C F2A F2B F2C F3A F3B F3C F4A F4B F4C F5A F5B F5C

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L524 - 438 / 0101 - 8795 L534 - 434 / 0101 - 8961 L538 - 432 / 0101 - 8507

Service Manual

Code F6A F6B F6C F7A F7B F7C F8A F8B F8C G1 G2 H2 H3 H4 H5 H6 H7 H8 H9 H10 H11 H12 H13 H15 H16 H17 H18 H19 H20 H21 H22 H23 H24 H25 H26 H27 H28 Ka Kb K1 K2 K3 K4 K5 K8 K11 K14 K17 K18 K22 K25 K26 K27 K29 M1 M2

Electrical System

Description 7.5A fuse for power supply A1, emergency steering button, pressure switch B3a 25A fuse (optional) 15A fuse for heater fan, air conditioning (optional) 7.5A fuse for left high beam 7.5A fuse for parking brake, control lever power supply 3A fuse for monitor supply (battery +30) 5A fuse for monitor (ignition +15) 10A fuse for engine stop 3A fuse for monitor supply (battery +15), preglow, engine stop Three-phase alternator with regulator Batteries (2x12 V) Preglow signal lamp Forward travel direction Engine oil pressure signal lamp Working hydraulics lockout signal lamp Battery charge indicator lamp Air filter contamination signal lamp Emergency steering signal lamp Reverse travel direction Direction indicator system signal lamp Parking brake signal lamp High beam signal lamp Engine overheating signal lamp Front left indicator light 24 V - 21 W Front right indicator light 24 V - 21 W Rear left indicator light 24 V - 21 W Rear right indicator light 24 V - 21 W Brake accumulator pressure signal lamp Left brake light 24V - 21W Right brake light 24V - 21W Flashing beacon 24V - 70W (optional) Hydraulic oil overheating signal lamp Emergency steering check signal lamp Travel range 1 signal lamp Travel range 2 signal lamp Safety belt signal lamp Special function signal lamp Reverse travel direction relay Forward travel direction relay Direction indicator relay Engine start relay Engine stop relay Preglow, afterglow relay Wiper washer interval relay Ignition on supply relay (+15) Ride control relay Relay for air conditioning coupling (optional) Lift kick-out relay Bucket return-to-dig relay Parking brake relay Right indicator relay Left indicator relay Start release relay Working hydraulics/parking brake relay Starter Front windscreen wiper motor

L524 - 438 / 0101 - 8795 L534 - 434 / 0101 - 8961 L538 - 432 / 0101 - 8507

MJFCIFSS

Step

Machine view

10/A

5/A 7/A 6/E 4/A 3/A 2/A 2/C 2/A 1/F 1/G-H 3/B-C 3/A 3/A 3/B 3/A 3/B 3/B 3/A 3/B-C 3/A 3/B-C 3/B-C 6/G 6/G 6/G 6/G 3/B 8/G-H 8/G-H 8/G-H 3/A 10/E 3/B-C 3/B-C 3/B-C 3/B-C 4/D 4/D 6/C 1/C-D 2/E 2/E 7/C 2/A-B 5/E 7/F 5/F 5/F 4/E-F 6/D-E 6/D-E 1/E 1/C-D 1/G 7/G-H

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

10.0-3 of 54

Electrical System

Service Manual

Code

Description

Step

M3 M4 M5 M8 M9 P3 P6 R1 R3 S1 S2 S3 S4 S6 S7 S8 S9 S10 S11 S12 S13 S14 S15 S16 S17 S18 S18 S19 S21 S22 S26 S100 S101 ST1 ST2 ST3 ST4 ST5 T1 V15 V30 W1 X1 X2 X3 X4 X5 X6 X7 X8 X9 X10 X11 X12 X13 X14 X15

Rear windscreen wiper motor Front windscreen washer pump Heater blower motor Emergency steering pump motor Rear windscreen washer pump Fuel level indicator Coolant temperature display Warning buzzer board resistor Flame glow system (L538 only) Ignition switch Forward/reverse travel direction button Steering column switch Hazard warning system switch Parking/driving light switch Front working floodlight switch Rear working floodlight switch (optional) * Flashing beacon switch (optional) Emergency steering pump button Heater blower motor knob Additional equipment switch (optional) Rear wiper/washer pump switch Bucket return-to-dig switch Battery main switch Ride control switch Parking brake switch Float position switch (L534, L538) Float position / lift kick-out switch (L524) Working hydraulics lockout switch Air conditioning switch (optional) Lift kick-out switch (L534, L538) Quick change device switch (optional) Travel range 1/2 switch MODE button ST1 connector, 15-pin / A1 Connector, 9-pin /A1 Connector, 15-pin /A1 Connector, 2-pin /A1 Connector, 2-pin /A1 24 V to 12 V transformer (radio) (optional) M5 screw connector M6 screw connector Radio antenna (optional) Connector, 9-pin / main WH Connector, 70-pin / main WH Connector, 11-pin / dash WH (monitor) Connector, 21-pin / dash WH (monitor) Connector, 6-pin Deutsch (front section) Connector, 6-pin Deutsch (front section) Connector, 6-pin Deutsch (rear left lighting) Connector, 6-pin Deutsch (rear right lighting) Connector, 2-pin Deutsch (parking brake SV Y10) Connector, 15-pin / dash WH (switch bar) Connector, 15-pin / dash WH (switch bar) Connector, 2-pin Junior Timer (working hydraulics SV Y14) Connector, 4-pin XLR (travel direction SV Y26) Connector, 4-pin XLR (reverse SV Y3) Connector, 4-pin XLR (forward SV Y2)

7/G-H 7/G-H 7/G-H 10/G-H 7/G-H 3/B 3/A-B 2/C-D 2/H 1/B 4, 11/E-F 6/A-B-C 6/D 6/D 8/C 8/C 8/C 10/E 7/C 11/D 7/C 5/C 1/H 5/D 4/D 5/D 5/D 5/C 7/C 5/C 5/D 4/E 5/A-B 4, 9, 10 4, 9, 10 4, 9, 10 4, 9, 10 4, 9, 10, 11 8/E 1/A 1/C 8/G 1/F 3 - 11 3/C 3/C 6/G-H 6/G-H 4, 6, 8 4, 6, 8 4/H 3, 5, 7, 11 5, 7, 10, 11 5/H 4/H 4/H 4/H

10.0-4 of 54

MJFCIFSS

Machine view -2 -3 2 ---3 -------------3 -----------------------------------

L524 - 438 / 0101 - 8795 L534 - 434 / 0101 - 8961 L538 - 432 / 0101 - 8507

Service Manual

Electrical System

Code

Description

Step

X16 X17 X18 X19 X20 X21 X22 X23 X24 X25 X26 X27 X28 X29 X30 X31 X32 X33 X34 X35 X36 X37 X38 X39 X40 X41 X42 X43 X44 X45 X46 X47 X48 X49 X50 X52

Connector. 6-pin / MATE-N-LOK (solenoids Y9, 17, 18) Connector, 4-pin / M12x1 (proximity switch B17) Connector, 2-pin Deutsch (backup alarm) Connector, 8-pin MATE-N-LOK (control panel) Connector, 5-pin MARK-II (preglow relay K4) Connector, 2-pin Deutsch (cab) Connector, 12-pin MATE-N-LOK (cab) Connector, 4-pin / M12x1 (tilt cylinder B15) Connector, 7-pin (steering column switch) Connector, 7-pin (steering column switch) Connector, 2-pin Deutsch (pressure switch B12) Connector, 2-pin Deutsch (number plate lighting) Connector, 6-pin Fastin-Faston (front wiper) Connector, 2-pin Fastin-Faston (front washer pump) Connector, 2x1-pin Fastin-Faston (flashing beacon) Connector, 2-pin Fastin-Faston (rear washer pump) Connector, 4-pin Fastin-Faston (rear wiper) Connector, 2x1-pin Fastin-Faston (cab roof E10) Connector, 2x1-pin Fastin-Faston (cab roof E12) Connector, 2x1-pin Fastin-Faston (cab roof E11) Connector, 4-pin Fastin-Faston (heater blower) Connector, 6-pin Fastin-Faston (cab radio) Connector, 2-pin Deutsch (air conditioning compressor) Connector, 2x1-pin Fastin-Faston (rear cab) Connector, 4-pin Deutsch (pressure switch B27) Socket (cab) Connector, 3-pin MATE-N-LOK (transformer T1) Connector, 2-pin Deutsch (pressure switch B19) Connector, 3-pin Deutsch (pressure switch B1) Connector, 2-pin Deutsch (proportional valve Y13) Connector, 2-pin Junior Timer (temperature sensor B21) Connector, 2-pin Junior Timer (temperature sensor B8) Connector, 2-pin Deutsch (pressure switch B3a) Connector, 2-pin Deutsch (pressure switch B3) Connector, 2-pin Junior Timer (travel range 1 SV) Connector, 2-pin Deutsch (proximity switch B28) Connector, 2-pin Deutsch (pressure switch B32) (L534, L538) Connector, 4-pin Deutsch (fuel level sensor R4) Connector, 2-pin Junior Timer (quick change SV Y28) Connector, 10-pin MATE-N-LOK (control panel) Connector, 10-pin MATE-N-LOK (control panel) Connector, 2-pin Junior Timer (0-inching 0 SV Y15) Connector, 2-pin Junior Timer (ride control SV Y20) Connector, 2-pin Junior Timer (ride control SV Y21) Connector, 2-pin Fastin-Faston (cab roof radio) Connector, 4-pin / M12x1 (proximity switch B29) Connector, 3-pin Deutsch (pressure switch B5) Connector, 4-pin / M12x1 (proximity switch B29) Screw connector (engine stop SV) Connector, 6-pin Fastin-Faston (relay K5) Connector, 4-pin Merit (ignition switch S1) Connector, 6-pin Merit (ignition switch S1) Connector, 2x1-pin Fastin-Faston (cab roof E2) Connector, 2-pin Superseal (temperature switch B31) Connector, 2-pin Junior Timer (additional equipment SV Y11) Connector, 2-pin Junior Timer (additional equipment SV Y12)

5/H 5/E 4/H 4, 8 2/E 8/D 6, 7, 8 5 6/A-B 6/B-C 8/C-D 6/G-H 7/G-H 7/G-H 8/G-H 7/G-H 7/G-H 8/G-H 8/G-H 8/G-H 7/G-H 8/G 7/G 7/C 7/D-E 8/G-H 8/E-F 3/H 9/G 9/G-H 9/G 9/G 10/G 10/G-H 4/H 5/F-G

Machine view -------------------------------------

5/F

3/H 5/H 4, 11/C-D 4, 11/C-D 9/G-H 5/H 5/H 8/F 4/E 4/E 9/G-H 2/H 7/C-D 2/C 1/B 8/G-H 1/G-H 11/G-H 11/G-H

--------------------

X53 X54 X55 X56 X57 X58 X59 X60 X61 X62 X64 X65 X66 X67 X68 X69 X70 X71 X72 X73

L524 - 438 / 0101 - 8795 L534 - 434 / 0101 - 8961 L538 - 432 / 0101 - 8507

MJFCIFSS

10.0-5 of 54

Electrical System

Service Manual

Code

Description

Step

X74 Y1 Y2 Y3 Y4 Y5 Y6 Y9 Y10 Y11 Y12 Y13 Y14 Y15 Y17 Y18 Y20 Y21 Y22 Y28

Connector, 2-pin (starting excess fuel Y4) Preglow solenoid valve (L538 only) Forward travel direction solenoid valve Reverse travel direction solenoid valve Injection adjuster solenoid valve (L524, L534) Engine stop solenoid Travel range 1 solenoid valve Bucket return-to-dig solenoid Parking brake solenoid valve Additional equipment solenoid valve (optional) Additional equipment solenoid valve (optional) Cooling system proportional pressure relief valve Working hydraulics lockout solenoid valve 0-inching solenoid valve Lift kick-out solenoid Float position solenoid Ride control solenoid valve Ride control and float position solenoid valve Air conditioning compressor magnetic coupling Quick change device solenoid valve

1/H 2/H 4/H 4/H 1/H 2/H 4/H 5/H 4/H 11/H 11/H 9/H 5/H 9/H 5/H 5/H 5/H 5/H 7/H 5/H

10.0-6 of 54

MJFCIFSS

Machine view -3 3 3 3 3 2 1 2 3 3 3 2 2 1 1 3 3 -3

L524 - 438 / 0101 - 8795 L534 - 434 / 0101 - 8961 L538 - 432 / 0101 - 8507

Service Manual

Electrical System

Machine view 1 (right)

Machine view 2 (left)

L524 - 438 / 0101 - 8795 L534 - 434 / 0101 - 8961 L538 - 432 / 0101 - 8507

MJFCIFSS

10.0-7 of 54

Electrical System

Service Manual

Machine view 3 (from above)

Function description Circuit diagrams The circuit diagrams are broken down into steps 1 to 11. The following list contains the steps and their main functions. Overview of sections for the electrical system: 1 Power supply: battery, alternator, ignition switch, battery main switch, starter 2 Engine control: engine stop, preglow, cold start solenoid valve L524, L534 / flame glow system solenoid valve L538 3 Engine monitoring: display unit A13, temperature switch, pressure switch, fuel level sensor 4 Travel drive: electronic controller A1, travel hydraulics solenoid valve, parking brake solenoid valve, control lever S2 and S100 5 Working hydraulics: switches, proximity switches, retaining solenoids, ride control 6 Lighting: steering column switch, driving headlights, direction indicator system, horn 7 Wiper system: front wipers, rear wiper, air conditioning 8 Lighting: working headlights, brake light, cab light, radio (optional) 9 Cooling system / 0-inching: temperature sensors, fan drive proportional solenoid, injection pump proximity switch, 0-inching solenoid valve, power take-off speed sensor 10 Emergency steering system: electronic controller A1, emergency steering pressure switch, emergency steering pump, emergency steering switch 11 Additional equipment: electronic controller A1, additional equipment switch, additional equipment solenoid valves

10.0-8 of 54

MJFCIFSS

L524 - 438 / 0101 - 8795 L534 - 434 / 0101 - 8961 L538 - 432 / 0101 - 8507

Service Manual

Electrical System The circuit diagrams of the electrical system show the function sequences for the entire machine, including optional equipment. All components and connections are marked with a code or number and shown with the appropriate switching code so that they are clearly identifiable. The keys also list the designations of the components. The circuit diagrams are vertically divided into steps, each of which can contain one or more functions. Power connections between the steps are indicated. The wire designation and the step/co-ordinates are shown at the end.

L524 - 438 / 0101 - 8795 L534 - 434 / 0101 - 8961 L538 - 432 / 0101 - 8507

MJFCIFSS

10.0-9 of 54

Electrical System

Service Manual

Step 1 power supply: main switch, battery, alternator, starter, ignition Step 2 engine control: preglow system, solenoid, engine stop

10.0-10 of 54

MJFCIFSS

L524 - 438 / 0101 - 8795 L534 - 434 / 0101 - 8961 L538 - 432 / 0101 - 8507

Service Manual

Code A4 B9 B31 CN1 CN2 CN5 CN8 CN11 CN12 CN13 CN14 D2 D5 D6 D12 D19 D31 D32 D50 F01 F03 F04 F1C F8A F8B F8C G1 G2 K2 K3 K4 K8 K27 K29 M1 R1 R3 S1 S15 X1 X20 X66 X68 X69 X71 X74 Y1 Y4 Y5

Electrical System

Description Step Fuse and relay board 1-2 Warning buzzer board 2/D Injection adjuster SV thermo switch L524, L534 1/G-H MATE-N-LOK connector, 9-pin, green 1-2 MATE-N-LOK connector, 9-pin, yellow 1-2 MATE-N-LOK connector, 15-pin, green 1-2 MATE-N-LOK connector, 4-pin, white 1-2 MATE-N-LOK connector, 12-pin, purple 1-2 MATE-N-LOK connector, 12-pin, white 1-2 MATE-N-LOK connector, 12-pin, red 1-2 MATE-N-LOK connector, 15-pin, purple 1-2 Diode 1N4007 1/C Diode 1N4007 2/B Diode 1N4007 1/E Diode 1N4007 1/C Diode P600 2/F Diode 1N4007 1/E Diode P300 2/E Diode P600 1/G 100 A main fuse (MEGA fuse) 1/E 60A preglow fuse (MEGA Fuse) 2/C 60A starter fuse (MEGA Fuse) 1/C 7.5A fuse for working attachment, fuel sensor, inductive sensor B29 1/A 5A fuse for monitor (ignition +15) 2/A 10A fuse for engine stop 2/C 3A fuse for monitor supply (battery +15), preglow, engine stop 2/A Three-phase alternator with regulator 1/F Batteries (2x12 V) 1/G-H Engine start relay 1/C-D Engine stop relay 2/E Preglow, afterglow relay 2/E Ignition on supply relay (+15) 2/A-B Start release relay 1/E Working hydraulics/parking brake relay 1/C-D Starter 1/G Resistor (warning buzzer board) 2/C-D Flame glow system (L538 only) 2/H Ignition switch 1/B Battery main switch 1/H Connector, 9-pin / main WH 1/F Connector, 5-pin MARK-II (preglow relay K4) 2/E Screw connector (engine stop SV) 2/H Connector, 4-pin Merit (ignition switch S1) 2/C Connector, 6-pin Merit (ignition switch S1) 1/B Connector, 2-pin Superseal (temperature switch B31) 1/G-H Connector, 2-pin (starting excess fuel Y4) 1/H Preglow solenoid valve (L538 only) 2/H Injection adjuster solenoid valve (L524, L534) 1/H Engine stop solenoid 2/H Cold start systems The job of the cold start systems is to make sure the machine starts at low temperatures. The following cold start systems are provided:

Preglow system At a temperature below 5Â°C, the preglow relay K4 is automatically activated. The preglow time depends on the outside temperature.

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Electrical System

Service Manual The voltage is relayed via the fuse F03 and the preglow relay K4 to the air heater L524, L534 / glow plug L538. On L538 machines, the solenoid valve Y1 is also activated to supply diesel to the glow plug. Glowing consists of two phases: – Preglowing, which is indicated by the preglow signal lamp H2 lighting up. – Afterglowing, which is three times as long as the preglow phase, but is not indicated.

Automatic injection adjuster L524 and L534 machines also have an automatic injection adjuster. If the coolant temperature is below 50°C, the thermo switch B31 energises the solenoid valve Y4. The injection adjuster solenoid valve Y4 adjusts the time of injection up to 50°C coolant temperature.

Relay functions – Engine start relay K2. This relay is activated by the ignition start switch S1. It switches the voltage from the fuse F04 (60A) to the starter terminal 50. – Engine stop relay K3. When the ignition is on, the relay is activated and switches the voltage from the fuse F8B to the starter solenoid Y5 and via the thermo switch B31 the injection adjuster solenoid valve Y4. – Ignition on power supply relay K8. When the ignition is on, this relay switches on the power for the remaining consumers. – Start release relay K27. When the ignition on the relay is picked up and the connection to the relay K14 is interrupted. The earth connection is made via the alternator terminal 61. When the engine is running terminal 61 is switched from earth to positive and the relay K27 drops off again. The voltage is directed from the fuse F1C via the relay K27 to the air conditioning coupling relay K14. The relay K14 picks up and connects the air conditioning pressure switch B27 to the air conditioning compressor solenoid coupling Y22. – Working hydraulics/parking brake relay K29. When the engine is running the relay is activated by the alternator terminal 61 and picks up. The fuse F1C supplies the switch S17 pin 7 for the parking brake and the switch S19 pin 4 for the working hydraulics lockout.

Buzzer B9 The buzzer sounds for the following faults: – Insufficient engine oil pressure – Excessive engine oil temperature – Insufficient brake accumulator oil pressure – Emergency steering activated – Cooling water overheating

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L524 - 438 / 0101 - 8795 L534 - 434 / 0101 - 8961 L538 - 432 / 0101 - 8507

Service Manual

L524 - 438 / 0101 - 8795 L534 - 434 / 0101 - 8961 L538 - 432 / 0101 - 8507

Electrical System

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Electrical System

Service Manual

Step 3 engine monitoring: display unit A13, temperature switch, pressure switch, fuel level sensor

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MJFCIFSS

L524 - 438 / 0101 - 8795 L534 - 434 / 0101 - 8961 L538 - 432 / 0101 - 8507

Service Manual

Code A5 A13 A4 B4 B7 B19 B20 B25 CN12 F7C H2 H3 H4 H5 H6 H7 H8 H9 H10 H11 H12 H13 H19 H23 H25 H26 H27 H28 P3 P6 X2 X3 X4 X10 X43 X54

Electrical System

Description Travel speed, service hours and clock LCD Display unit Fuse and relay board Air filter contamination vacuum switch Engine oil pressure switch Brake accumulator pressure 90 bar switch Coolant temperature indicator + thermostat Fuel level sensor MATE-N-LOK connector, 12-pin, white 3A fuse for monitor supply (battery +30) Preglow signal lamp Forward travel direction Engine oil pressure signal lamp Working hydraulics lockout signal lamp Battery charge indicator lamp Air filter contamination signal lamp Emergency steering signal lamp Reverse travel direction Direction indicator system signal lamp Parking brake signal lamp High beam signal lamp Engine overheating signal lamp Brake accumulator pressure signal lamp Hydraulic oil overheating signal lamp Travel range 1 signal lamp Travel range 2 signal lamp Safety belt signal lamp Special function signal lamp Fuel level indicator Coolant temperature display Connector, 70-pin / main WH Connector, 11-pin / dash WH (monitor) Connector, 21-pin / dash WH (monitor) Connector, 15-pin / dash WH (switch bar) Connector, 2-pin Deutsch (pressure switch B19) Connector, 4-pin Deutsch (fuel level sensor R4)

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MJFCIFSS

Step 3/A-B 3/A-C 3/B 3/H 3/H 3/H 3/H 3/H 3/B 3/A 3/B-C 3/A 3/A 3/B 3/A 3/B 3/B 3/A 3/B-C 3/A 3/B-C 3/B-C 3/B 3/A 3/B-C 3/B-C 3/B-C 3/B-C 3/B 3/A-B 3/G 3/C 3/C 3/F 3/H 3/H

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Electrical System

Service Manual Valid for:

L538-432/ from 0101 - 6870

Step 4 travel drive: electronic controller A1, travel hydraulics solenoid valve, parking brake solenoid valve, control lever S2

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Service Manual

Electrical System

Code A1 A4 B5 B16 CN12 CN13 CN14 D11 D24 E1 E5 F7B Ka Kb K22 S2 S17 ST2 ST3 ST4 X2 X7 X8 X9 X13 X14 X15 X18 X50 X56 X57 X64 Y2 Y3 Y6 Y10 Y26

Description Step Electronic controller 4/A Fuse and relay board 4 Parking brake pressure switch 4/E Back-up alarm 4/H MATE-N-LOK connector, 12-pin, white 4/B MATE-N-LOK connector, 12-pin, red 4/B MATE-N-LOK connector, 15-pin, purple 4/E Diode 1N4007 4/F Diode 1N4007 4/F Left reversing light 24 V - 21 W 4/H Left reversing light 24 V - 21 W 4/H 7.5A fuse for parking brake, control lever power supply 4/A Reverse travel direction relay 4/D Forward travel direction relay 4/D Parking brake relay 4/E-F Forward/reverse travel direction button 4/E-F Parking brake switch 4/D Connector, 9-pin /A1 4/A Connector, 15-pin /A1 4/A Connector, 2-pin /A1 4/A Connector, 70-pin / main WH 4 Connector, 6-pin Deutsch (rear left lighting) 4/H Connector, 6-pin Deutsch (rear right lighting) 4/H Connector, 2-pin Deutsch (parking brake SV Y10) 4/H Connector, 4-pin XLR (travel direction SV Y26) 4/H Connector, 4-pin XLR (reverse SV Y3) 4/H Connector, 4-pin XLR (forward SV Y2) 4/H Connector, 2-pin Deutsch (backup alarm) 4/H Connector, 2-pin Junior Timer (travel range 1 SV) 4/H Connector, 10-pin MATE-N-LOK (control panel) 4/C-D Connector, 10-pin MATE-N-LOK (control panel) 4/C-D Connector, 3-pin Deutsch (pressure switch B5) 4/E Forward travel direction solenoid valve 4/H Reverse travel direction solenoid valve 4/H Travel range 1 solenoid valve 4/H Parking brake solenoid valve 4/H Coupling solenoid valve (absent) 4/H Electric travel hydraulics circuit The travel hydraulics are controlled via the LH control lever S2, the relay Ka/Kb and the electronic controller A1. When the ignition is on there must always be voltage from the fuse F7B via the two relays Ka, Kb connection 87a to the electronic controller ST2 pin 7 and 8 (safety circuit). The travel range can be preselected when the ignition is on. The travel range can only be activated with the motor running and the parking brake off. Safety circuit If the travel direction is preselected and the voltage signal between the relays Ka, Kb and the electronic controller ST2 pin 7 and 8 is interrupted, the machine will not move. This is indicated by the red LED H12 on the control board A1 lighting up. Travelling forwards When the parking brake is engaged, the pressure switch B5 closes and sends a voltage signal to the electronic controller A1 ST2 pin 7. When you select forward travel direction with the switch S2 the relay Kb is activated. As long as the switch is pressed, the voltage signal from the relay

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Electrical System

Service Manual Kb changes from 87a to 87. Forward travel is activated. Output ST3 pin 5 to the forward solenoid valve Y2 is active. If the parking brake is engaged, the pressure switch B5 is depressurised and the voltage supply from the fuse (F7B - ST2 pin 6) is interrupted. When ST2 pin 6 is not energised, the preselected travel direction is deactivated. Travelling in reverse When the parking brake is engaged, the pressure switch B5 closes and sends a voltage signal to the electronic controller A1 ST2 pin 7. When you select forward travel direction with the switch S2 the relay Ka is activated. As long as the switch is pressed, the voltage signal from the relay Ka changes from 87a to 87. Reverse travel is activated. Output ST3 pin 6 to the forward solenoid valve Y3 is active. If the parking brake is engaged, the pressure switch B5 is depressurised and the voltage supply from the fuse (F7B - ST2 pin 6) is interrupted. When ST2 pin 6 is not energised, the preselected travel direction is deactivated. Switching between travel ranges 1, 2 and neutral After the engine is started, travel range 2 is always activated. If you select travel range 1 on the switch S2, a voltage signal is sent to the electronic controller A1 ST2 pin 11. The electronic controller A1 sends a voltage signal on ST3 pin 2 to the travel range 1 solenoid valve Y6. When the travel range 1 solenoid valve Y6 is energised, the travel motor M2 is held at the maximum angle. If you select travel range 2 on the switch S2, a voltage signal is sent to the electronic controller A1 ST2 pin 10. The output on the electronic controller A1 (ST3 pin 2 to the travel range 1 solenoid valve Y6) is de-energised, and so therefore is the travel range 1 solenoid valve Y6 on the cut-in block. When the travel range 1 solenoid valve Y6 is de-energised, the travel motor M2 returns to the minimum angle. To select neutral travel direction, hold the switch S2 on travel range 1 for 3 seconds. Hydraulic oil temperature protection If the hydraulic oil overheats (more than 106°C measured by the temperature sensor B8), the machine automatically switches down to travel range 1 after a minute. In this condition the following warning signals are activated: – Warning buzzer B13: 3 seconds on, 10 seconds off etc. – The travel range 1 and 2 indicators H25 and H26 flash alternately every 500ms. – Hydraulic oil overheating signal lamp H23 lights up continuously. – The green LED H13 on the electronic controller A1 lights up. The warning signals and travel range 1 remain active until the hydraulic oil temperature falls back below 106 °C.

Overspeed protection

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Reversing block The reversing block is activated at above 16 km/h. If the travel direction is switched at a speed above 16 km/h, the pump is first switched to neutral. The machine speed is reduced while the pump is in neutral. The travel direction is changed once the speed is below 16 km/h. Overspeed protection is activated in the following situations: – At full throttle and speeds above 37.2 km/h the travel range 1 solenoid valve Y6 is activated.

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Service Manual

Function of parking brake switch S17

Electrical System â&#x20AC;&#x201C; At speeds above 37.2 km/h with the gas pedal in the idle position, the travel pump is switched to neutral. â&#x20AC;&#x201C; If the travel speed exceeds 41.7 km/h the warning buzzer B13 makes a continuous tone. Parking brake switch S17 with positions 2, 0, 1 Position 1 (OFF) When you start the engine, you must briefly press position 1 (OFF) to release the brake. The safety circuit prevents inadvertent release of the brake.

With the motor running, voltage is directed via the relay K29 (working hydraulics, parking brake) to the switch pin 7. When you press the switch S17 in position 1 the contact in the switch closes pins 7 and 5, the relay K22 picks up, the contact in K22 closes a circuit and the connection to S17 pin 6. Position 0 When you let go of the button, the switch S17 is in the 0 position, pins 4 and 6 are connected and the solenoid valve Y10 is energised. The pressure switch B5 switches when the opening pressure is reached. The positive signal to the parking brake signal lamp H11 is interrupted and a positive signal is sent to the electronic controller A1. Position 2 (ON) When the switch S17 is pressed in position 2 (ON), the connection to Y10 is interrupted and the parking brake is engaged. The pressure switch B5 switches the signal lamp H11 on and the travel direction to neutral. The relay K22 remains picked up.

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Electrical System

Service Manual Valid for:

L524-438/from 0101 - 9315; L534-434/from 0101 - 9419; L538-432/from 6871 9436

Step 4 travel drive: electronic controller A1, travel hydraulics solenoid valve, parking brake solenoid valve, control lever S100

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Service Manual

Code A1 A4 B5 B16 CN12 CN13 CN14 D11 D24 E1 E5 F7B Ka Kb K22 S2 S17 S100 ST1 ST2 ST3 X2 X7 X8 X9 X13 X14 X15 X18 X50 X56 X57 X64 Y2 Y3 Y6 Y10 Y26

Electrical System

Description Electronic controller Fuse and relay board Parking brake pressure switch Back-up alarm MATE-N-LOK connector, 12-pin, white MATE-N-LOK connector, 12-pin, red MATE-N-LOK connector, 15-pin, purple Diode 1N4007 Diode 1N4007 Left reversing light 24 V -21 W Left reversing light 24 V -21 W 7.5A fuse for parking brake, control lever power supply Reverse travel direction relay Forward travel direction relay Parking brake relay Forward/reverse travel direction button Parking brake switch Travel range 1/2 switch Connector, 15-pin /A1 Connector, 9-pin /A1 Connector, 15-pin /A1 Connector, 70-pin / main WH Connector, 6-pin Deutsch (rear left lighting) Connector, 6-pin Deutsch (rear right lighting) Connector, 2-pin Deutsch (parking brake SV Y10) Connector, 4-pin XLR (travel direction SV Y26) Connector, 4-pin XLR (reverse SV Y3) Connector, 4-pin XLR (forward SV Y2) Connector, 2-pin Deutsch (backup alarm) Connector, 2-pin Junior Timer (travel range 1 SV) Connector, 10-pin MATE-N-LOK (control panel) Connector, 10-pin MATE-N-LOK (control panel) Connector, 3-pin Deutsch (pressure switch B5) Forward travel direction solenoid valve Reverse travel direction solenoid valve Travel range 1 solenoid valve Parking brake solenoid valve Coupling solenoid valve (absent)

Electric travel hydraulics citcuit

Step 4/A 4 4/E 4/H 4/B 4/B 4/E 4/F 4/F 4/H 4/H 4/A 4/D 4/D 4/E-F 4/E-F 4/D 4/E 4/A 4/A 4/A 4 4/H 4/H 4/H 4/H 4/H 4/H 4/H 4/H 4/C-D 4/C-D 4/E 4/H 4/H 4/H 4/H 4/H

The travel hydraulics are controlled via the LH control lever S2, the switch S100, the relay Ka/Kb and the electronic controller A1. The travel range and direction can only be activated with the motor running and the parking brake off. Switching between travel ranges 1, 2 and neutral After the engine is started, travel range 2 is always activated. If you select travel range 1 (tortoise) on the button S100, a voltage signal is sent to the electronic controller A1 ST2 pin 11. The electronic controller A1 sends a voltage signal on ST3 pin 2 to the travel range 1 solenoid valve Y6. When the travel range 1 solenoid valve Y6 is energised, the travel motor M2 is held at the maximum angle. If you select travel range 2 (hare) on the button S100, a voltage signal is sent to the electronic controller A1 ST2 pin 10. The output on the electronic controller A1 (ST3 pin 2 to the travel range 1 solenoid valve Y6) is de-energised, and so therefore is the travel range 1 solenoid valve Y6.

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Electrical System

Service Manual When the travel range 1 solenoid valve Y6 is de-energised, the travel motor M2 returns to the minimum angle. To select neutral travel direction, hold the button S100 on travel range 1 for 3 seconds.

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L524 - 438 / 0101 - 8795 L534 - 434 / 0101 - 8961 L538 - 432 / 0101 - 8507

Service Manual

L524 - 438 / 0101 - 8795 L534 - 434 / 0101 - 8961 L538 - 432 / 0101 - 8507

Electrical System

MJFCIFSS

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Electrical System

Service Manual Valid for:

L524 -438 / from 0101

Step 5 working hydraulics: switches, proximity switches, retaining solenoids, ride control

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MJFCIFSS

L524 - 438 / 0101 - 8795 L534 - 434 / 0101 - 8961 L538 - 432 / 0101 - 8507

Service Manual

Code A4 B15 B17 B28 B30 CN2 CN5 CN11 CN13 D7 D8 D15 D23 D25 D69 F2A F5B F6B K11 K17 K18 S14 S16 S18 S19 S22 S26 S101 X2 X10 X11 X12 X16 X17 X23 X52 X55 X60 X61 Y9 Y14 Y17 Y18 Y20 Y21 Y28

Electrical System

Description Fuse and relay board Bucket return-to-dig proximity switch Lift kick-out proximity switch Ride control off pressure switch (optional) Quick-change device buzzer (optional) MATE-N-LOK connector, 9-pin, yellow MATE-N-LOK connector, 15-pin, green MATE-N-LOK connector, 12-pin, purple MATE-N-LOK connector, 12-pin, red Diode 1N4007 Diode 1N4007 Diode 1N4007 Diode 1N4007 Diode 1N4007 Diode 1N4007 15A fuse for lighting, switch lighting 7.5A fuse for ride control system (optional) 25A fuse (optional) Ride control relay Lift kick-out relay Bucket return-to-dig relay Bucket return-to-dig switch Ride control switch Float position, lift kick-out switch Working hydraulics lockout switch Lift kick-out switch (L534, L538) Quick change device switch (optional) MODE button Connector, 70-pin / main WH Connector, 15-pin / dash WH (switch bar) Connector, 15-pin / dash WH (switch bar) Connector, 2-pin Junior Timer (working hydraulics SV Y14) Connector 6-pin / MATE-N-LOK (solenoids Y9, 17, 18) Connector, 4-pin / M12x1 (proximity switch B17) Connector, 4-pin / M12x1 (tilt cylinder B15) Connector, 2-pin Deutsch (proximity switch B28) Connector, 2-pin Junior Timer (quick change SV Y28) Connector, 2-pin Junior Timer (ride control SV Y20) Connector, 2-pin Junior Timer (ride control SV Y21) Bucket return-to-dig solenoid Working hydraulics lockout solenoid valve Lift kick-out solenoid Float position solenoid Ride control solenoid valve Ride control solenoid valve (optional) Quick change device solenoid valve

Electric working hydraulics circuit

Step 5 5/E 5/E 5/F-G 5/H 5 5 5 5/A 5/E 5/F 5/F 5/F 5/F 5/F 5/A 5/A 5/A 5/E 5/F 5/F 5/C 5/D 5/D 5/C 5/C 5/D 5/A-B 5 5 5 5/H 5/H 5/E 5 5/F-G 5/H 5/H 5/H 5/H 5/H 5/H 5/H 5/H 5/H 5/H

Automatic bucket return-to-dig function When the bucket return-to-dig switch S14 is pressed, the inductive proximity switch B15 (N/O) is energised. The proximity switch B15 is closed when actuated (N/O). The relay K18 on the board (fuses, relays) A4 is activated and the solenoid Y9 on the pilot control device is energised. If the pilot control lever is moved fully to "tilt in", the solenoid Y19 holds it in position.

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Electrical System

Service Manual The bucket is now tilted in until the proximity switch B15 is switched off and the circuit to the magnet Y9 is broken by the relay K18. The pilot control lever returns by spring force to the neutral position. The bucket remains in the horizontal position. Lift kick-out function If the float position / lift kick-out switch S18 is pressed, the proximity switch B17 activates the relay K17. The proximity switch B17 is closed when not actuated (N/C). The relay K17 on the electronic controller A4 is activated and the solenoid Y17 in the pilot control device is activated. If the pilot control lever is moved fully to "lift up", the solenoid Y18 holds it in position. The lift arms move up until the proximity switch B17 switches off. The circuit to the solenoid Y17 is interrupted by the relay K17. The pilot control lever returns by spring force to the neutral position and the lift movement is stopped. Float position function If the float position / lift kick-out switch S18 is pressed, the proximity switch B17 and the relay K17 energise the solenoid Y18. If the pilot control lever is moved fully to "down", the solenoid Y18 holds it in position.

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MJFCIFSS

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Service Manual

L524 - 438 / 0101 - 8795 L534 - 434 / 0101 - 8961 L538 - 432 / 0101 - 8507

Electrical System

MJFCIFSS

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Electrical System

Service Manual Valid for:

L534 – 434/0101 – 6870; L538 – 432/0101 - 6870

Step 5 working hydraulics: switches, proximity switches, retaining solenoids, ride control

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MJFCIFSS

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Service Manual

Code A4 B15 B17 B18 B28 B30 B32 CN2 CN5 CN11 CN13 D7 D8 D15 D23 D25 D69 D79 F2A F5B F6B K11 K17 K18 S14 S16 S18 S19 S22 S26 S101 X2 X10 X11 X12 X16 X17 X23 X52 X53 X55 X60 X61 Y9 Y14 Y17 Y18 Y20 Y21 Y28

Electrical System

Description Fuse and relay board Bucket return-to-dig proximity switch Lift kick-out proximity switch Ride control proximity switch Ride control off pressure switch (optional) Quick-change device buzzer (optional) Float position pressure switch MATE-N-LOK connector, 9-pin, yellow MATE-N-LOK connector, 15-pin, green MATE-N-LOK connector, 12-pin, purple MATE-N-LOK connector, 12-pin, red Diode 1N4007 Diode 1N4007 Diode 1N4007 Diode 1N4007 Diode 1N4007 Diode 1N4007 Diode 1N4007 15A fuse for lighting, switch lighting 7.5A fuse for ride control system (optional) 25A fuse (optional) Ride control relay Lift kick-out relay Bucket return-to-dig relay Bucket return-to-dig switch Ride control switch Float position switch (L534, L538) Working hydraulics lockout switch Lift kick-out switch (L534, L538) Quick change device switch (optional) MODE button Connector, 70-pin / main WH Connector, 15-pin / dash WH (switch bar) Connector, 15-pin / dash WH (switch bar) Connector, 2-pin Junior Timer (working hydraulics SV Y14) Connector 6-pin / MATE-N-LOK (solenoids Y9, 17, 18) Connector, 4-pin / M12x1 (proximity switch B17) Connector, 4-pin / M12x1 (tilt cylinder B15) Connector, 2-pin Deutsch (proximity switch B28) Connector, 2-pin Deutsch (pressure switch B32) Connector, 2-pin Junior Timer (quick change SV Y28) Connector, 2-pin Junior Timer (ride control SV Y20) Connector, 2-pin Junior Timer (ride control SV Y21) Bucket return-to-dig solenoid Working hydraulics lockout solenoid valve Lift kick-out solenoid Float position solenoid Ride control solenoid valve Ride control and float position solenoid valve Quick change device solenoid valve

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MJFCIFSS

Step 5 5/E 5/E 5/C 5/F-G 5/H 5/F 5 5 5 5/A 5/E 5/F 5/F 5/F 5/F 5/F 5/F 5/A 5/A 5/A 5/E 5/F 5/F 5/C 5/D 5/D 5/C 5/C 5/D 5/A-B 5 5 5 5/H 5/H 5/E 5 5/F-G 5/F 5/H 5/H 5/H 5/H 5/H 5/H 5/H 5/H 5/H 5/H

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Electrical System

Electric working hydraulics circuit

Service Manual Function of the working hydraulics lockout switch S19

Switch position 1 with ignition off (safety): – When you press the switch in position 1 the contact in the switch connects pins 7 and 5, and the voltage comes directly from the battery to the solenoid valve Y14 (working hydraulics lockout). – Circuit: batteries G2, fuse F01, fuse F3A, switch S19 pin 7 to pin 5, and to solenoid Y14. – As long as the button is pressed in position 1 and there is pressure in the hydro accumulator (pilot control), the lift arms can be lowered. The main switch S15 must be switched on. Switch position 0 (operation) with the engine running: – In switch position 0 pin 4 is connected to pin 6 and the voltage is directed from (terminal D+) to the solenoid valve Y14 and various components. The valve opens and the pilot control pressure is available to the pilot control device. – Circuit: from (terminal D+) via fuse F1C, relay K29, switch S19 to the solenoid valve Y14. Switch position 2 (OFF, road travel): – When you press the switch S19 in position 2, the contacts 4 and 2 are connected. The connection to the solenoid valve Y14 and the components is interrupted. – The working hydraulics lockout symbol field lights up (activated via pins 4 and 2 in the switch S19). Pin assignment of the inductive switches B15 and B17 1 Power supply + 2 Switch output N/C + signal 3 Earth connection 4 Switch output N/O + signal Automatic bucket return-to-dig function When the bucket return-to-dig switch S14 is pressed, the inductive proximity switch B15 (N/O) is energised. The proximity switch B15 is closed when actuated (N/O). The relay K18 on the board (fuses, relays) A4 is activated and the solenoid Y9 on the pilot control device is energised. If the pilot control lever is moved fully to "tilt in", the retaining disc touches the solenoid Y9 and the lever is held in position. The bucket is now tilted in until the proximity switch B15 is switched off and the circuit to the magnet Y9 is broken by the relay K18. The pilot control lever returns by spring force to the neutral position. The bucket remains in the horizontal position. Float position function When the bucket return-to-dig switch S18 is pressed, the pressure switch B32 is energised. If the pilot control lever is moved fully to "lower" then the pilot control pressure switches the pressure switch B32. The pressure switch B32 activates the retaining solenoid Y18, which holds the lever in position by the retaining disc touching the solenoid Y18. The pressure switch B32 activates the solenoid valve Y21 and the piston base end of the lift cylinder is hydraulically connected to the rod end and the bucket can adapt to irregular terrain. Lift kick-out function

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MJFCIFSS

L524 - 438 / 0101 - 8795 L534 - 434 / 0101 - 8961 L538 - 432 / 0101 - 8507

Service Manual

Electrical System When the bucket lift kick-out switch S14 is pressed, the inductive proximity switch B17 is energised. The proximity switch B17 is closed when not actuated (N/C). The relay K17 on the electronic controller A4 is activated and the solenoid Y17 in the pilot control device is activated. If the pilot control lever is moved fully to "lift up", the retaining disc touches the solenoid Y17 and the lever is held in position. The lift arms move up until the proximity switch B17 switches off. The circuit to the solenoid Y17 is interrupted by the relay K17. The pilot control lever returns by spring force to the neutral position and the lift movement is stopped.

L524 - 438 / 0101 - 8795 L534 - 434 / 0101 - 8961 L538 - 432 / 0101 - 8507

MJFCIFSS

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Electrical System

Service Manual Valid for:

L534 -434 / from 6871; L538 -432 / from 6871

Step 5 working hydraulics: switches, proximity switches, retaining solenoids, ride control .

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MJFCIFSS

L524 - 438 / 0101 - 8795 L534 - 434 / 0101 - 8961 L538 - 432 / 0101 - 8507

Service Manual

Code A4 B15 B17 B28 B30 B32 CN2 CN5 CN11 CN13 D7 D8 D15 D23 D25 D69 D79 F2A F5B F6B K11 K17 K18 S14 S16 S18 S19 S22 S26 S101 X2 X10 X11 X12 X16 X17 X23 X52 X53 X55 X60 X61 Y9 Y14 Y17 Y18 Y20 Y21 Y28

Electrical System

Description Fuse and relay board Bucket return-to-dig proximity switch Lift kick-out proximity switch Ride control off pressure switch (optional) Quick-change device buzzer (optional) Float position pressure switch MATE-N-LOK connector, 9-pin, yellow MATE-N-LOK connector, 15-pin, green MATE-N-LOK connector, 12-pin, purple MATE-N-LOK connector, 12-pin, red Diode 1N4007 Diode 1N4007 Diode 1N4007 Diode 1N4007 Diode 1N4007 Diode P600 Diode P600 15A fuse for lighting, switch lighting 7.5A fuse for ride control system (optional) 25A fuse (optional) Ride control relay Lift kick-out relay Bucket return-to-dig relay Bucket return-to-dig switch Ride control switch Float position switch (L534, L538) Working hydraulics lockout switch Lift kick-out switch (L534, L538) Quick change device switch (optional) MODE button Connector, 70-pin / main WH Connector, 15-pin / dash WH (switch bar) Connector, 15-pin / dash WH (switch bar) Connector, 2-pin Junior Timer (working hydraulics SV Y14) Connector 6-pin / MATE-N-LOK (solenoids Y9, 17, 18) Connector, 4-pin / M12x1 (proximity switch B17) Connector, 4-pin / M12x1 (tilt cylinder B15) Connector, 2-pin Deutsch (proximity switch B28) Connector, 2-pin Deutsch (pressure switch B32) Connector, 2-pin Junior Timer (quick change SV Y28) Connector, 2-pin Junior Timer (ride control SV Y20) Connector, 2-pin Junior Timer (ride control SV Y21) Bucket return-to-dig solenoid Working hydraulics lockout solenoid valve Lift kick-out solenoid Float position solenoid Ride control solenoid valve Ride control and float position solenoid valve Quick change device solenoid valve

L524 - 438 / 0101 - 8795 L534 - 434 / 0101 - 8961 L538 - 432 / 0101 - 8507

MJFCIFSS

Step 5 5/E 5/E 5/F-G 5/H 5/F 5 5 5 5/A 5/E 5/F 5/F 5/F 5/F 5/F 5/F 5/A 5/A 5/A 5/E 5/F 5/F 5/C 5/D 5/D 5/C 5/C 5/D 5/A-B 5 5 5 5/H 5/H 5/E 5 5/F-G 5/F 5/H 5/H 5/H 5/H 5/H 5/H 5/H 5/H 5/H 5/H

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Electrical System

Elektric working hydraulics circuit

Service Manual Function of the working hydraulics lockout switch S19

Switch position 1 with ignition off (safety): – When you press the switch in position 1 the contact in the switch connects pins 7 and 5, and the voltage comes directly from the battery to the solenoid valve Y14 (working hydraulics lockout). – Circuit: batteries G2, fuse F01, fuse F3A, switch S19 pin 7 to pin 5, and to solenoid Y14. – As long as the button is pressed in position 1 and there is pressure in the hydro accumulator (pilot control), the lift arms can be lowered. The main switch S15 must be switched on. Switch position 0 (operation) with the engine running: – In switch position 0 pin 4 is connected to pin 6 and the voltage is directed from (terminal D+) to the solenoid valve Y14 and various components. The valve opens and the pilot control pressure is available to the pilot control device. – Circuit: from (terminal D+) via fuse F1C, relay K29, switch S19 to the solenoid valve Y14. Switch position 2 (OFF, road travel): – When you press the switch S19 in position 2, the contacts 4 and 2 are connected. The connection to the solenoid valve Y14 and the components is interrupted. – The working hydraulics lockout symbol field lights up (activated via pins 4 and 2 in the switch S19). Pin assignment of the inductive switches B15 and B17 1 Power supply + 2 Switch output N/C + signal 3 Earth connection 4 Switch output N/O + signal Automatic bucket return-to-dig function When the bucket return-to-dig switch S14 is pressed, the inductive proximity switch B15 (N/O) is energised. The proximity switch B15 is closed when actuated (N/O). The relay K18 on the board (fuses, relays) A4 is activated and the solenoid Y9 on the pilot control device is energised. If the pilot control lever is moved fully to "tilt in", the retaining disc touches the solenoid Y9 and the lever is held in position. The bucket is now tilted in until the proximity switch B15 is switched off and the circuit to the magnet Y9 is broken by the relay K18. The pilot control lever returns by spring force to the neutral position. The bucket remains in the horizontal position. Float position function When the pilot control lever is moved to the full extent, the float position is activated even if the switch S18 is not pressed, but the lever is not held in place by the retaining solenoid. When the bucket return-to-dig switch S18 is pressed, the solenoid Y18 on the pilot control device is energised. If the pilot control lever is moved fully to "lower", the retaining disc touches the solenoid Y18 and the lever is held in position. When the pilot control valve is fully actuated, the pilot control pressure activates the pressure switch B32.

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MJFCIFSS

L524 - 438 / 0101 - 8795 L534 - 434 / 0101 - 8961 L538 - 432 / 0101 - 8507

Service Manual

Electrical System The pressure switch B32 directs the voltage from the fuse F5B to the solenoid valve Y21. The piston base end of the lift cylinder is hydraulically connected to the rod end and the bucket can adapt to irregular terrain. Lift kick-out function When the bucket lift kick-out switch S14 is pressed, the inductive proximity switch B17 is energised. The proximity switch B17 is closed when not actuated (N/C). The relay K17 on the electronic controller A4 is activated and the solenoid Y17 in the pilot control device is activated. If the pilot control lever is moved fully to "lift up", the retaining disc touches the solenoid Y17 and the lever is held in position. The lift arms move up until the proximity switch B17 switches off. The circuit to the solenoid Y17 is interrupted by the relay K17. The pilot control lever returns by spring force to the neutral position and the lift movement is stopped.

L524 - 438 / 0101 - 8795 L534 - 434 / 0101 - 8961 L538 - 432 / 0101 - 8507

MJFCIFSS

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Electrical System

Service Manual

Step 6 lighting: steering column switch, driving headlights, direction indicator system, horn

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MJFCIFSS

L524 - 438 / 0101 - 8795 L534 - 434 / 0101 - 8961 L538 - 432 / 0101 - 8507

Service Manual

Code A4 B10 CN1 CN5 CN12 CN14 D3 D17 D18 D20 D21 D89 D99 E3 E4 E6 E7 E8 E9 E14 F2B F2C F3A F4A F4B F5A F5C F7A H15 H16 H17 H18 K1 K25 K26 S3 S4 S6 X2 X5 X6 X7 X8 X22 X24 X25 X27

Electrical System

Description Fuse and relay board Klaxon MATE-N-LOK connector, 9-pin, green MATE-N-LOK connector, 15-pin, green MATE-N-LOK connector, 12-pin, white MATE-N-LOK connector, 15-pin, purple Diode 1N4007 Diode 1N4007 Diode P600 Diode 1N4007 Diode P600 Diode P600 Diode P600 Left headlight 24 V - 70/75 W Right headlight 24 V - 70/75 W Left tail light 24 V - 10 W Right tail light 24 V - 10 W Right profile light 24 V - 4 W Left profile light 24 V - 4 W Left/right number plate light 24 V - 10/10 W 15A fuse for front wiper, horn 7.5A fuse for right driving light 10A fuse for hazard warning system, working attachment, flashing beacon (optional) 7.5A fuse for right high beam 3A fuse for left parking light, registration lighting 3A fuse for right parking light, monitor background lighting 7.5A fuse for left driving light 7.5A fuse for left high beam Front left indicator light 24 V - 21 W Front right indicator light 24 V - 21 W Rear left indicator light 24 V - 21 W Rear right indicator light 24 V - 21 W Direction indicator relay Right indicator relay Left indicator relay Steering column switch Hazard warning system switch Parking/driving light switch Connector, 70-pin / main WH Connector, 6-pin Deutsch (front section) Connector, 6-pin Deutsch (front section) Connector, 6-pin Deutsch (rear left lighting) Connector, 6-pin Deutsch (rear right lighting) Connector, 12-pin MATE-N-LOK (cab) Connector, 7-pin (steering column switch) Connector, 7-pin (steering column switch) Connector, 2-pin Deutsch (number plate lighting)

L524 - 438 / 0101 - 8795 L534 - 434 / 0101 - 8961 L538 - 432 / 0101 - 8507

MJFCIFSS

Step 6 6/A 6 6 6 6 6/D-E 6/E 6/C 6/E 6/C 6/E 6/E 6/G 6/G 6/G 6/G 6/G 6/G 6/G 6/A 6/E 6/A 6/E 6/E 6/E 6/E 6/E 6/G 6/G 6/G 6/G 6/C 6/D-E 6/D-E 6/A-B-C 6/D 6/D 6 6/G-H 6/G-H 6 6 6 6/A-B 6/B-C 6/G-H

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Electrical System Indicator system function

Service Manual The indicator system works when the main switch S15 is on. It is powered by the battery via the fuse F3A to the relay K1 terminal 49 input. The output voltage from the relay K1 terminal 49a output goes to the following consumers: â&#x20AC;&#x201C; Steering column switch S3 terminal 49a via the diode D21 â&#x20AC;&#x201C; Hazard light switch S4 pin 5 The two relays K25 and K26 have no switching function on this type of machine. Indicator system If you press the indicator switch on the steering column the voltage is directed to the appropriate consumer units and the indicator relay K1 starts flashing automatically. The indicator relay K1 pin C also sends a signal to the indicator light on the display unit H10. Hazard warning system If you switch on the hazard lights the voltage is directed to the consumer units and the indicator relay K1 starts flashing automatically. The indicator relay K1 pin C also sends a signal to the indicator light on the display unit H10.

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MJFCIFSS

L524 - 438 / 0101 - 8795 L534 - 434 / 0101 - 8961 L538 - 432 / 0101 - 8507

Service Manual

L524 - 438 / 0101 - 8795 L534 - 434 / 0101 - 8961 L538 - 432 / 0101 - 8507

Electrical System

MJFCIFSS

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Electrical System

Service Manual

Step 7 washer system: front wipers, rear wiper, air conditioning

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MJFCIFSS

L524 - 438 / 0101 - 8795 L534 - 434 / 0101 - 8961 L538 - 432 / 0101 - 8507

Service Manual

Code A4 B26 B27 CN2 CN5 CN11 CN13 D14 F4C F6C K5 K14 M2 M3 M4 M5 M9 S11 S13 S21 X2 X10 X11 X22 X28 X29 X31 X32 X36 X38 X39 X40 X67 Y22

Electrical System

Description Fuse and relay board Air conditioning thermostat (optional) Air conditioning pressure switch (optional) MATE-N-LOK connector, 9-pin, yellow MATE-N-LOK connector, 15-pin, green MATE-N-LOK connector, 12-pin, purple MATE-N-LOK connector, 12-pin, red Diode 1N4007 7.5A fuse for rear wiper 15A fuse for heater fan, air conditioning (optional) Wiper washer interval relay Relay for air conditioning coupling (optional) Front windscreen wiper motor Rear windscreen wiper motor Front windscreen washer pump Heater blower motor Rear windscreen washer pump Heater blower motor knob Rear wiper/washer pump switch Air conditioning switch (optional) Connector, 70-pin / main WH Connector, 15-pin / dash WH (switch bar) Connector, 15-pin / dash WH (switch bar) Connector, 12-pin MATE-N-LOK (cab) Connector, 6-pin Fastin-Faston (front wiper) Connector, 2-pin Fastin-Faston (front washer pump) Connector, 2-pin Fastin-Faston (rear washer pump) Connector, 4-pin Fastin-Faston (rear wiper) Connector, 4-pin Fastin-Faston (heater blower) Connector, 2-pin Deutsch (air conditioning compressor) Connector, 2x1-pin Fastin-Faston (rear cab) Connector, 4-pin Deutsch (pressure switch B27) Connector, 6-pin Fastin-Faston (relay K5) Air conditioning compressor magnetic coupling

L524 - 438 / 0101 - 8795 L534 - 434 / 0101 - 8961 L538 - 432 / 0101 - 8507

MJFCIFSS

Step 7 7/C 7/D 7 7 7 7 7/F 7/A 7/A 7/C 7/F 7/G-H 7/G-H 7/G-H 7/G-H 7/G-H 7/C 7/C 7/C 7 7 7 7 7/G-H 7/G-H 7/G-H 7/G-H 7/G-H 7/G 7/C 7/D-E 7/C-D 7/H

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Electrical System

Service Manual

Step 8 lighting: working headlights, brake light, cab light, radio (optional)

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MJFCIFSS

L524 - 438 / 0101 - 8795 L534 - 434 / 0101 - 8961 L538 - 432 / 0101 - 8507

Service Manual

Code A3 A4 B11 B12 CN1 CN11 CN13 CN14 E2 E10 E11 E12 E13 F1A F1B F3B F3C H20 H21 H22 S7 S8 S9 T1 W1 X2 X7 X8 X19 X21 X22 X26 X30 X33 X34 X35 X37 X41 X42 X59 X62 X70

Electrical System

Description Radio (optional) Fuse and relay board Speaker Brake light button MATE-N-LOK connector, 9-pin, green MATE-N-LOK connector, 12-pin, purple MATE-N-LOK connector, 12-pin, red MATE-N-LOK connector, 15-pin, purple Cab light with switch 24 V -10 W Front left working floodlight 24 V - 70 W Front right working floodlight 24 V - 70 W Rear left working floodlight 24 V - 70 W (optional) Rear right working floodlight 24 V - 70 W (optional) 7.5A brake light fuse 10A fuse for interior lighting, socket, radio (optional), compressor seat (optional) 15A fuse for front working floodlight 15A fuse for rear working floodlight (optional) Left brake light 24V - 21W Right brake light 24V - 21W Flashing beacon 24V - 70W (optional) Front working floodlight switch Rear working floodlight switch (optional) * Flashing beacon switch (optional) 24 V to 12 V transformer (radio) (optional) Radio antenna (optional) Connector, 70-pin / main WH Connector, 6-pin Deutsch (rear left lighting) Connector, 6-pin Deutsch (rear right lighting) Connector, 8-pin MATE-N-LOK (control panel) Connector, 2-pin Deutsch (cab) Connector, 12-pin MATE-N-LOK (cab) Connector, 2-pin Deutsch (pressure switch B12) Connector, 2x1-pin Fastin-Faston (flashing beacon) Connector, 2x1-pin Fastin-Faston (cab roof E10) Connector, 2x1-pin Fastin-Faston (cab roof E12) Connector, 2x1-pin Fastin-Faston (cab roof E11) Connector, 6-pin Fastin-Faston (cab radio) Socket (cab) Connector, 3-pin MATE-N-LOK (transformer T1) Connector, 2x1-pin Fastin-Faston (cab roof E13) Connector, 2-pin Fastin-Faston (cab roof radio) Connector, 2x1-pin Fastin-Faston (cab roof E2)

L524 - 438 / 0101 - 8795 L534 - 434 / 0101 - 8961 L538 - 432 / 0101 - 8507

MJFCIFSS

Step 8/G 8 8/H 8/C 8/B 8/B 8/B 8/A 8/G-H 8/G-H 8/G-H 8/G-H 8/G-H 8/A 8/A 8/A 8/A 8/G-H 8/G-H 8/G-H 8/C 8/C 8/C 8/E 8/G 8/C 8/G-H 8/G-H 8/C 8/D 8/F 8/C-D 8/G-H 8/G-H 8/G-H 8/G-H 8/G 8/G-H 8/E-F 8/G-H 8/F 8/G-H

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Electrical System

Service Manual

Step 9 Cooler and inching system: Cooler system / 0-inching temperature sensors, proportional solenoid, proximity switch, solenoid valve, speed sensor.

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MJFCIFSS

L524 - 438 / 0101 - 8795 L534 - 434 / 0101 - 8961 L538 - 432 / 0101 - 8507

Service Manual

Code A1 B1 B8 B13 B21 B29 ST1 ST2 ST3 X2 X44 X45 X46 X47 X58 X65 Y13 Y15

Electrical System

Description Step Electronic controller 9/A Rear axle power take-off speed sensor 9/G-H Hydraulic oil temperature sensor (fan control) 9/G-H Warning buzzer 1 9/H Coolant temperature sensor (fan control) 9/G-H Injection pump proximity switch 9/G-H Connector, 15-pin /A1 9/A Connector, 9-pin /A1 9/A Connector, 15-pin /A1 9/A Connector, 70-pin / main WH 9/F Connector, 3-pin Deutsch (pressure switch B1) 9/G Connector, 2-pin Deutsch (proportional valve Y13) 9/G-H Connector, 2-pin Junior Timer (temperature sensor B21) 9/G Connector, 2-pin Junior Timer (temperature sensor B8) 9/G Connector, 2-pin Junior Timer (0-inching 0 SV Y15) 9/G-H Connector, 4-pin / M12x1 (proximity switch B29) 9/G-H Cooling system proportional pressure relief valve 9/H 0-inching solenoid valve 9/H Hydraulic fan function The fan speed is controlled by the hydraulic oil temperature, the engine coolant temperature and the engine speed. The resistance of the temperature sensors for the hydraulic oil B8 and coolant B21 changes according to the temperature of the medium. At low temperatures the resistance is low, and at high temperatures it is high. To determine the temperature, voltage is sent through the sensors. Depending on the temperature (resistance), a lower voltage is returned to the electronic controller A1. This voltage signal is evaluated by the electronic controller A1, which sends the appropriate current to the proportional valve Y13 (low temperature – high current, high temperature – low current). The proportional valve Y13 controls the pressure relief valve and therefore the fan speed. At excess temperature (106°C hydraulic oil) / (103°C coolant L524, L534), (100°C coolant L538) or if there is an interruption to the temperature sensors, or if a sensor fails, the output from the electronic controller A1 to the proportional valve Y13 is de-energised. The following warning signals are activated in one of these conditions: – After a minute, the machine switches down to travel range 1. The travel range indicators H25 and H26 flash alternately every 500ms. – Repeated audible warning signal, 3 seconds on, 10 seconds off etc. – Hydraulic oil overheating: the hydraulic oil overheating lamp H23 lights up continuously, the green LED H13 on the electronic controller A1 lights up. – Coolant overheating: the hydraulic oil overheating lamp H23 flashes, the red LED H14 on the electronic controller A1 lights up. 0-inching function To protect the hydraulic units and the engine from excess speeds when travelling downhill, it is important that inching is deactivated when the pedal is in the zero position. The proximity switch B29 on the injection pump is closed when actuated (N/O). The proximity switch B29 is supplied by terminal 15 via the fuse F1C on pin 1. In the zero pedal position the proximity switch B29 is activated by the speed adjusting lever and supplies voltage at pin 2 to the electronic controller A1.

L524 - 438 / 0101 - 8795 L534 - 434 / 0101 - 8961 L538 - 432 / 0101 - 8507

MJFCIFSS

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Electrical System

Service Manual The electronic controller A1 activates the 0-inching solenoid valve Y15 and closes it. This prevents oil from flowing through the inching valve into the tank (inching is deactivated).

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MJFCIFSS

L524 - 438 / 0101 - 8795 L534 - 434 / 0101 - 8961 L538 - 432 / 0101 - 8507

Service Manual

L524 - 438 / 0101 - 8795 L534 - 434 / 0101 - 8961 L538 - 432 / 0101 - 8507

Electrical System

MJFCIFSS

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Electrical System

Service Manual

Step 10 emergency steering system: electronic controller A1, pressure switch, emergency steering pump

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MJFCIFSS

L524 - 438 / 0101 - 8795 L534 - 434 / 0101 - 8961 L538 - 432 / 0101 - 8507

Service Manual

Code A1 A4 B3 B3a CN13 F02 F6A H24 M8 S10 ST1 ST2 ST3 X2 X11 X48 X49

Electrical System

Description Electronic controller Fuse and relay board Emergency steering pressure switch Emergency steering check pressure switch MATE-N-LOK connector, 12-pin, red 200A emergency steering pump fuse (MEGA Fuse) 7.5A fuse for power supply A1, emergency steering button, pressure switch B3a Emergency steering check signal lamp Emergency steering pump motor Emergency steering pump button Connector, 15-pin /A1 Connector, 9-pin /A1 Connector, 15-pin /A1 Connector, 70-pin / main WH Connector, 15-pin / dash WH (switch bar) Connector, 2-pin Deutsch (pressure switch B3a) Connector, 2-pin Deutsch (pressure switch B3)

Emergency steering function

Step 10/A 10 10/G-H 10/G-H 10/A 10/G 10/A 10/E 10/E 10/E 10/A 10/A 10/A 10/F 10/D 10/G 10/G-H

Activation of the emergency steering pump if the steering pressure fails If the hydraulic pressure falls below the level set on the pressure switch B3 for more than 0.5 seconds, the emergency steering pump is activated. The emergency steering pressure switch B3 opens and disconnects the electronic controller ST1 pin 14 from earth. On the electronic controller A1 ST3 pin 1, the emergency steering switch output is switched on for 50 seconds. The solenoid switch on the emergency steering pump picks up and switches on the motor of the emergency steering pump. Pressure accumulates again in the hydraulic steering circuit, thus restoring the steering function.

L524 - 438 / 0101 - 8795 L534 - 434 / 0101 - 8961 L538 - 432 / 0101 - 8507

MJFCIFSS

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Electrical System

Service Manual If the steering function is still required after 50 seconds and the pressure again falls below the level set on the pressure switch B3a, the emergency steering pump is started again. The emergency steering pump can be activated until it is switched off by the thermo switch in the motor. The emergency steering pump can be activated manually using the button S10. When the emergency steering pump is activated, the following warning signals are generated: â&#x20AC;&#x201C; Emergency steering symbol field H8 lights up â&#x20AC;&#x201C; Interval tone 3 seconds on 3 seconds off etc.

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MJFCIFSS

L524 - 438 / 0101 - 8795 L534 - 434 / 0101 - 8961 L538 - 432 / 0101 - 8507

Service Manual

L524 - 438 / 0101 - 8795 L534 - 434 / 0101 - 8961 L538 - 432 / 0101 - 8507

Electrical System

MJFCIFSS

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Electrical System

Service Manual Valid for:

L524 – 438/from 0101 - 9314; L534 – 434/from 0101 - 9314; L538 – 432/from 0101 - 9436;

Step 11 additional equipment: electronic controller A1, switch, solenoid valves

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MJFCIFSS

L524 - 438 / 0101 - 8795 L534 - 434 / 0101 - 8961 L538 - 432 / 0101 - 8507

Service Manual

Code A1 S2 S12 ST4 ST5 X2 X10 X11 X56 X57 X72 X73 Y11 Y12

Electrical System

Description Electronic controller Forward/reverse travel direction button Additional equipment switch (optional) Connector, 2-pin /A1 Connector, 2-pin /A1 Connector, 70-pin / main WH Connector, 15-pin / dash WH (switch bar) Connector, 15-pin / dash WH (switch bar) Connector, 10-pin MATE-N-LOK (control panel) Connector, 10-pin MATE-N-LOK (control panel) Connector, 2-pin Junior Timer (additional equipment SV Y11) Connector, 2-pin Junior Timer (additional equipment SV Y12) Additional equipment solenoid valve (optional) Additional equipment solenoid valve (optional)

L524 - 438 / 0101 - 8795 L534 - 434 / 0101 - 8961 L538 - 432 / 0101 - 8507

MJFCIFSS

Step 11/A 11/E-F 11/D 11/A 11/A 11/F 11/C 11/C 11/C-D 11/C-D 11/G-H 11/G-H 11/H 11/H

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Electrical System

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Service Manual

MJFCIFSS

L524 - 438 / 0101 - 8795 L534 - 434 / 0101 - 8961 L538 - 432 / 0101 - 8507

Service Manual

Electrical System

10.0.2

Electrical system with circuit diagrams (emissions tier II)

Valid for:

L524 -438 / from 8796; L534 -434 / from 8962; L538 -432 / from 8508

Design Components of the electrical system

The table below lists all the components of the electrical system. The entry in the step column helps you locate the component in the circuit diagrams. Abbreviations: â&#x20AC;&#x201C; WH = Wiring harness â&#x20AC;&#x201C; SV = Solenoid valve

Code

Description

Step

A1 A3 A4 A5 A13 A14 B1 B3 B3a B4 B5 B7 B8 B9 B10 B11 B12 B13 B15 B16 B17 B19 B20 B20a B21 B25 B26 B27 B28 B29 B30 B31 B32 B35 B36 B37 CN1 CN2 CN5 CN8 CN11 CN12

Electronic controller Radio (Option) Fuse and relay board Travel speed, service hours and clock LCD Display unit Electronic engine controller (injection pump regulation) (L524, L534) Rear axle power take-off speed sensor Emergency steering pressure switch Emergency steering check pressure switch Air filter contamination vacuum switch Parking brake pressure switch Engine oil pressure switch Hydraulic oil temperature sensor (fan control) Warning buzzer board Klaxon Speaker Brake light pressure switch Warning buzzer 1 Bucket return-to-dig proximity switch Back-up alarm Lift kick-out proximity switch Brake accumulator pressure 90 bar switch Coolant temperature indicator + thermostat Coolant temperature sensor (L524. L534) Coolant temperature sensor (fan control) Fuel level sensor Air conditioning thermostat (optional) Air conditioning pressure switch (optional) Ride control off pressure switch (optional) Injection pump proximity switch Quick-change device buzzer (optional) Injection adjuster SV thermo switch L538 Float position pressure switch (L534, L538) Fuel temperature sensor (L524. L534) Intake air temperature sensor (L524, L534) Engine speed and position sensor (L524, L534) MATE-N-LOK connector, 9-pin, green MATE-N-LOK connector, 9-pin, yellow MATE-N-LOK connector, 15-pin, green MATE-N-LOK connector, 4-pin, white MATE-N-LOK connector, 12-pin, purple MATE-N-LOK connector, 12-pin, white

4, 9, 10, 11 8/G 1 - 8, 10 3/A-B 3/A-B-C 12/A 9/G-H 10/G-H 10/G-H 3/H 4/E 3/H 9/G-H 2/D 6/A 8/H 8/C 9/H 5/E 4/H 5/E 3/H 3/H 12/F 9/G-H 3/H 7/C 7/D 5/F-G 9/G-H 5/H 1/G-H 5/F 12/F 12/F 12/F 1 - 11 1 - 11 1 - 11 1 - 11 1 - 11 1 - 11

L524 - 438 / from 8796 L534 - 434 / from 8962 L538 - 432 / from 8505

MJFCIFSS

Maschine view 1 -1 ---1 3 3 3 2 2 3 -1 -2 -2 3 2 2 1 -1 1 ---3 -3 1 ----------

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Electrical System

Service Manual

Code

Description

Step

CN13 CN14 D2 D3 D5 D6 D7 D8 D11 D12 D14 D15 D17 D18 D19 D20 D21 D23 D24 D25 D31 D32 D50 D69 D79 D89 D99 E1 E2 E3 E4 E5 E6 E7 E8 E9 E10 E11 E12 E13 E14 F01 F02 F03 F04 F09 F10 F1A

MATE-N-LOK connector, 12-pin, red MATE-N-LOK connector, 14-pin, purple Diode 1N4007 Diode 1N4007 Diode 1N4007 Diode 1N4007 Diode 1N4007 Diode 1N4007 Diode 1N4007 Diode 1N4007 Diode 1N4007 Diode 1N4007 Diode 1N4007 Diode P600 Diode P600 Diode 1N4007 Diode P600 Diode 1N4007 Diode 1N4007 Diode 1N4007 Diode 1N4007 Diode P300 Diode P600 Diode P600 Diode P600 Diode P600 Diode P600 Left reversing light 24 V -21 W Cab light with switch 24 V -10 W Left headlight 24 V - 70/75 W Right headlight 24 V - 70/75 W Left reversing light 24 V -21 W Left tail light 24 V - 10 W Right tail light 24 V - 10 W Right profile light 24 V - 4 W Left profile light 24 V - 4 W Front left working floodlight 24 V - 70 W Front right working floodlight 24 V - 70 W Rear left working floodlight 24 V - 70 W (optional) Rear right working floodlight 24 V - 70 W (optional) Left/right number plate light 24 V - 10/10 W 100A main fuse (MEGA Fuse) 200A emergency steering pump fuse (MEGA Fuse) 60A preglow fuse (MEGA Fuse) 60A starter fuse (MEGA Fuse) 5A fuse for diagnostic plug supply (L524, L534) 5A fuse for electronic controller diagnostic plug supply (L524, L534) 7.5A brake light fuse 10A fuse for interior lighting, socket, radio (optional), compressor seat (optional) 7.5A fuse for working attachment, fuel sensor, inductive sensor B29 15A fuse for lighting, switch lighting 15A fuse for front wiper, horn 7.5A fuse for right driving light 10A fuse for hazard warning system, working attachment, flashing beacon (optional) 15A fuse for front working floodlight

1 - 11 1 - 11 1/C 6/D-E 2/B 1/E 5/E 5/F 4/F 1/C 7/F 5/F 6/E 6/C 2/F 6/E 6/C 5/F 4/F 5/F 1/E 2/E 1/G 5/F 5/F 6/E 6/E 4/H 8/G-H 6/G 6/G 4/H 6/G 6/G 6/G 6/G 8/G-H 8/G-H 8/G-H 8/G-H 6/G 1/E 10/G 12/B 1/C 12/B 12/B 8/A

Maschine view ---------------------------3 -3 3 3 3 3 3 3 3 3 --3 3 3 1 1 1 1 --

8/A

1/A 5/A 6/A 6/E

-----

6/A

8/A

F1B F1C F2A F2B F2C F3A F3B

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Service Manual

Electrical System

Code

Description

Step

F3C F4A F4B F4C F5A F5B F5C

15A fuse for rear working floodlight (optional) 7.5A fuse for right high beam 3A fuse for left parking light, registration lighting 7.5A fuse for rear wiper 3A fuse for right parking light, monitor background lighting 7.5A fuse for ride control system (optional) 7.5A fuse for left driving light 7.5A fuse for power supply A1, emergency steering button, pressure switch B3a 25A fuse (optional) 15A fuse for heater fan, air conditioning (optional) 7.5A fuse for left high beam 7.5A fuse for parking brake, control lever power supply 3A fuse for monitor supply (battery +30) 5A fuse for monitor (ignition +15) 10A fuse for engine stop 3A fuse for monitor supply (battery +15), preglow, engine stop Three-phase alternator with regulator Batteries (2x12 V) Preglow signal lamp Forward travel direction Engine oil pressure signal lamp Working hydraulics lockout signal lamp Battery charge indicator lamp Air filter contamination signal lamp Emergency steering signal lamp Reverse travel direction Direction indicator system signal lamp Parking brake signal lamp High beam signal lamp Engine overheating signal lamp Front left indicator light 24 V - 21 W Front right indicator light 24 V - 21 W Rear left indicator light 24 V - 21 W Rear right indicator light 24 V - 21 W Brake accumulator pressure signal lamp Left brake light 24V - 21W Right brake light 24V - 21W Flashing beacon 24V - 70W (optional) Hydraulic oil overheating signal lamp Emergency steering check signal lamp Travel range 1 signal lamp Travel range 2 signal lamp Safety belt signal lamp Special function signal lamp Direction indicator relay Engine start relay Engine stop relay Preglow relay Wiper washer interval relay Ignition on supply relay (+15) Ride control relay Relay for air conditioning coupling (optional) Lift kick-out relay Bucket return-to-dig relay Parking brake relay Right indicator relay

8/A 6/E 6/E 7/A 6/E 5/A 6/E

Maschine view --------

10/A

5/A 7/A 6/E 4/A 3/A 2/A 2/C 2/A 1/F 1/G-H 3/B-C 3/A 3/A 3/B 3/A 3/B 3/B 3/A 3/B-C 3/A 3/B-C 3/B-C 6/G 6/G 6/G 6/G 3/B 8/G-H 8/G-H 8/G-H 3/A 10/E 3/B-C 3/B-C 3/B-C 3/B-C 6/C 1/C-D 2/E 2/E, 12/E 7/C 2/A-B 5/E 7/F 5/F 5/F 4/E-F 6/D-E

--------3 3 ------------3 3 3 3 -3 3 --------1 -1, 3 2 --------

F6A F6B F6C F7A F7B F7C F8A F8B F8C G1 G2 H2 H3 H4 H5 H6 H7 H8 H9 H10 H11 H12 H13 H15 H16 H17 H18 H19 H20 H21 H22 H23 H24 H25 H26 H27 H28 K1 K2 K3 K4 K5 K8 K11 K14 K17 K18 K22 K25

L524 - 438 / from 8796 L534 - 434 / from 8962 L538 - 432 / from 8505

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Service Manual

Code

Description

Step

K26 K27 K29 M1 M2 M3 M4 M5 M8 M9 P3 P6 R1 R3 R3 R5 R7 R8 S1 S2 S3 S4 S6 S7 S8 S9 S10 S11 S12 S13 S14 S15 S16 S17 S18 S18 S19 S21 S22 S26 S41 S100 S101 ST1 ST2 ST3 ST4 ST5 T1 V15 V30 W1 X1 X2 X3 X4 X5

Left indicator relay Start release relay Working hydraulics/parking brake relay Starter Front windscreen wiper motor Rear windscreen wiper motor Front windscreen washer pump Heater blower motor Emergency steering pump motor Rear windscreen washer pump Fuel level indicator Coolant temperature display Warning buzzer board resistor Intake air preheating flange (L524, L534) Flame glow system (L538 only) Gas pedal angle sensor (L524, L534) Engine speed resistor (L524, L534) CAN bus terminating resistor (L524, L534) Ignition switch Forward/reverse travel direction button Steering column switch Hazard warning system switch Parking/driving light switch Front working floodlight switch Rear working floodlight switch (optional) * Flashing beacon switch (optional) Emergency steering pump button Heater blower motor knob Additional equipment switch (optional) Rear wiper/washer pump switch Bucket return-to-dig switch Battery main switch Ride control switch Parking brake switch Float position switch (L534, L538) Float position / lift kick-out switch (L524) Working hydraulics lockout switch Air conditioning switch (optional) Lift kick-out switch (L534, L538) Quick change device switch (optional) Engine diagnosis button and warning lamp (L524, L534) Travel range 1/2 switch MODE button ST1 connector, 15-pin / A1 Connector, 9-pin /A1 Connector, 15-pin /A1 Connector, 2-pin /A1 Connector, 2-pin /A1 24 V to 12 V transformer (radio) (optional) M5 screw connector M6 screw connector Radio antenna (optional) Connector, 9-pin / main WH Connector, 70-pin / main WH Connector, 11-pin / dash WH (monitor) Connector, 21-pin / dash WH (monitor) Connector, 6-pin Deutsch (front section)

6/D-E 1/E 1/C-D 1/G 7/G-H 7/G-H 7/G-H 7/G-H 10/G-H 7/G-H 3/B 3/A-B 2/C-D 12/F 2/H 12/F 12/F 12/B 1/B 4, 11/E-F 6/A-B-C 6/D 6/D 8/C 8/C 8/C 10/E 7/C 11/D 7/C 5/C 1/H 5/D 4/D 5/D 5/D 5/C 7/C 5/C 5/D 12/E 4/E 5/A-B 4, 9, 10 4, 9, 10 4, 9, 10 4, 9, 10 4, 9, 10, 11 8/E 1/A 1/C 8/G 1/F 3 - 12 3/C 3/C 6/G-H

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Maschine view ---3 --2 -3 2 ---3 3 1 1 1 -------------3 --------------------------

L524 - 438 / from 8796 L534 - 434 / from 8962 L538 - 432 / from 8505

Service Manual

Electrical System

Code

Description

Step

X6 X7 X8 X9 X10 X11 X12 X13 X14 X15 X16 X17 X18 X19 X20 X21 X22 X23 X24 X25 X26 X27 X28 X29 X30 X31 X32 X33 X34 X35 X36 X37 X38 X39 X40 X41 X42 X43 X44 X45 X46 X47 X48 X49 X50 X52

Connector, 6-pin Deutsch (front section) Connector, 6-pin Deutsch (rear left lighting) Connector, 6-pin Deutsch (rear right lighting) Plug connector, 2-pin Deutsch (parking brake SV Y10) Connector, 15-pin / dash WH (switch bar) Connector, 15-pin / dash WH (switch bar) Connector, 2-pin Junior Timer (working hydraulics SV Y14) Connector, 4-pin XLR (travel direction SV Y26) Connector, 4-pin XLR (reverse SV Y3) Connector, 4-pin XLR (forward SV Y2) Connector. 6-pin / MATE-N-LOK (solenoids Y9, 17, 18) Connector, 4-pin / M12x1 (proximity switch B17) Connector, 2-pin Deutsch (backup alarm) Connector, 8-pin MATE-N-LOK (control panel) Connector, 5-pin MARK-II (preglow relay K4) Connector, 2-pin Deutsch (cab) Connector, 12-pin MATE-N-LOK (cab) Connector, 4-pin / M12x1 (tilt cylinder B15) Connector, 7-pin (steering column switch) Connector, 7-pin (steering column switch) Connector, 2-pin Deutsch (pressure switch B12) Connector, 2-pin Deutsch (number plate lighting) Connector, 6-pin Fastin-Faston (front wiper) Connector, 2-pin Fastin-Faston (front washer pump) Connector, 2x1-pin Fastin-Faston (flashing beacon) Connector, 2-pin Fastin-Faston (rear washer pump) Connector, 4-pin Fastin-Faston (rear wiper) Connector, 2x1-pin Fastin-Faston (cab roof E10) Connector, 2x1-pin Fastin-Faston (cab roof E12) Connector, 2x1-pin Fastin-Faston (cab roof E11) Connector, 4-pin Fastin-Faston (heater blower) Connector, 6-pin Fastin-Faston (cab radio) Connector, 2-pin Deutsch (air conditioning compressor) Connector, 2x1-pin Fastin-Faston (rear cab) Connector, 4-pin Deutsch (pressure switch B27) Socket (cab) Connector, 3-pin MATE-N-LOK (transformer T1) Connector, 2-pin Deutsch (pressure switch B19) Connector, 3-pin Deutsch (pressure switch B1) Connector, 2-pin Deutsch (proportional valve Y13) Connector, 2-pin Junior Timer (temperature sensor B21) Connector, 2-pin Junior Timer (temperature sensor B8) Connector, 2-pin Deutsch (pressure switch B3a) Connector, 2-pin Deutsch (pressure switch B3) Connector, 2-pin Junior Timer (travel range 1 SV) Connector, 2-pin Deutsch (proximity switch B28) Connector, 2-pin Deutsch (pressure switch B32) (L534, L538) Connector, 4-pin Deutsch (fuel level sensor R4) Connector, 2-pin Junior Timer (quick change SV Y28) Connector, 10-pin MATE-N-LOK (control panel) Connector, 10-pin MATE-N-LOK (control panel) Connector, 2-pin Junior Timer (0-inching 0 SV Y15) Plug connector, 2-pin Junior Timer (ride control SV Y20) Connector, 2-pin Junior Timer (ride control SV Y21) Connector, 2-pin Fastin-Faston (cab roof radio) Connector, 4-pin / M12x1 (proximity switch B29)

6/G-H 4, 6, 8 4, 6, 8 4/H 3, 5, 7, 11 5, 7, 10, 11 5/H 4/H 4/H 4/H 5/H 5/E 4/H 4, 8 2/E 8/D 6, 7, 8 5 6/A-B 6/B-C 8/C-D 6/G-H 7/G-H 7/G-H 8/G-H 7/G-H 7/G-H 8/G-H 8/G-H 8/G-H 7/G-H 8/G 7/G 7/C 7/D-E 8/G-H 8/E-F 3/H 9/G 9/G-H 9/G 9/G 10/G 10/G-H 4/H 5/F-G

Maschine view -----------------------------------------------

5/F

3/H 5/H 4, 11/C-D 4, 11/C-D 9/G-H 5/H 5/H 8/F 4/E

----------

X53 X54 X55 X56 X57 X58 X59 X60 X61 X62

L524 - 438 / from 8796 L534 - 434 / from 8962 L538 - 432 / from 8505

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Service Manual

Code

Description

Step

X64 X65 X66 X67 X68 X69 X70 X71 X72 X73 X74 X78 X141 X142 Y1 Y2 Y3 Y4 Y5 Y6 Y9 Y10 Y11 Y12 Y13 Y14 Y15 Y17 Y18 Y20 Y21 Y22 Y28 Y54

Connector, 3-pin Deutsch (pressure switch B5) Connector, 4-pin / M12x1 (proximity switch B29) Screw connector (engine stop SV) Connector, 6-pin Fastin-Faston (relay K5) Connector, 4-pin Merit (ignition switch S1) Connector, 6-pin Merit (ignition switch S1) Connector, 2x1-pin Fastin-Faston (cab roof E2) Connector, 2-pin Superseal (temperature switch B31) Connector, 2-pin Junior Timer (additional equipment SV Y11) Connector, 2-pin Junior Timer (additional equipment SV Y12) Connector, 2-pin (starting excess fuel SV Y4) Connector, 3-pin MATE-N-LOK (control panel) (L524, L534) Connector, 9-pin Deutsch HP (L524, L534) Connector, 4-pin Deutsch DT06 (L524, L534) Preglow solenoid valve (L538 only) Forward travel direction solenoid valve Reverse travel direction solenoid valve Injection adjuster solenoid valve (L524, L534) Engine stop solenoid Travel range 1 solenoid valve Bucket return-to-dig solenoid Parking brake solenoid valve Additional equipment solenoid valve (optional) Additional equipment solenoid valve (optional) Cooling system proportional pressure relief valve Working hydraulics lockout solenoid valve 0-inching solenoid valve Lift kick-out solenoid Float position solenoid Ride control solenoid valve Ride control and float position solenoid valve Air conditioning compressor magnetic coupling Quick change device solenoid valve Injection pump solenoid (L524, L534)

4/E 9/G-H 2/H 7/C-D 2/C 1/B 8/G-H 1/G-H 11/G-H 11/G-H 1/H 12/D 12/F 12/B 2/H 4/H 4/H 1/H 2/H 4/H 5/H 4/H 11/H 11/H 9/H 5/H 9/H 5/H 5/H 5/H 5/H 7/H 5/H 12/F

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Maschine view --------------3 3 3 3 3 2 1 2 3 3 3 2 2 1 1 3 3 -3 1

L524 - 438 / from 8796 L534 - 434 / from 8962 L538 - 432 / from 8505

Service Manual

Electrical System

Machine view 1 (right)

Machine view 2 (left)

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Electrical System

Service Manual

Machine view 3 (from above)

Function description Circuit diagrams The circuit diagrams are broken down into steps 1 to 12. The following list contains the steps and their main functions. Overview of sections for the electrical system: 1 Power supply: battery, alternator, ignition switch, battery main switch, starter 2 Engine control L524, L534: engine stop, relay terminal 15 Engine control L538: engine stop, preglow, cold start solenoid valve, flame glow system solenoid valve 3 Engine monitoring: display unit A13, temperature switch, pressure switch, fuel level sensor 4 Travel drive: electronic controller A1, travel hydraulics solenoid valve, parking brake solenoid valve, control lever S2 and S100 5 Working hydraulics: switches, proximity switches, retaining solenoids, ride control 6 Lighting: steering column switch, driving headlights, direction indicator system, horn 7 Wiper system: front wipers, rear wiper, air conditioning 8 Lighting: working headlights, brake light, cab light, radio (optional) 9 Cooling system / 0-inching: temperature sensors, fan drive proportional solenoid, injection pump proximity switch, 0-inching solenoid valve, power take-off speed sensor 10 Emergency steering system: electronic controller A1, emergency steering pressure switch, emergency steering pump, emergency steering switch 11 Additional equipment: electronic controller A1, additional equipment switch, additional equipment solenoid valves

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Service Manual

Electrical System 12 Engine control L524, L534: electronic controller A14, diagnostic plug, temperature sensors, gas pedal angle sensor, engine speed and position sensor, injection pump solenoid The circuit diagrams of the electrical system show the function sequences for the entire machine, including optional equipment. All components and connections are marked with a code or number and shown with the appropriate switching code so that they are clearly identifiable. The keys also list the designations of the components. The circuit diagrams are vertically divided into steps, each of which can contain one or more functions. Power connections between the steps are indicated. The wire designation and the step/co-ordinates are shown at the end.

L524 - 438 / from 8796 L534 - 434 / from 8962 L538 - 432 / from 8505

MJFCIFSS

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Electrical System

Service Manual Valid for:

L524 -438 / from 8796; L534 -434 / from 8962;

Step 1 power supply: battery, alternator, ignition switch, battery main switch, starter Step 2 Engine control L524, L534: engine stop, relay terminal 15

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L524 - 438 / from 8796 L534 - 434 / from 8962 L538 - 432 / from 8505

Service Manual

Code A4 B9 CN1 CN2 CN5 CN8 CN11 CN12 CN13 CN14 D2 D5 D6 D12 D19 D31 D32 D50 F01 F03 F04 F1C F8A F8B F8C G1 G2 K2 K3 K8 K27 K29 M1 R1 S1 S15 X1 X20 X66 X68 X69 X71 X74

Electrical System

Description Fuse and relay board Warning buzzer board MATE-N-LOK connector, 9-pin, green MATE-N-LOK connector, 9-pin, yellow MATE-N-LOK connector, 15-pin, green MATE-N-LOK connector, 4-pin, white MATE-N-LOK connector, 12-pin, purple MATE-N-LOK connector, 12-pin, white MATE-N-LOK connector, 12-pin, red MATE-N-LOK connector, 15-pin, purple Diode 1N4007 Diode 1N4007 Diode 1N4007 Diode 1N4007 Diode P600 Diode 1N4007 Diode P300 Diode P600 100 A main fuse (MEGA fuse) 60A preglow fuse (MEGA Fuse) 60A starter fuse (MEGA Fuse) 7.5A fuse for working attachment, fuel sensor, inductive sensor B29 5A fuse for monitor (ignition +15) 10A fuse for engine stop 3A fuse for monitor supply (battery +15), preglow, engine stop Three-phase alternator with regulator Batteries (2x12 V) Engine start relay Engine stop relay Ignition on supply relay (+15) Start release relay Working hydraulics/parking brake relay Starter Resistor (warning buzzer board) Ignition switch Battery main switch Connector, 9-pin / main WH Connector, 5-pin MARK-II (preglow relay K4) Screw connector (engine stop SV) Connector, 4-pin Merit (ignition switch S1) Connector, 6-pin Merit (ignition switch S1) Connector, 2-pin Superseal (temperature switch B31) Connector, 2-pin (starting excess fuel SV Y4)

Step 1-2 2/D 1-2 1-2 1-2 1-2 1-2 1-2 1-2 1-2 1/C 2/B 1/E 1/C 2/F 1/E 2/E 1/G 1/E 2/C 1/C 1/A 2/A 2/C 2/A 1/F 1/G-H 1/C-D 2/E 2/A-B 1/E 1/C-D 1/G 2/C-D 1/B 1/H 1/F 2/E 2/H 2/C 1/B 1/G-H 1/H

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Electrical System

Service Manual made via the alternator terminal 61. When the engine is running terminal 61 is switched from earth to positive and the relay K27 drops off again. The voltage is directed from the fuse F1C via the relay K27 to the air conditioning coupling relay K14. The relay K14 picks up and connects the air conditioning pressure switch B27 to the air conditioning compressor solenoid coupling Y22. – Working hydraulics/parking brake relay K29. When the engine is running the relay is activated by the alternator terminal 61 and picks up. The fuse F1C supplies the switch S17 pin 7 for the parking brake and the switch S19 pin 4 for the working hydraulics lockout.

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L524 - 438 / from 8796 L534 - 434 / from 8962 L538 - 432 / from 8505

Service Manual

L524 - 438 / from 8796 L534 - 434 / from 8962 L538 - 432 / from 8505

Electrical System

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Electrical System

Service Manual Valid for:

L538 -432 / from 8508

Step 1 power supply: battery, alternator, ignition switch, battery main switch, starter Step 2 engine control: engine stop, preglow, cold start solenoid valve, flame glow system solenoid valve

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Service Manual

Code A4 B9 B31 CN1 CN2 CN5 CN8 CN11 CN12 CN13 CN14 D2 D5 D6 D12 D19 D31 D32 D50 F01 F03 F04 F1C F8A F8B F8C G1 G2 K2 K3 K4 K8 K27 K29 M1 R1 R3 S1 S15 X1 X20 X66 X68 X69 X71 X74 Y1 Y4 Y5

Electrical System

Description Fuse and relay board Warning buzzer board Injection adjuster SV thermo switch L524, L534 MATE-N-LOK connector, 9-pin, green MATE-N-LOK connector, 9-pin, yellow MATE-N-LOK connector, 15-pin, green MATE-N-LOK connector, 4-pin, white MATE-N-LOK connector, 12-pin, purple MATE-N-LOK connector, 12-pin, white MATE-N-LOK connector, 12-pin, red MATE-N-LOK connector, 15-pin, purple Diode 1N4007 Diode 1N4007 Diode 1N4007 Diode 1N4007 Diode P600 Diode 1N4007 Diode P300 Diode P600 100 A main fuse (MEGA fuse) 60A preglow fuse (MEGA Fuse) 60A starter fuse (MEGA Fuse) 7.5A fuse for working attachment, fuel sensor, inductive sensor B29 5A fuse for monitor (ignition +15) 10A fuse for engine stop 3A fuse for monitor supply (battery +15), preglow, engine stop Three-phase alternator with regulator Batteries (2x12 V) Engine start relay Engine stop relay Preglow, afterglow relay Ignition on supply relay (+15) Start release relay Working hydraulics/parking brake relay Starter Resistor (warning buzzer board) Flame glow system (L538 only) Ignition switch Battery main switch Connector, 9-pin / main WH Connector, 5-pin MARK-II (preglow relay K4) Screw connector (engine stop SV) Connector, 4-pin Merit (ignition switch S1) Connector, 6-pin Merit (ignition switch S1) Connector, 2-pin Superseal (temperature switch B31) Connector, 2-pin (starting excess fuel SV Y4) Preglow solenoid valve (L538 only) Injection adjuster solenoid valve (L524, L534) Engine stop solenoid

Cold start systems

L524 - 438 / from 8796 L534 - 434 / from 8962 L538 - 432 / from 8505

Step 1-2 2/D 1/G-H 1-2 1-2 1-2 1-2 1-2 1-2 1-2 1-2 1/C 2/B 1/E 1/C 2/F 1/E 2/E 1/G 1/E 2/C 1/C 1/A 2/A 2/C 2/A 1/F 1/G-H 1/C-D 2/E 2/E 2/A-B 1/E 1/C-D 1/G 2/C-D 2/H 1/B 1/H 1/F 2/E 2/H 2/C 1/B 1/G-H 1/H 2/H 1/H 2/H

The job of the cold start systems is to make sure the engine starts at low temperatures. The following cold start systems are provided:

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Electrical System

Service Manual Preglow system At a temperature below 5°C, the preglow relay K4 is automatically activated. The preglow time depends on the outside temperature. The voltage is relayed via the fuse F03 and the preglow relay K4 to the glow plug R3. The solenoid valve Y1 is also activated to supply diesel to the glow plug. Glowing consists of two phases: – Preglowing, which is indicated by the preglow signal lamp H2 lighting up. – Afterglowing, which is three times as long as the preglow phase, but is not indicated.

Automatic injection adjuster An automatic injection adjuster is also fitted. If the coolant temperature is below 50°C, the thermo switch B31 energises the solenoid valve Y4. The injection adjuster solenoid valve Y4 adjusts the time of injection up to 50°C coolant temperature.

Relay functions – Engine start relay K2. This relay is activated by the ignition start switch S1. It switches the voltage from the fuse F04 (60A) to the starter terminal 50. – Engine stop relay K3. When the ignition is on, the relay is activated and switches the voltage from the fuse F8B to the starter solenoid Y5 and via the thermo switch B31 the injection adjuster solenoid valve Y4. – Ignition on power supply relay K8. When the ignition is on, this relay switches on the power for the remaining consumers. – Start release relay K27. With the ignition on the relay is picked up and the connection to the relay K14 is interrupted. The earth connection is made via the alternator terminal 61. When the engine is running terminal 61 is switched from earth to positive and the relay K27 drops off again. The voltage is directed from the fuse F1C via the relay K27 to the air conditioning coupling relay K14. The relay K14 picks up and connects the air conditioning pressure switch B27 to the air conditioning compressor solenoid coupling Y22. – Working hydraulics/parking brake relay K29. When the engine is running the relay is activated by the alternator terminal 61 and picks up. The fuse F1C supplies the switch S17 pin 7 for the parking brake and the switch S19 pin 4 for the working hydraulics lockout.

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MJFCIFSS

L524 - 438 / from 8796 L534 - 434 / from 8962 L538 - 432 / from 8505

Service Manual

Electrical System Valid for:

L524 -438 / from 8796; L534 -434 / from 8962;

Step 3 engine monitoring: display unit A13, temperature switch, pressure switch, fuel level sensor

L524 - 438 / from 8796 L534 - 434 / from 8962 L538 - 432 / from 8505

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Electrical System

Code A5 A13 A4 B4 B7 B19 B20 B25 CN12 F7C H2 H3 H4 H5 H6 H7 H8 H9 H10 H11 H12 H13 H19 H23 H25 H26 H27 H28 P3 P6 X2 X3 X4 X10 X43 X54

Service Manual

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Step 3/A-B 3/A-C 3/B 3/H 3/H 3/H 3/H 3/H 3/B 3/A 3/B-C 3/A 3/A 3/B 3/A 3/B 3/B 3/A 3/B-C 3/A 3/B-C 3/B-C 3/B 3/A 3/B-C 3/B-C 3/B-C 3/B-C 3/B 3/A-B 3/G 3/C 3/C 3/F 3/H 3/H

L524 - 438 / from 8796 L534 - 434 / from 8962 L538 - 432 / from 8505

Service Manual

Electrical System Valid for:

L538 -432 / from 0101

Step 3 engine monitoring: display unit A13, temperature switch, pressure switch, fuel level sensor

L524 - 438 / from 8796 L534 - 434 / from 8962 L538 - 432 / from 8505

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Electrical System

Code A5 A13 A4 B4 B7 B19 B20 B25 CN12 F7C H2 H3 H4 H5 H6 H7 H8 H9 H10 H11 H12 H13 H19 H23 H25 H26 H27 H28 P3 P6 X2 X3 X4 X10 X43 X54

Service Manual

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Step 3/A-B 3/A-C 3/B 3/H 3/H 3/H 3/H 3/H 3/B 3/A 3/B-C 3/A 3/A 3/B 3/A 3/B 3/B 3/A 3/B-C 3/A 3/B-C 3/B-C 3/B 3/A 3/B-C 3/B-C 3/B-C 3/B-C 3/B 3/A-B 3/G 3/C 3/C 3/F 3/H 3/H

L524 - 438 / from 8796 L534 - 434 / from 8962 L538 - 432 / from 8505

Service Manual

Electrical System Valid for:

L524 -438 / from 9316; L534 -434 / from 9420; L538 -432 / from 9437;

Step 4 travel drive: electronic controller A1, travel hydraulics solenoid valve, parking brake solenoid valve, control lever S2 and S100

L524 - 438 / from 8796 L534 - 434 / from 8962 L538 - 432 / from 8505

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Electrical System

Code A1 A4 B5 B16 CN12 CN13 CN14 D11 D24 E1 E5 F7B K22 S2 S17 S100 ST1 ST2 ST3 X2 X7 X8 X9 X13 X14 X15 X18 X50 X56 X57 X64 Y2 Y3 Y6 Y10

Service Manual

Description Electronic controller Fuse and relay board Parking brake pressure switch Back-up alarm MATE-N-LOK connector, 12-pin, white MATE-N-LOK connector, 12-pin, red MATE-N-LOK connector, 15-pin, purple Diode 1N4007 Diode 1N4007 Left reversing light 24 V -21 W Left reversing light 24 V -21 W 7.5A fuse for parking brake, control lever power supply Parking brake relay Forward/reverse travel direction button Parking brake switch Travel range 1/2 switch Connector, 15-pin /A1 Connector, 9-pin /A1 Connector, 15-pin /A1 Connector, 70-pin / main WH Connector, 6-pin Deutsch (rear left lighting) Connector, 6-pin Deutsch (rear right lighting) Plug connector, 2-pin Deutsch (parking brake SV Y10) Connector, 4-pin XLR (travel direction SV Y26) Connector, 4-pin XLR (reverse SV Y3) Connector, 4-pin XLR (forward SV Y2) Connector, 2-pin Deutsch (backup alarm) Connector, 2-pin Junior Timer (travel range 1 SV) Connector, 10-pin MATE-N-LOK (control panel) Connector, 10-pin MATE-N-LOK (control panel) Connector, 3-pin Deutsch (pressure switch B5) Forward travel direction solenoid valve Reverse travel direction solenoid valve Travel range 1 solenoid valve Parking brake solenoid valve

Electric travel hydraulics circuit

Step 4/A 4 4/E 4/H 4/B 4/B 4/E 4/F 4/F 4/H 4/H 4/A 4/E-F 4/E-F 4/D 4/E 4/A 4/A 4/A 4 4/H 4/H 4/H 4/H 4/H 4/H 4/H 4/H 4/C-D 4/C-D 4/E 4/H 4/H 4/H 4/H

The travel hydraulics are controlled via the LH control lever S2 and the electronic controller A1. When the ignition is on there must always be voltage from the fuse F7B via the two switches SW1 and SW2 to the electronic controller ST2 pin 7 and 8 (safety circuit). The travel range and direction can only be activated with the motor running and the parking brake off. Safety circuit If the travel direction is preselected and the voltage signal between the two switches SW1 and SW2 and the electronic controller ST2 pin 7 and 8 is interrupted, the machine will not move. This is indicated by the red LED H12 on the control board A1 lighting up. Releasing the parking brake When the parking brake is released, the pressure switch B5 closes and sends a voltage signal to the electronic controller A1 ST2 pin 7. Selecting forward travel direction: As long as the switch SW2 is pressed, the signal at A1 on the plug ST2 changes from pin 7 to pin 9 and forward travel direction is activated.

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MJFCIFSS

L524 - 438 / from 8796 L534 - 434 / from 8962 L538 - 432 / from 8505

Service Manual

Electrical System If the parking brake is engaged, the pressure switch B5 is depressurised and the voltage supply from the fuse (F7B - ST2 pin 6) is interrupted. When ST2 pin 6 is not energised, the preselected travel direction is deactivated. Selecting reverse travel direction: As long as the switch SW1 is pressed, the signal at A1 on the plug ST2 changes from pin 8 to pin 9 and reverse travel direction is activated. If the parking brake is engaged, the pressure switch B5 is depressurised and the voltage supply from the fuse (F7B - ST2 pin 6) is interrupted. When ST2 pin 6 is not energised, the preselected travel direction is deactivated. Switching between travel ranges 1, 2 and neutral After the engine is started, travel range 2 is always activated. The travel range can only be changed if the parking brake is released. If you select travel range 1 (tortoise) on the switch S100, a voltage signal is sent to the electronic controller A1 ST2 pin 11. The electronic controller A1 sends a voltage signal on ST3 pin 2 to the travel range 1 solenoid valve Y6. When the travel range 1 solenoid valve Y6 is energised, the travel motor M2 is held at the maximum angle. If you select travel range 2 (hare) on the switch S100, a voltage signal is sent to the electronic controller A1 ST2 pin 10. The output on the electronic controller A1 (ST3 pin 2 to the travel range 1 solenoid valve Y6) is de-energised, and so therefore is the travel range 1 solenoid valve Y6 on the cut-in block. When the travel range 1 solenoid valve Y6 is de-energised, the travel motor M2 returns to the minimum angle. To select neutral travel direction, hold the switch S100 on travel range 1 for 3 seconds. Hydraulic oil temperature protection If the hydraulic oil overheats (more than 106°C measured by the temperature sensor B8), the machine automatically switches down to travel range 1 after a minute. In this condition the following warning signals are activated: – Warning buzzer 3 seconds on, 10 seconds off etc. – The travel range 1 and 2 indicators H25 and H26 flash alternately every 500ms. – Hydraulic oil overheating signal lamp H23 lights up continuously. – The red LED H13 on the electronic controller A1 lights up. The warning signals and travel range 1 remain active until the hydraulic oil temperature falls back below 106 °C. Coolant temperature protection If the coolant overheats (more than 100°C (L538) or 103°C (L534, L534) measured by the temperature sensor B21), the machine automatically switches down to travel range 1 after a minute. In this condition the following warning signals are activated: – Warning buzzer 3 seconds on, 10 seconds off etc. – The travel range 1 and 2 indicators H25 and H26 flash alternately every 500ms. – Hydraulic oil overheating signal lamp H23 flashes. – The red LED H14 on the electronic controller A1 lights up. The warning signals and travel range 1 remain active until the coolant temperature falls back below 103°C. Reversing block The reversing block is activated at above 16 km/h.

L524 - 438 / from 8796 L534 - 434 / from 8962 L538 - 432 / from 8505

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Electrical System

Service Manual If the travel direction is switched at a speed above 16 km/h, the pump is first switched to neutral. The machine speed is reduced while the pump is in neutral. The travel direction is changed once the speed is below 16 km/h.

Overspeed protection

Function of the parking brake switch S17

Excess speed is indicated as follows: â&#x20AC;&#x201C; At a speed above 35.7 km/h both lamps on the travel direction display light up. â&#x20AC;&#x201C; At speeds above 37.2 km/h the travel range 1 solenoid valve Y6 is activated. â&#x20AC;&#x201C; If the travel speed exceeds 43.3 km/h the warning buzzer B13 makes a continuous tone. Parking brake switch S17 with positions 2, 0, 1 Position 1 (OFF) When you start the engine, you must briefly press position 1 (OFF) to release the brake. The safety circuit prevents inadvertent release of the brake.

With the motor running, voltage is directed via the relay K29 (working hydraulics, parking brake) to the switch S17 pin 7. When you press the switch S17 in position 1 the contacts 7 and 5 are connected, the relay K22 picks up, the contact in the relay K22 closes a circuit and the connection to S17 pin 6. Position 0 When you let go of the button, the switch S17 is in the 0 position, pins 4 and 6 are connected and the solenoid valve Y10 and button S100 are energised. The pressure switch B5 switches when the opening pressure is reached. The positive signal to the parking brake signal lamp H11 is interrupted and a positive signal is sent to the electronic controller A1. Position 2 (ON) When the switch S17 is pressed in position 2 (ON), the connection to Y10 is interrupted and the parking brake is engaged. The travel range can no longer be changed. The pressure switch B5 switches the signal lamp H11 on and the travel direction to neutral. The relay K22 remains picked up.

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MJFCIFSS

L524 - 438 / from 8796 L534 - 434 / from 8962 L538 - 432 / from 8505

Service Manual

Electrical System Valid for:

L524 -438 / from 0101

Step 5 working hydraulics: switches, proximity switches, retaining solenoids, ride control

L524 - 438 / from 8796 L534 - 434 / from 8962 L538 - 432 / from 8505

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Electrical System

Code A4 B15 B17 B28 B30 CN2 CN5 CN11 CN13 D7 D8 D15 D23 D25 D69 F2A F5B F6B K11 K17 K18 S14 S16 S18 S19 S22 S26 S101 X2 X10 X11 X12 X16 X17 X23 X52 X55 X60 X61 Y9 Y14 Y17 Y18 Y20 Y21 Y28

Service Manual

Description Fuse and relay board Bucket return-to-dig proximity switch Lift kick-out proximity switch Ride control off pressure switch (optional) Quick-change device buzzer (optional) MATE-N-LOK connector, 9-pin, yellow MATE-N-LOK connector, 15-pin, green MATE-N-LOK connector, 12-pin, purple MATE-N-LOK connector, 12-pin, red Diode 1N4007 Diode 1N4007 Diode 1N4007 Diode 1N4007 Diode 1N4007 Diode 1N4007 15A fuse for lighting, switch lighting 7.5A fuse for ride control system (optional) 25A fuse (optional) Ride control relay Lift kick-out relay Bucket return-to-dig relay Bucket return-to-dig switch Ride control switch Float position, lift kick-out switch Working hydraulics lockout switch Lift kick-out switch (L534, L538) Quick change device switch (optional) MODE button Connector, 70-pin / main WH Connector, 15-pin / dash WH (switch bar) Connector, 15-pin / dash WH (switch bar) Connector, 2-pin Junior Timer (working hydraulics SV Y14) Connector. 6-pin / MATE-N-LOK (solenoids Y9, 17, 18) Connector, 4-pin / M12x1 (proximity switch B17) Connector, 4-pin / M12x1 (tilt cylinder B15) Connector, 2-pin Deutsch (proximity switch B28) Connector, 2-pin Junior Timer (quick change SV Y28) Plug connector, 2-pin Junior Timer (ride control SV Y20) Connector, 2-pin Junior Timer (ride control SV Y21) Bucket return-to-dig solenoid Working hydraulics lockout solenoid valve Lift kick-out solenoid Float position solenoid Ride control solenoid valve Ride control solenoid valve (optional) Quick change device solenoid valve

Electric working hydraulics circuit

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Step 5 5/E 5/E 5/F-G 5/H 5 5 5 5/A 5/E 5/F 5/F 5/F 5/F 5/F 5/A 5/A 5/A 5/E 5/F 5/F 5/C 5/D 5/D 5/C 5/C 5/D 5/A-B 5 5 5 5/H 5/H 5/E 5 5/F-G 5/H 5/H 5/H 5/H 5/H 5/H 5/H 5/H 5/H 5/H

Lift kick-out function If the float position / lift kick-out switch S18 is pressed, the proximity switch B17 activates the relay K17. The proximity switch B17 is closed when not actuated (N/C).

MJFCIFSS

L524 - 438 / from 8796 L534 - 434 / from 8962 L538 - 432 / from 8505

Service Manual

Electrical System The relay K17 on the board (fuses, relays) A4 is activated and the solenoid Y17 in the pilot control device is activated. If the pilot control lever is moved fully to "lift up", the solenoid Y18 holds it in position. The lift arms move up until the proximity switch B17 switches off. The circuit to the solenoid Y17 is interrupted by the relay K17. The pilot control lever returns by spring force to the neutral position and the lift movement is stopped. Float position function If the float position / lift kick-out switch S18 is pressed, the proximity switch B17 and the relay K17 energise the solenoid Y18. If the pilot control lever is moved fully to "down", the solenoid Y18 holds it in position.

L524 - 438 / from 8796 L534 - 434 / from 8962 L538 - 432 / from 8505

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Electrical System

Service Manual Valid for:

L534 -434 / from 6871; L538 -432 / from 6871

Step 5 working hydraulics: switches, proximity switches, retaining solenoids, ride control

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MJFCIFSS

L524 - 438 / from 8796 L534 - 434 / from 8962 L538 - 432 / from 8505

Service Manual

Code A4 B15 B17 B28 B30 B32 CN2 CN5 CN11 CN13 D7 D8 D15 D23 D25 D69 D79 F2A F5B F6B K11 K17 K18 S14 S16 S18 S19 S22 S26 S101 X2 X10 X11 X12 X16 X17 X23 X52 X53 X55 X60 X61 Y9 Y14 Y17 Y18 Y20 Y21 Y28

Electrical System

Description Fuse and relay board Bucket return-to-dig proximity switch Lift kick-out proximity switch Ride control off pressure switch (optional) Quick-change device buzzer (optional) Float position pressure switch MATE-N-LOK connector, 9-pin, yellow MATE-N-LOK connector, 15-pin, green MATE-N-LOK connector, 12-pin, purple MATE-N-LOK connector, 12-pin, red Diode 1N4007 Diode 1N4007 Diode 1N4007 Diode 1N4007 Diode 1N4007 Diode P600 Diode P600 15A fuse for lighting, switch lighting 7.5A fuse for ride control system (optional) 25A fuse (optional) Ride control relay Lift kick-out relay Bucket return-to-dig relay Bucket return-to-dig switch Ride control switch Float position switch (L534, L538) Working hydraulics lockout switch Lift kick-out switch (L534, L538) Quick change device switch (optional) MODE button Connector, 70-pin / main WH Connector, 15-pin / dash WH (switch bar) Connector, 15-pin / dash WH (switch bar) Connector, 2-pin Junior Timer (working hydraulics SV Y14) Connector. 6-pin / MATE-N-LOK (solenoids Y9, 17, 18) Connector, 4-pin / M12x1 (proximity switch B17) Connector, 4-pin / M12x1 (tilt cylinder B15) Connector, 2-pin Deutsch (proximity switch B28) Connector, 2-pin Deutsch (pressure switch B32) Connector, 2-pin Junior Timer (quick change SV Y28) Plug connector, 2-pin Junior Timer (ride control SV Y20) Connector, 2-pin Junior Timer (ride control SV Y21) Bucket return-to-dig solenoid Working hydraulics lockout solenoid valve Lift kick-out solenoid Float position solenoid Ride control solenoid valve Ride control and float position solenoid valve Quick change device solenoid valve

Electric working hydraulics circuit

L524 - 438 / from 8796 L534 - 434 / from 8962 L538 - 432 / from 8505

Step 5 5/E 5/E 5/F-G 5/H 5/F 5 5 5 5/A 5/E 5/F 5/F 5/F 5/F 5/F 5/F 5/A 5/A 5/A 5/E 5/F 5/F 5/C 5/D 5/D 5/C 5/C 5/D 5/A-B 5 5 5 5/H 5/H 5/E 5 5/F-G 5/F 5/H 5/H 5/H 5/H 5/H 5/H 5/H 5/H 5/H 5/H

Function of the working hydraulics lockout switch S19 Switch position 1 with ignition off (safety): â&#x20AC;&#x201C; When you press the switch in position 1 the contact in the switch connects pins 7 and 5, and the voltage comes directly from the battery to the solenoid valve Y14 (working hydraulics lockout).

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Electrical System

Service Manual – Circuit: batteries G2, fuse F01, fuse F3A, switch S19 pin 7 to pin 5, and to solenoid Y14. – As long as the button is pressed in position 1 and there is pressure in the hydro accumulator (pilot control), the lift arms can be lowered. The main switch S15 must be switched on. Switch position 0 (operation) with the engine running: – In switch position 0 pin 4 is connected to pin 6 and the voltage is directed from terminal 15 to the solenoid valve Y14 and various components. The valve opens and the pilot control pressure is available to the pilot control device. – Circuit: from terminal 15 via fuse F1C, relay K29, switch S19 to the solenoid valve Y14. Switch position 2 (OFF, road travel): – When you press the switch S19 in position 2, the contacts 4 and 2 are connected. The connection to the solenoid valve Y14 and the components is interrupted. – The working hydraulics lockout symbol field lights up (activated via pins 4 and 2 in the switch S19). Pin assignment of the inductive switches B15 and B17 1 Power supply + 2 Switch output N/C + signal 3 Earth connection 4 Switch output N/O + signal Automatic bucket return-to-dig function When the bucket return-to-dig switch S14 is pressed, the inductive proximity switch B15 (N/O) is energised. The proximity switch B15 is closed when actuated (N/O). The relay K18 on the board (fuses, relays) A4 is activated and the solenoid Y9 on the pilot control device is energised. If the pilot control lever is moved fully to "tilt in", the retaining disc touches the solenoid Y9 and the lever is held in position. The bucket is now tilted in until the proximity switch B15 is switched off and the circuit to the magnet Y9 is broken by the relay K18. The pilot control lever returns by spring force to the neutral position. The bucket remains in the horizontal position. Lift kick-out function When the bucket lift kick-out switch S14 is pressed, the inductive proximity switch B17 is energised. The proximity switch B17 is closed when not actuated (N/C). The relay K17 on the board (fuses, relays) A4 is activated and the solenoid Y17 in the pilot control device is activated. If the pilot control lever is moved fully to "lift up", the retaining disc touches the solenoid Y17 and the lever is held in position. The lift arms are now raised until the proximity switch B15 is switched off and the circuit to the magnet Y17 is broken by the relay K17. The pilot control lever returns by spring force to the neutral position and the lift movement is stopped. Float position function When the bucket return-to-dig switch S18 is pressed, the solenoid Y18 on the pilot control device is energised. If the pilot control lever is moved fully to "lower", the retaining disc touches the solenoid Y18 and the lever is held in position.

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MJFCIFSS

L524 - 438 / from 8796 L534 - 434 / from 8962 L538 - 432 / from 8505

Service Manual

L524 - 438 / from 8796 L534 - 434 / from 8962 L538 - 432 / from 8505

Electrical System

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Electrical System

Service Manual

Step 6 lighting: steering column switch, driving headlights, direction indicator system, horn

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MJFCIFSS

L524 - 438 / from 8796 L534 - 434 / from 8962 L538 - 432 / from 8505

Service Manual

Code A4 B10 CN1 CN5 CN12 CN14 D3 D17 D18 D20 D21 D89 D99 E3 E4 E6 E7 E8 E9 E14 F2B F2C F3A F4A F4B F5A F5C F7A H15 H16 H17 H18 K1 K25 K26 S3 S4 S6 X2 X5 X6 X7 X8 X22 X24 X25 X27

Electrical System

L524 - 438 / from 8796 L534 - 434 / from 8962 L538 - 432 / from 8505

MJFCIFSS

Step 6 6/A 6 6 6 6 6/D-E 6/E 6/C 6/E 6/C 6/E 6/E 6/G 6/G 6/G 6/G 6/G 6/G 6/G 6/A 6/E 6/A 6/E 6/E 6/E 6/E 6/E 6/G 6/G 6/G 6/G 6/C 6/D-E 6/D-E 6/A-B-C 6/D 6/D 6 6/G-H 6/G-H 6 6 6 6/A-B 6/B-C 6/G-H

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Electrical System Indicator system function

Service Manual The indicator system works when the main switch S15 is on. It is powered by the battery via the fuse F3A to the relay K1 terminal 49 input. The output voltage from the relay K1 terminal 49a output goes to the following consumers: â&#x20AC;&#x201C; Steering column switch S3 terminal 49a via the diode D21 â&#x20AC;&#x201C; Hazard light switch S4 pin 5 The two relays K25 and K26 have no switching function on the European version. Indicator system If you press the indicator switch on the steering column the voltage is directed to the appropriate consumer units and the indicator relay K1 starts flashing automatically. The indicator relay K1 pin C also sends a signal to the indicator light on the display unit H10. Hazard warning system If you switch on the hazard lights the voltage is directed to the consumer units and the indicator relay K1 starts flashing automatically. The indicator relay K1 pin C also sends a signal to the indicator light on the display unit H10.

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MJFCIFSS

L524 - 438 / from 8796 L534 - 434 / from 8962 L538 - 432 / from 8505

Service Manual

L524 - 438 / from 8796 L534 - 434 / from 8962 L538 - 432 / from 8505

Electrical System

MJFCIFSS

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Electrical System

Service Manual

Step 7 washer system: front wipers, rear wiper, air conditioning

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MJFCIFSS

L524 - 438 / from 8796 L534 - 434 / from 8962 L538 - 432 / from 8505

Service Manual

Code A4 B26 B27 CN2 CN5 CN11 CN13 D14 F4C F6C K5 K14 M2 M3 M4 M5 M9 S11 S13 S21 X2 X10 X11 X22 X28 X29 X31 X32 X36 X38 X39 X40 X67 Y22

Electrical System

L524 - 438 / from 8796 L534 - 434 / from 8962 L538 - 432 / from 8505

MJFCIFSS

Step 7 7/C 7/D 7 7 7 7 7/F 7/A 7/A 7/C 7/F 7/G-H 7/G-H 7/G-H 7/G-H 7/G-H 7/C 7/C 7/C 7 7 7 7 7/G-H 7/G-H 7/G-H 7/G-H 7/G-H 7/G 7/C 7/D-E 7/C-D 7/H

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Electrical System

Service Manual

Step 8 lighting: working headlights, brake light, cab light, radio (optional)

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MJFCIFSS

L524 - 438 / from 8796 L534 - 434 / from 8962 L538 - 432 / from 8505

Service Manual

Code A3 A4 B11 B12 CN1 CN11 CN13 CN14 E2 E10 E11 E12 E13 F1A F1B F3B F3C H20 H21 H22 S7 S8 S9 T1 W1 X2 X7 X8 X19 X21 X22 X26 X30 X33 X34 X35 X37 X41 X42 X59 X62 X70

Electrical System

L524 - 438 / from 8796 L534 - 434 / from 8962 L538 - 432 / from 8505

MJFCIFSS

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Electrical System

Service Manual

Step 9 Cooler and inching system: Cooler system / 0-inching temperature sensors, proportional solenoid, proximity switch, solenoid valve, speed sensor.

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MJFCIFSS

L524 - 438 / from 8796 L534 - 434 / from 8962 L538 - 432 / from 8505

Service Manual

Code A1 B1 B8 B13 B21 B29 ST1 ST2 ST3 X2 X44 X45 X46 X47 X58 X65 Y13 Y15

Electrical System

Description Electronic controller Rear axle power take-off speed sensor Hydraulic oil temperature sensor (fan control) Warning buzzer 1 Coolant temperature sensor (fan control) Injection pump proximity switch Connector, 15-pin /A1 Connector, 9-pin /A1 Connector, 15-pin /A1 Connector, 70-pin / main WH Connector, 3-pin Deutsch (pressure switch B1) Connector, 2-pin Deutsch (proportional valve Y13) Connector, 2-pin Junior Timer (temperature sensor B21) Connector, 2-pin Junior Timer (temperature sensor B8) Connector, 2-pin Junior Timer (0-inching 0 SV Y15) Connector, 4-pin / M12x1 (proximity switch B29) Cooling system proportional pressure relief valve 0-inching solenoid valve Hydraulic fan funtion

Step 9/A 9/G-H 9/G-H 9/H 9/G-H 9/G-H 9/A 9/A 9/A 9/F 9/G 9/G-H 9/G 9/G 9/G-H 9/G-H 9/H 9/H

The fan speed depends on the following factors: – Hydraulic oil temperature B8 – Coolant temperature B21 – Engine speed B1 The resistance of the temperature sensors for the hydraulic oil B8 and coolant B21 changes according to the temperature of the medium. At low temperatures the resistance is low, and at high temperatures it is high. To determine the temperature, voltage is sent through the sensors. Depending on the temperature (resistance), a lower voltage is returned to the electronic controller A1. This voltage signal is evaluated by the electronic controller A1, which sends an appropriate current to the proportional valve Y13: – Low temperature – high current – High temperature – low current The proportional valve Y13 controls the pressure relief valve and therefore the fan speed. Overheating solenoid valve de-energised (high fan speed) The proportional solenoid Y13 is de-energised in the following conditions: – Hydraulic oil above 106°C – Coolant above 103°C (L524, L534) / 100°C (L538) The fan turns at high speed, depending on the engine speed. The following warning signals are activated in one of these conditions: – After a minute the machine switches down to travel range 1 – Repeated audible warning signal, 3 seconds on, 10 seconds off etc. – Hydraulic oil overheating: the hydraulic oil overheating lamp H23 lights up continuously, the red LED H13 on the electronic controller A1 lights up. – Coolant overheating: the hydraulic oil overheating lamp H23 flashes, the red LED H14 on the electronic controller A1 lights up. If the wire to one of the sensors is interrupted or if a sensor fails, the current to the proportional magnet is set to 550 mA.

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Electrical System

Service Manual 0-inching function To protect the hydraulic units and the engine from excess speeds when travelling downhill, it is important that inching is deactivated when the pedal is in the zero position. The proximity switch B29 on the injection pump is closed when actuated (N/O). The proximity switch B29 is supplied by terminal 15 via the fuse F1C on pin 1. In the zero throttle position the proximity switch B29 is activated by the speed adjusting lever and supplies voltage at pin 2 to the electronic controller A1. The electronic controller A1 activates the 0-inching solenoid valve Y15 and closes it. This prevents oil from flowing through the inching valve into the tank (inching is deactivated).

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L524 - 438 / from 8796 L534 - 434 / from 8962 L538 - 432 / from 8505

Service Manual

L524 - 438 / from 8796 L534 - 434 / from 8962 L538 - 432 / from 8505

Electrical System

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Electrical System

Service Manual

Step 10 emergency steering system: electronic controller A1, pressure switch, emergency steering pump

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MJFCIFSS

L524 - 438 / from 8796 L534 - 434 / from 8962 L538 - 432 / from 8505

Service Manual

Code A1 A4 B3 B3a CN13 F02 F6A H24 M8 S10 ST1 ST2 ST3 X2 X11 X48 X49

Electrical System

Emergency steering function

Step 10/A 10 10/G-H 10/G-H 10/A 10/G 10/A 10/E 10/E 10/E 10/A 10/A 10/A 10/F 10/D 10/G 10/G-H

The emergency steering pump M8 is an electric gear pump which is tested each time the engine is started. The emergency steering pump M8 is operated directly from the batteries via the fuse F02 (200A). Emergency steering check procedure Once the engine is running smoothly (at a constant speed above 500 rpm) and the charge control H6 from terminal 61 is switched off, the emergency steering pump M8 is tested for 3 seconds. On the electronic controller A1 ST3 pin 1, the emergency steering switch output is switched on for 3 seconds. The solenoid switch on the emergency steering pump picks up and switches on the motor of the emergency steering pump. Pressure accumulates in the hydraulic circuit of the emergency steering pump; this is monitored by the pressure switch B3a. At the same time the emergency steering check lamp H24 is switched on. If the pressure accumulates within the 3 seconds, the self-test is successfully completed and the emergency steering check lamp H24 goes out. If no pressure accumulates (self-test unsuccessful), the emergency steering pump switch output on the electronic controller A1 ST3 pin 1 is switched off after 3 seconds. CAUTION: there is no emergency steering function! This is signalled by the emergency steering check lamp H24. Activation of the emergency steering pump if the steering pressure fails If the hydraulic pressure falls below the level set on the pressure switch B3 for more than 0.5 seconds, the emergency steering pump is activated. The emergency steering pressure switch B3 opens and disconnects the electronic controller ST1 pin 14 from earth. On the electronic controller A1 ST3 pin 1, the emergency steering switch output is switched on for 50 seconds. The solenoid switch on the emergency steering pump picks up and switches on the motor of the emergency steering pump. Pressure accumulates again in the hydraulic steering circuit, thus restoring the steering function.

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Electrical System

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MJFCIFSS

L524 - 438 / from 8796 L534 - 434 / from 8962 L538 - 432 / from 8505

Service Manual

L524 - 438 / from 8796 L534 - 434 / from 8962 L538 - 432 / from 8505

Electrical System

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Electrical System

Service Manual Valid for:

L524-438/from 8796 -; L534-434/from 8962 -; L538-/from 8508

Step 11 additional equipment: electronic controller A1, switch, solenoid valves

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MJFCIFSS

L524 - 438 / from 8796 L534 - 434 / from 8962 L538 - 432 / from 8505

Service Manual

Code A1 S2 S12 ST4 ST5 X2 X10 X11 X56 X57 X72 X73 Y11 Y12

Electrical System

L524 - 438 / from 8796 L534 - 434 / from 8962 L538 - 432 / from 8505

MJFCIFSS

Step 11/A 11/E-F 11/D 11/A 11/A 11/F 11/C 11/C 11/C-D 11/C-D 11/G-H 11/G-H 11/H 11/H

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Electrical System

Service Manual Valid for:

Step 12 Engine control L524, L534:

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L524 -438 / from 8796; L534 -434 / from 8962

electronic controller A14, diagnostic plug, temperature sensors, engine speed and position sensor, injection pump solenoid

MJFCIFSS

L524 - 438 / from 8796 L534 - 434 / from 8962 L538 - 432 / from 8505

Service Manual

Code A14 B20a B35 B36 B37 F03 F09 F10 K4 R3 R5 R7 R8 S41 X2 X78 X141 X142 Y54

Electrical System

Description Electronic engine controller (injection pump regulation) Coolant temperature sensor Fuel temperature sensor Intake air temperature sensor Engine speed and position sensor 60A preglow fuse (MEGA Fuse) 5A fuse for diagnostic plug supply 5A fuse for electronic controller diagnostic plug supply Preglow relay Intake air preheating flange Gas pedal angle sensor Diesel engine speed resistor CAN bus terminating resistor Engine diagnosis button and warning lamp Connector, 70-pin / main WH Connector, 3-pin MATE-N-LOK (control panel) Plug connector, 9-pin Deutsch HD Plug connector, 4-pin Deutsch DT06 Injection pump solenoid Engine control function

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Step 12/A 12/F 12/F 12/F 12/F 12/B 12/B 12/B 12/E 12/F 12/F 12/F 12/B 12/E 12/C 12/D 12/F 12/B 12/F

The engine injection system is regulated by the electronic controller A14 attached on the back of the engine under the injection pump. Ignition on: When the ignition is switched on, pin A2 of the electronic controller A14 is energised. This voltage signal activates the electronic controller A14 for operating the engine. If the coolant temperature measured by the sensor B20a is less than 5°C the preglow relay K4 is activated and the heating flange R3 is energised. Starting the engine: When the engine is started, the electronic controller A14 processes the following signals: – Speed signal from the speed and position sensor B37 – Position signal from the speed and position sensor B37 From these two signals, the electronic controller A14 calculates the current impulses for the starter solenoid Y54. The starter solenoid Y54 is re-energised for each stroke of each cylinder. Running the engine: The electronic controller A14 processes the following signals for running the engine: – Speed signal from the speed and position sensor B37 – Position signal from the speed and position sensor B37 – Signal from gas pedal angle sensor R5 – Signal from coolant temperature sensor B20a – Signal from fuel temperature sensor B35 – Signal from intake air temperature sensor B36 The signal from the speed and position sensor B37 is essential for running the engine. The other signals only affect the speed and performance characteristics of the engine. The values from the temperature sensors affect the engine performance, which is reduced if the temperatures are too high.

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Electrical System

Service Manual The electronic controller A14 has an error code memory which can be read using the engine diagnosis signal lamp and button and via the diagnostic plug.

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L524 - 438 / from 8796 L534 - 434 / from 8962 L538 - 432 / from 8505

Service Manual

Electrical System Fuse and relay board A4

10.1 Fuse and relay board A4 The fuse and relay board A4 is fitted inside the right control panel at the rear.

Design The fuse and relay board A4 contains relays, fuses, diodes, the electronic indicator, plug connectors, the warning buzzer B9 and screw connections for the power supply.

Fuse and relay board A4 F1A 7.5A Brake light F2A 15A Lighting, switch lighting F3A 10A Hazard warning system, working attachment, flashing beacon F4A 7.5A Right high beam F5A 3A Right parking light, monitor background lighting F6A 7.5A Power supply A1, emergency steering button, pressure switch B3a F7A 7.5A Left high beam F8A 5A Monitor (ignition +15) F1B 10A Interior lighting, socket, radio (optional), compressor

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

MJFCIFSS

D12 1N4007 extinguishing diode K29 D14 1N4007 extinguishing diode K14 D15 1N4007 extinguishing diode K7 D17 1N4007 high beam blocking diode D18 P600 indicator blocking diode D19 P600 working attachment blocking diode D20 1N4007 high beam blocking diode D21 P600 indicator blocking diode D23 1N4007 extinguishing diode

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Electrical System

Service Manual

Fuse and relay board A4

seat (optional) F2B 15A Front wiper, horn F3B 15A Front working floodlights F4B 3A Left parking light, registration lighting F5B 7.5A Ride control F6B 25A (optional) F7B 7.5A Parking brake, control lever power supply F8B 10A Engine stop F1C 7.5A Working attachment, fuel sensor, proximity switch B29 F2C 7.5A Right driving light F3C 15A Rear working floodlights F4C 7.5A Rear wiper F5C 7.5A Left driving light F6C 15A Heater blower, airconditioning F7C 3A Monitor supply (battery +30) F8C 3A Monitor supply (battery +15), preglow, engine stop GND Earth connection (M3) +15V V15 connection "ignition on" (M5) +30V V30 connection "battery +30“ (M6) SHUT OFF Engine stop solenoid connection Y5 (M4) B9 Warning buzzer D3 1N4007 extinguishing diode K25 D5 1N4007 extinguishing diode K8 D6 1N4007 extinguishing diode K27 D7 1N4007 extinguishing diode K11 D8 1N4007 extinguishing diode Y17 D11 1N4007 blocking diode K22

K18 D24 1N4007 extinguishing diode K22 D25 1N4007 extinguishing diode Y9 D31 1N4007 T61 blocking diode K27 D32 P300 extinguishing diode Y5 D69 P600 float position blocking diode D79 P600 float position blocking diode D89 P600 indicator blocking diode D99 P600 indicator blocking diode K1 Direction indicator relay K3 Engine stop relay K8 Ignition on supply relay (+15) K11 LFD system relay K14 Relay for air conditioning coupling (optional) K17 Lift kick-out relay K18 Bucket return-to-dig relay K22 Parking brake relay K25 Right indicator relay K26 Left indicator relay K27 Start release relay K29 Working hydraulics/parking brake relay CN1 MATE-N-LOK connector, 9pin, green CN2 MATE-N-LOK connector, 9pin, yellow CN5 MATE-N-LOK connector, 15pin, green CN8 MATE-N-LOK connector, 4pin, white CN11 MATE-NLOK connector, 12pin, purple CN12 MATE-NLOK connector, 12pin, white CN13 MATE-NLOK connector, 12pin, red CN14 MATE-NLOK connector, 15pin, purple

Function description Basic function

Warning buzzer B9

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The electrical system is powered by the batteries via the fuse and relay board A4 and the screw connections to each fuse. Also, the control signals go directly to the relays on the fuse and relay board A4. The extinguishing diodes attenuate peaks which may occur during switching. The warning buzzer B9 is activated for the following faults: – Engine temperature over 100°C (triggered by temperature sensor B20) – Engine oil pressure below 0.5 bar (triggered by pressure switch B7) – Brake system accumulator pressure below 90 bar (triggered by pressure switch B19)

MJFCIFSS

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

Service Manual

Electrical System Electronic controller A1

10.2 Electronic controller A1 10.2.1

Electronic controller A1 version I (ID 938613301)

Valid for:

L524-438/ 0101 - 12075; L534-434 / 0101 - 12121; L538-432 / 0101 - 12096

The electronic controller A1 is fitted inside the right control panel at the front. The electronic controller A1 is fitted with connectors, LEDs, output stages, potentiometers, coding switches and other electronic components.

Design

Electronic controller A1 H1 Green transformer power supply LED

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H19 Green output N24 active LED H20 Green output N17 active LED

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N31 Additional function 2 output stage

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Electrical System

Service Manual

Electronic controller A1

H2 Green controller power supply LED H3 Red output N20 error LED H4 Red output N21 error LED H5 Red output N22 status LED H6 Red LED (no function) H7 Red output N24 status LED H8 Red output N18 status LED H9 Red output N17 status LED H10 Red output N16 status LED H12 Red safety logic LED H13 Green hydraulic oil overheating LED H14 Red coolant overheating LED H15 Green output N20 active LED H16 Green output N21 active LED H17 Green output N22 LED H18 Green LED (no function)

H21 H22 H23 H24 H25 N15 N16 N17 N18 N20 N21 N22 N23 N24

Green output N16 active LED Red output N15 status LED Green output N15 active LED Red output N31 status LED Green output N31 active LED Additional function 1 output stage Pump forward output stage Pump reverse output stage Fan proportional valve output stage Emergency steering pump output Ride control output stage Zero throttle output stage Coupling output stage (no function) Slow travel range output stage 1

Pot1 Maximum fan current potentiometer Pot2 Minimum fan current potentiometer Pot3 Sensor B8 calibration potentiometer Pot4 Sensor B8 amplification potentiometer S1.1 Fan control coding switch NORMAL / TROPICS S1.2 Coding switch for temperature adjustment L524, L534 / L538 ST1 Connector 15-pin female ST2 Connector 15-pin male ST3 Connector 12-pin female ST4 Connector 2-pin female ST5 Connector 2-pin male

Plug assignment ST1 connector (15-pin female) 1 2 3 4 5 6 7 8 9 10 11 12 13

Hydraulic oil temperature sensor B8 supply (earth) Unassigned Hydraulic oil temperature sensor B8 input (analogue signal) Hydraulic oil temperature sensor B8 supply (earth) Overheating warning output H23 (earth-switching) Hydraulic oil temperature sensor B8 input (analogue signal) Power take-off sensor B1 supply (earth) Power take-off sensor shield B1 Power take-off speed input B1 (frequency) Unassigned Unassigned Engine speed input TW G1 (frequency) Emergency steering pump manual activation input S10 (positive switching) 14 Emergency steering pressure switch input B3 (earth switching) 15 Emergency steering check pressure switch input B3a (positive switching)

ST2 connector (15-pin male) 1 2 3 4 5 6 7 8 9 10 11

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Power supply - F6A 24V (+) Power supply - earth (-) Charge control input T61 G1 (positive switching) Travel range 2 lamp output H26 (positive switching) Travel range 1 lamp output H25 (positive switching) Parking brake input B5 (positive switching) Forward selection input, N/C, Ka/Kb (positive switching) Reverse selection input, N/C, Ka/Kb (positive switching) C signal input, Ka/Kb (positive switching) Upshift S100 input (positive switching) Downshift S100 input (positive switching)

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Service Manual

Electrical System Electronic controller A1

12 13 14 15

Injection pump zero throttle proximity switch B29 input (earth switching) Unassigned Unassigned Unassigned

ST3 connector (12-pin female) 1 2 3 4 5 6 7 8 9 10 11 12

Emergency steering pump output M8 (positive switching) Travel range 1 output Y6 (positive switching) Fan proportional solenoid output Y13 Forward lamp output H3 (positive switching) Forward pump output Y2 (positive switching) Reverse pump output Y3 (positive switching) Reverse lamp output H9 (positive switching) 0-inching no throttle solenoid valve output Y15 (positive switching) Coupling output Y26 (positive switching) – no function Emergency steering check lamp output H24 (earth switching) Buzzer output B13 (earth switching) Ride control output S16 (positive switching)

ST4 connector (2-pin female) 1 Additional equipment 1 input (positive switching) 2 Additional equipment 2 input (positive switching)

ST5 connector (2-pin male) 1 Additional equipment 1 output Y11 (positive switching) 2 Additional equipment 1 output Y12 (positive switching)

Function description Electronic controller A1 Basic function

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Operating temperature -20°C to +80°C The electronic controller A1 has the following main functions: – Controlling the travel drive – Controlling the fan drive – Controlling the emergency steering pump – Controlling additional functions – Activating the external buzzer B13 The electronic controller A1 is powered when the ignition is on. The electronic controller A1 converts incoming signals into commands and sends them to the consumers. The warning buzzer B13 is activated for the following faults: – Hydraulic oil temperature above 106°C (triggered by temperature sensor B8) – Engine coolant temperature above 103°C (L524, L534) or 100°C (L538) (triggered by the temperature sensor B21) – Travel speed above 41.7 km/h (triggered by the speed sensor B1) – Emergency steering pump pressure below 10 bar (triggered by pressure switch B3)

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Electrical System

Service Manual

Electronic controller A1

Travel drive The electronic controller A1 regulates the travel drive. The following components affect the travel drive: – A1 power supply from fuse F7b – Travel direction selection switch S2 relay Ka/Kb – Parking brake pressure switch B5 – Travel range switch S100 – Forward solenoid valve Y2, reverse Y3, travel range Y6 – Temperature sensors for hydraulic oil B8 and coolant B21 – Proximity switch on the injection pump B29 – Engine speed alternator terminal W When the ignition is on a voltage signal goes from the fuse F7B via the two relays Ka and Kb to the electronic controller A1. Travel range 2 is preselected. In travel range 2 the travel range 1 solenoid valve Y6 is not energised. The travel direction and range can only be selected once the parking brake is released. The parking brake can only be released when the engine is running. If the parking brake is released and there is pressure on the brake and the parking brake pressure switch B5, the pressure switch B5 sends a voltage signal to the electronic controller A1. The parking brake switch S17 energises the travel range switch S100. When travel range 1 is selected using the switch S100, the electronic controller A1 energises the travel range 1 solenoid valve Y6. When another travel range is selected, the corresponding relay Ka or Kb picks up as the button is pressed and the signal on the relay changes from output 87a to output 87 (C signal). This tells the electronic controller that it must switch to a travel range.

0-inching 0-inching is activated when the gas pedal is in the idle position. Signal sequence: – In the idle position, the proximity switch B29 is activated by the speed adjusting lever on the injection pump. – The proximity switch B29 sends a voltage signal to the electronic controller A1. – The electronic controller A1 sends a voltage signal to the solenoid valve Y15. – The solenoid valve Y15 stops the flow of oil to the inching valve. See the detailed description in the section on the inching function.

Reversing block The reversing block is activated at 16 km/h. If the travel direction is changed at a speed above 16 km/h the travel pump is changed after up to 800 milliseconds in neutral. If the travel direction is changed at a speed above 16 km/h and at full throttle, the travel pump is switched to neutral to decelerate the machine. When the speed is below 16 km/h the travel pump is activated in the opposite direction. If the travel direction is changed at a speed above 16 km/h with the gas pedal in the idle position, the travel pump is switched to neutral to decelerate the machine.

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Service Manual

Electrical System Electronic controller A1

If the gas pedal is pressed at a speed below 16 km/h, the opposite direction is selected. If the gas pedal is not pressed, the machine is slowed to 2 km/h and then the opposite direction is selected.

Overspeed protection Overspeed protection is activated at speeds above 37.2 km/h (3120 Hz on the speed sensor B1). If the machine exceeds 37.2 km/h at full throttle the travel range 1 solenoid valve is activated. If the machine exceeds 37.2 km/h at zero throttle (travelling downhill) the travel pump is switched to neutral. If the speed still increases, a continuous tone sounds at 41.7 km/h (3500 Hz) and above. Signal sequence at full throttle: – The speed is measured by the sensor B1 on the rear axle – The speed sensor B1 sends a frequency signal to the electronic controller A1 – If the frequency is above 3120 Hz, the electronic controller A1 sends a voltage signal to the travel range 1 solenoid valve Y6. – The travel range 1 solenoid valve Y6 stops the control pressure to the variable displacement motor 2, thus increasing the angle, and the machine is slowed down. Signal sequence at zero throttle: – If the frequency is below 3120 Hz, the electronic controller A1 deenergises the active solenoid valve on the travel pump. – This depressurises the travel pump displacement. The travel pump swivels to the zero position and the machine is slowed down.

Fan control The electronic controller A1 regulates the fans speed according to the temperature and engine speed Signals from the following components affect the fan speed: – A1 power supply from fuse F7b – Hydraulic oil temperature sensor B8 – Coolant temperature sensor B21 – Proportional solenoid Y13 – Coding switch on the electronic controller S1.1 / S1.2 – Alternator terminal W The two temperature sensors for the hydraulic oil B8 and coolant B21 regulate the current on the proportional solenoid Y13 via the electronic controller A1. See the detailed description in the section on electrical fan speed control. Emergency steering pump control The electronic controller A1 activates the emergency steering pump if the steering pump or the engine fails. Signals from the following components affect the emergency steering pump: – A1 power supply from fuse F7b – Emergency steering pressure switch B3 – Emergency steering check pressure switch B3a – 150A fuse F02 – Manual activation button S10 – Emergency steering pump motor M8

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Service Manual

Electronic controller A1

See the detailed description in the section on emergency steering. LED display

LED H1 H2 H11 H15 H16 H17 H18 H19 H20 H21 H23 H25

Colour Green Green Green Green Green Green Green Green Green Green Green Green

The following LEDs should light up during operation: They show the status of the power supply and the terminals of the electronic controller.

Status Shows the power supply via the fuse F6a Shows the power supply via the fuse F6a Always lit, no function Lights up when the emergency steering pump output N20 is activated Lights up when the ride control output N21 is activated Lights up when the gas pedal idle output N20 is activated Lights up when the gas pedal idle output N20 is activated Lights up when the travel range 1 output N24 is activated Lights up when the pump reverse output N17 is activated Lights up when the pump forward output N16 is activated Lights up when the additional function 1 output N15 is activated Lights up when the additional function 2 output N31 is activated The following LEDs indicate faults: They indicate electrical faults or overheating. Control output error means: If the LED lights up there is a short circuit between the output and the component.

LED H3 H4 H5 H6 H7 H8 H9 H10 H12

Colour Red Red Red Red Red Red Red Red Red

H13 H14 H22 H24

Green Red Red Red

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Status Fault at the emergency steering pump output N20 Fault at the ride control output N20 Fault at the inching solenoid valve output N22 No function Fault at the travel range 1 solenoid valve output N22 Fault at the fan proportional solenoid output N18 Fault at the reverse solenoid valve output N17 Fault at the forward solenoid valve output N16 Lights up if there is an interruption between relays Ka, Kb and the electronic controller A1 Lights up if the hydraulic oil is above 106°C Lights up if the coolant temperature is above 103°C (L524,L534) or 100°C (L538) Fault at the additional function 1 solenoid valve output N15 Fault at the additional function 2 solenoid valve output N15

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Service Manual

Electrical System Electronic controller A1

The coding switches have the following functions: Coding switch

Switch / function

Switch ON

Switch OFF

S1.1 Fan control

Current 390 – 1000 mA

Current 550 -1060 mA

L524, L534 103°C

L538 100°C

S1.2 Engine overheating Switch positions:

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Machine / switch

S1.1

S1.2

L524, L534 normal

L538 normal

OFF

L524, L534 tropics

OFF

L538 tropics

OFF

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Service Manual

Electronic controller A1

10.2.2

Electronic controller A1 version II (ID 9067410)

Valid for:

L524 -438 / from 12076; L534 -434 / from 12122; L538 -432 / from 12097

Design

Electronic controller A1

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MJFCIFSS

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Service Manual

Electrical System Electronic controller A1

H1 Green transformer power supply LED H2 Green controller power supply LED H3 Red output N20 error LED H4 Red output N21 error LED H5 Red output N22 status LED H6 Red LED (no function) H7 Red output N24 status LED H8 Red output N18 status LED H9 Red output N17 status LED H10 Red output N16 status LED H12 Red safety logic LED H13 Red hydraulic oil overheating LED H14 Red coolant overheating LED H15 Green output N20 active LED H16 Green output N21 active LED H17 Green output N22 LED

H18 Green LED (no function) H19 Green output N24 active LED H20 Green output N17 active LED H21 Green output N16 active LED H22 Red output N15 status LED H23 Green output N15 active LED H24 Red output N31 status LED H25 Green output N31 active LED N15 Additional function 1 output stage N16 Pump forward output stage N17 Pump reverse output stage N18 Fan proportional valve output stage N20 Emergency steering pump output N21 Ride control output stage N22 Zero throttle output stage

N23 Coupling output stage (no function) N24 Slow travel range output stage 1 N31 Additional function 2 output stage S1.1 Fan control coding switch NORMAL / TROPICS S1.2 Coding switch for temperature adjustment L524, L534 / L538 S2.1 Joystick coding switch â&#x20AC;&#x201C; latch/push direction button S2.2 Coding switch with no function ST1 Connector 15-pin female ST2 Connector 15-pin male ST3 Connector 12-pin female ST4 Connector 2-pin female ST5 Connector 2-pin male

Plug assignment ST1 connector (15-pin female) 3 4 5 6 7 8 9 10 11 12 13 14 15

Hydraulic oil temperature sensor B8 supply (earth) Unassigned Coolant temperature sensor B21 input (analogue signal) Hydraulic oil temperature sensor B8 supply (earth) Overheating warning output H23 (earth-switching) Hydraulic oil temperature sensor B8 input (analogue signal) Power take-off sensor B1 supply (earth) Power take-off sensor shield B1 Power take-off speed input B1 (frequency) Unassigned Unassigned Engine speed input TW G1 (frequency) Emergency steering pump manual activation input S10 (positive switching) 16 Emergency steering pressure switch input B3 (earth switching) 17 Emergency steering check pressure switch input B3a (positive switching)

ST2 connector (15-pin male) 1 2 3 4 5 6 7 8 9 10

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Power supply - F6A 24V (+) Power supply - earth (-) Charge control input T61 G1 (positive switching) Travel range 2 lamp output H26 (positive switching) Travel range 1 lamp output H25 (positive switching) Parking brake input B5 (positive switching) Forward selection input, N/C (positive switching) Reverse selection input, N/C (positive switching) C signal input (positive switching) Upshift S100 input (positive switching)

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Service Manual

Electronic controller A1

11 12 13 14 15

Downshift S100 input (positive switching) Injection pump zero throttle proximity switch B29 input (earth switching) Unassigned Unassigned Unassigned

ST3 connector (12-pin female) 1 2 3 4 5 6 7 8 9 10 11 12

Emergency steering pump output M8 (positive switching) Travel range 1 output Y6 (positive switching) Fan proportional solenoid output Y13 Forward lamp output H3 (positive switching) Forward pump output Y2 (positive switching) Reverse pump output Y3 (positive switching) Reverse lamp output H9 (positive switching) 0-inching no throttle solenoid valve output Y15 (positive switching) Spare output Emergency steering check lamp output H24 (earth switching) Buzzer output B13 (earth switching) Ride control output S16 (positive switching)

ST4 connector (2-pin female) 1 Additional equipment 1 input (positive switching) 2 Additional equipment 2 input (positive switching)

ST5 connector (2-pin male) 1 Additional equipment 1 output Y11 (positive switching) 2 Additional equipment 2 output Y12 (positive switching)

Function description Electronic controller A1 Basic Function

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Operating temperature -20°C to +80°C The electronic controller A1 has the following main functions: – Controlling the travel drive – Controlling the fan drive – Emergency steering pump control – Controlling additional functions – Activating the external buzzer B13 The electronic controller A1 is powered when the ignition is on. The electronic controller A1 converts incoming signals into commands and sends them to the consumers.

MJFCIFSS

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

Service Manual

Electrical System Electronic controller A1

The warning buzzer B13 is activated for the following faults: – Hydraulic oil temperature above 106°C (triggered by temperature sensor B8) – Engine coolant temperature above 103°C (L524, L534) or 100°C (L538) (triggered by the temperature sensor B21) – Travel speed above 43.3 km/h (triggered by the speed sensor B1) – Emergency steering pump pressure below 10 bar (triggered by pressure switch B3)

Travel drive The electronic controller A1 regulates the travel drive. The following components affect the travel drive: – A1 power supply from fuse F6A – Travel directions selection switch S2 – Parking brake pressure switch B5 – Travel range switch S100 – Forward solenoid valve Y2, reverse Y3, travel range Y6 – Temperature sensors for hydraulic oil B8 and coolant B21 – Proximity switch on the injection pump B29 – Engine speed alternator terminal W When the ignition is on a voltage signal goes from the fuse F7B via the switch S2 to the electronic controller A1. Travel range 2 is preselected. In travel range 2 the travel range 1 solenoid valve Y6 is not energised. The travel direction and range can only be selected once the parking brake is released. The parking brake can only be released when the engine is running. If the parking brake is released and there is pressure on the brake and the parking brake pressure switch B5, the pressure switch B5 sends a voltage signal to the electronic controller A1. The parking brake switch S17 energises the travel range switch S100. When travel range 1 is selected using the switch S100, the electronic controller A1 energises the travel range 1 solenoid valve Y6. When a travel direction is preselected, the switch S2 changes the signal for the direction to the C signal. This tells the electronic controller that it must switch to a travel range.

0-inching 0-inching is activated when the gas pedal is in the idle position. Signal sequence: – In the idle position, the proximity switch B29 is activated by the speed adjusting lever on the injection pump (L538) or the gas pedal (L524, L534). – The proximity switch B29 sends a voltage signal to the electronic controller A1. – The electronic controller A1 sends a voltage signal to the solenoid valve Y15. – The solenoid valve Y15 stops the flow of oil to the inching valve. See the detailed description in the section on the inching function.

Reversing block The reversing block is activated at 16 km/h.

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Service Manual

Electronic controller A1

If the travel direction is changed at a speed above 16 km/h the travel pump is changed after up to 800 milliseconds in neutral. If the travel direction is changed at a speed above 16 km/h and at full throttle, the travel pump is switched to neutral to decelerate the machine. When the speed is below 16 km/h the travel pump is activated in the opposite direction. If the travel direction is changed at a speed above 16 km/h with the gas pedal in the idle position, the travel pump is switched to neutral to decelerate the machine. If the gas pedal is pressed at a speed below 16 km/h, the opposite direction is selected. If the gas pedal is not pressed, the machine is slowed to 2 km/h and then the opposite direction is selected.

Overspeed protection Overspeed protection is activated at 37.2 km/h and above. This corresponds to a frequency on the speed sensor B1 of: L524 2544 Hz L534, L538 3110 Hz If the machine exceeds 37.2 km/h the travel range 1 solenoid valve is activated. If the speed still increases, a continuous tone sounds at 43.3 km/h and above. Signal sequence: – The speed is measured by the sensor B1 on the rear axle. – The speed sensor B1 sends a frequency signal to the electronic controller A1. – If the speed is above 37.2 km/h, the electronic controller A1 sends a voltage signal to the travel range 1 solenoid valve Y6. – The travel range 1 solenoid valve Y6 stops the control pressure to the variable displacement motor 2, thus increasing the angle, and the machine is slowed down.

Fan control The electronic controller A1 regulates the fan speed according to the temperature and engine speed Signals from the following components affect the fan speed: – A1 power supply from fuse F6A – Hydraulic oil temperature sensor B8 – Coolant temperature sensor B21 – Proportional solenoid Y13 – Coding switch on the electronic controller S1.1 / S1.2 – Alternator terminal W The two temperature sensors for the hydraulic oil B8 and coolant B21 regulate the current on the proportional solenoid Y13 via the electronic controller A1. See the detailed description in the section on electrical fan speed control. Emergency steering pump control The electronic controller A1 activates the emergency steering pump if the steering pump or the engine fails. Signals from the following components affect the emergency steering pump: – A1 power supply from fuse F6A – Emergency steering pressure switch B3 – Emergency steering check pressure switch B3a

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Service Manual

Electrical System Electronic controller A1

– 150A fuse F02 – Manual activation button S10 – Emergency steering pump motor M8 See the detailed description in the section on emergency steering. LED display

LED H1 H2 H15 H16 H17 H19 H20 H21 H23 H25

Colour Green Green Green Green Green Green Green Green Green Green

The following LEDs should light up during operation: They show the status of the power supply and the terminals of the electronic controller.

Status Shows the power supply via the fuse F6A Shows the power supply via the fuse F6A Lights up when the emergency steering pump output N20 is activated Lights up when the ride control output N21 is activated Lights up when the gas pedal idle output N20 is activated Lights up when the travel range 1 output N24 is activated Lights up when the pump reverse output N17 is activated Lights up when the pump forward output N16 is activated Lights up when the additional function 1 output N15 is activated Lights up when the additional function 2 output N31 is activated The following LEDs indicate faults: They indicate electrical faults or overheating. Control output error means: If the LED lights up there is a short circuit or a break between the output and the component.

LED H3 H4 H5 H7 H8 H9 H10

Colour Red Red Red Red Red Red Red

H12

Red

H13 H14 H22 H24

Green Red Red Red

Status Fault at the emergency steering pump output N20 Fault at the ride control output N21 Fault at the inching solenoid valve output N22 Fault at the travel range 1 solenoid valve output N24 Fault at the fan proportional solenoid output N18 Fault at the reverse solenoid valve output N17 Fault at the forward solenoid valve output N16 Lights up if there is an interruption between the forward/reverse button and the electronic controller A1 Lights up if the hydraulic oil is above 106°C Lights up if the coolant temperature is above 103°C (L524,L534) or 100°C (L538) Fault at the additional function 1 solenoid valve output N15 Fault at the additional function 2 solenoid valve output N31

Coding switch

The coding switches have the following functions: Switch / function

Switch ON

Switch OFF

S1.1 Fan control

Current 550 -1060 mA

Current 390 -1000 mA

L524, L534 - 103°C

L538 - 100°C

Latch travel range switch

Push travel range switch

---

S1.2 Engine overheating S2.1 Joystick function S2.2 No function

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

MJFCIFSS

10.2-13 of 14

Electrical System

Service Manual

Electronic controller A1

Switch positions:

10.2-14 of 14

Machine / switch

S1.1

S1.2

S2.1

S2.2

L524, L534 normal

OFF

---

L538 normal

OFF

---

L524, L534 tropics

OFF

---

L538 tropics

OFF

---

MJFCIFSS

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

Service Manual

Electrical System Electronic controller A14 (diesel engine)

10.3 Electronic controller A14 (diesel engine) Valid for:

L524 -438 / from 8796; L534 -434 / from 8962

The electronic controller A14 is mounted on the rear of the engine below the injection pump. The electronic controller A14 has a plug connection for the power supply and controlling the engine.

Design

Electronic controller A14 (diesel engine) 1 Pioneer connector

2 Electronic controller A14

Plug assignment ST14 connector (30-pin female) A1 A2 A3 B1 B2 B3 C1 C2 C3 D1 D2 D3 E1 E2 E3 F1 F2

L524 - 438 / from 8796 L534 - 434 / from 8962

Unassigned Terminal 15 switched Injection pump solenoid valve return line Y54 (earth) Coolant temperature input B20a Speed and position sensor input B37 Start of diagnosis input signal S41 Manual speed adjustment input (optional) Unassigned Fuel temperature input B35 Intake air temperature input B36 Speed and position sensor supply B37 Sensors (earth) Angle sensor input R5 Sensor voltage supply (+5V) Unassigned CAN bus low Unassigned

MJFCIFSS

10.3-1 of 6

Electrical System

Service Manual

Electronic controller A14 (diesel engine)

F3 G1 G2 G3 H1 H2 H3 J1 J2 J3 K1 K2 K3

Unassigned CAN bus high Preglow lamp output H2 Diagnosis control signal S41 Unassigned Unassigned Unassigned Unassigned Electronic controller earth A14 Unassigned Electronic controller A14 power supply terminal 30 Injection pump solenoid output Y54 Preglow relay output K4

Function description

Sensors for electronic injection system 1 2 3 4 5

Injection pump solenoid Y54 Electronic controller A14 Angle encoder R5 Speed and position sensor B37 Fuel temperature sensor B35

6 Coolant temperature sensor B20a 7 Intake air temperature sensor B36 8 Diagnostic connector X141

Electronic controller A14 (diesel engine) Basic Function

10.3-2 of 6

The electronic controller A14 has the following main functions: â&#x20AC;&#x201C; Controlling the preglow system â&#x20AC;&#x201C; Controlling the injection system

MJFCIFSS

L524 - 438 / from 8796 L534 - 434 / from 8962

Service Manual

Electrical System Electronic controller A14 (diesel engine)

– Controlling the engine speed – Lowering the engine output at excess temperature – Storing service codes when tolerances are exceeded – Issuing service codes on the display S41 – Issuing service codes via the MURPHY GAGE diagnostic tool The electronic controller A14 is powered when the mains switch is on. The electronic controller A14 converts incoming signals into commands and sends them to the consumers.

Preglow system The electronic controller A14 controls the preglow system according to the coolant temperature. If the coolant temperature is below 5°C the controller activates the relay K4. The preglow time depends on the coolant temperature.

Injection system

Electronic injection pump controller 1 Actuating roller for piston 6 Control valve with spring pressure. Bottom view rotated 7 Fuel in pump housing by 90°. 8 Tappet magnet 2 Piston high pressure 9 Magnet coil 3 Rotor distributes force to 10 Connection to injection nozzles injection nozzles 11 Electronic controller A14 4 Pressure duct 5 Injection pump The electronic controller A14 regulates the start and quantity of delivery in the injection system. The following components affect the control of the injection system: – Engine speed and position sensor B37 (this signal is essential) – Gas pedal angle sensor R5 – Fuel temperature sensor B35 – Coolant temperature sensor B20a – Intake air temperature sensor B36 – Injection pump solenoid (this function is essential) The electronic controller A14 converts information from the sensors into current impulses for the injection pump solenoid Y54 8. The signal from the engine speed and position sensor B37 is essential for running the engine, because otherwise the electronic controller A14 cannot calculate current impulses.

L524 - 438 / from 8796 L534 - 434 / from 8962

MJFCIFSS

10.3-3 of 6

Electrical System

Service Manual

Electronic controller A14 (diesel engine)

The injection pump solenoid Y54 8 is also essential. The solenoid activates via the tappet 7 the valve 5 in the injection pump 4, which directs fuel to the nozzles. The rotor 2 ensures that the fuel is distributed to the correct nozzles.

Injection pump solenoid activation 1 Solenoid not activated 2 Solenoid activated The activation of the solenoid on the injection pump depends on the following conditions: – Gas pedal position (signal from angle sensor R5) – Fuel temperature (sensor B35) – Power consumption by working or travel hydraulics When the gas pedal is in the idle position the solenoid on the injection pump is controlled with short current impulses as shown in "A". At full throttle and corresponding power consumption the solenoid on the injection pump is controlled with long current impulses as shown in "A". The time of injection (start of delivery) is also regulated by the electronic controller A14.

Engine speed control The upper and lower idle speeds are set in the electronic controller A14 and cannot be altered.

Speed adjustment (angle sensor R5) 1 Voltage 2 Maximum angle sensor control range 0.4V – 4.6V 3 Voltage range processed by controller 1.2V – 4.5V

4 Gas pedal path 5 Angle sensor path (degrees) 6 Percentage shown on MURPHY GAGE diagnostic device in the THROTTLE menu 7 Engine speed (min-1) The angle sensor R5, which is connected via a linkage to the gas pedal, issues a voltage signal between 0.4V and 4.6V. The electronic controller A14 processes a voltage signal between 1.2V and 4.5V and adjusts the engine speed accordingly using current impulses.

10.3-4 of 6

MJFCIFSS

L524 - 438 / from 8796 L534 - 434 / from 8962

Service Manual

Electrical System Electronic controller A14 (diesel engine)

Lowering the engine output at excess temperature If the intake air, coolant or fuel is too hot, the electronic controller A14 reduces the engine output proportionately. The following temperatures cause a reduction in engine output: Item

Temperature

Power reduction

Intake air temperature

> 150°C

20%

Coolant temperature

> 108°C > 113°C > 118°C*

5% 40% 60%

Fuel temperature

> 120°C

20%

*If the coolant temperature exceeds 118°C, in addition after 30 seconds the electronic controller switches off the engine.

Storing service codes when tolerances are exceeded If preset tolerances are not maintained, the electronic controller A14 stores a service code. For a detailed description see section 19

Issuing service codes on the display S41 If preset tolerances are not maintained, one of the following warnings is issued on the button S41 for the duration: – The lamp flashes – The lamp lights up You can also press the button to read the service code in the form of a flashing signal. For a detailed description see section 19

Reading service codes with the MURPHY GAGE diagnostic tool The following information can be obtained by connecting the MURPHY GAGE to the diagnostic connector: – Units – either metric or imperial units – Eng. Conf. – engine configurations (see the list in the engine manual) – Throttle – value from angle sensor R5 0 – 100% – Load RPM – engine suppression – Eng. Torq – engine torque – Eng. RPM – engine speed from the speed and position sensor B37 – Eng. Hrs – service hours – Fuel Used – total fuel consumption – Cool Temp. – coolant temperature from sensor B20a – Fuel Temp. – fuel temperature from sensor B35 – Oil Press – oil pressure not connected – Fuel Rate – hourly fuel consumption – Mani Temp. – intake air temperature from sensor B36 – Batt. Volt – battery voltage – Service Code – active service codes – Stor Code – stored service codes

L524 - 438 / from 8796 L534 - 434 / from 8962

MJFCIFSS

10.3-5 of 6

Electrical System

Service Manual

Electronic controller A14 (diesel engine)

Plug assignment X141 DEUTSCH connector (9-pin female) A B C D E F G H J

10.3-6 of 6

Weight Battery voltage terminal 30 CAN high signal CAN low signal CAN bus shield Unassigned Unassigned Unassigned Unassigned

MJFCIFSS

L524 - 438 / from 8796 L534 - 434 / from 8962

Service Manual

Electrical System Battery installation

10.4 Battery installation The electrical system operates at 24 volts.

Design

Battery installation 1 Batteries 3 Main fuse 2 Battery main switch The batteries 1 are installed in the right ballast weight. The two batteries are connected in series. The battery main switch is located at the rear right of the engine compartment.

10.4.1

Battery (ID 6905637, 6905186) Apart from the terminals, the batteries require no maintenance during normal operation.

Design

Battery 1 Battery 2 Back-ignition protection

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

MJFCIFSS

3 Drip catcher

10.4-1 of 2

Electrical System

Service Manual

Battery installation

The battery has a gas escape mechanism and is equipped with back-ignition protection and a drip catcher. The free channels must be sealed with dummy plugs.

Technical data

10.4-2 of 2

MJFCIFSS

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

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16 Cab, Heating, Air Conditioning 16.0 Chapter contents 16

Cab, Heating, Air Conditioning ......................................... 16.0-1 16.0.1 16.1

Instrument panel ...........................................................................16.1-1 16.1.1

Display unit .........................................................................16.1-2

16.1.2

Switches on the instrument panel ....................................16.1-11

16.1.3

Switches on the side console ...........................................16.1-13

16.1.4

LH control lever ................................................................16.1-16

16.2

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Cab, heating and air-conditioning.......................................16.0-1

Heating and ventilation .................................................................16.2-1 16.2.1

Blower.................................................................................16.2-2

16.2.2

Heat exchanger ..................................................................16.2-3

16.2.3

Water valve.........................................................................16.2-4

16.2.4

Air filter ...............................................................................16.2-4

16.3

Air-conditioning system.................................................................16.3-1

16.4

Windscreen wiper and washer system .........................................16.4-1

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16.0.1

Cab, heating and air-conditioning The cab is a safety cab which has been tested and approved according to the ROPS/FOPS specifications. It is elastically supported on the rear section. The cab is equipped with heating and ventilation as standard. On request, an air conditioning system can be installed as an option. The cab can be accessed from the left side of the machine via the steps and the door. The right door can be used as an exit in emergencies.

Design

Driverâ&#x20AC;&#x2122;s cab - exterior view 1 2 3 4 5

Front windscreen wiper Front windscreen Right cab door Seat with safety belt Access to electronics, fuses and relays 6 Right working floodlight 7 Access to cab fresh air filter

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8 9 10 11 12 13 14

Rear wiper Rear windscreen Left working floodlight Round compartment Left exterior mirror Shelf and storage space Access to wiper washer fluid reservoir

15 16 17 18 19 20 21

Door bolt Left cab door Door lock Outlet nozzles Access aid Adjustable steering column Outlet nozzles

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Driverâ&#x20AC;&#x2122;s cab, view from right 1 2 3 4 5

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Working floodlight Exterior mirror LH control lever Door lock Door bolt

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6 7 8 9

Access to cab air filter Star grip screw Handle Air flap lever

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Inside view of the driverâ&#x20AC;&#x2122;s cab 1 2 3 4 5 6 7 8

Speaker Sun visor Interior lights with switch Interior mirror Radio compartment (optional) Inch/brake pedal Steering column switch Adjustable steering column with steering wheel 9 Instrument panel with display unit 10 Steering column adjustment lever Cab window panes

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11 Ignition switch 12 Gas pedal 13 Heater/ventilation/ air-conditioning outlet nozzles (8 in total) 14 LIEBHERR control lever 15 Ashtray 16 Control lever fitting for optional working functions 17 Emergency exit door handle (right-hand door) 18 Adjustable arm rest

19 20 21 22 23 24 25 26 27 28 29

Electronic controller box A1 Fuse and relay box A14 Switches on the side console Driverâ&#x20AC;&#x2122;s seat Air flap adjustment lever Ventilation control Heater control Round compartment Glove compartment Socket Compartment with lockable lid

Single-pane safety glass is used in all Liebherr cabs. Around the field of vision, the glass is specially hardened (approx. 50 x 60 cm). The glass cannot be drilled, cut or machined in any way. The three-piece panes each consist if a centre part and two side parts, held by a rubber mounting strips in the window frame. The strip seals the window frame inside. The strip for the front window is a single piece. It starts and ends at the top left corner below the bracket of the working floodlight. The strip for the rear window consists of four pieces.

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Service Manual Fitting the glass The glass in the rear window needs particular care because the rubber strip has to be mitred at the corners. The sections must be precisely and cleanly cut to the right length, as otherwise there will be leaks.

The profile around the roof gutter 1 must also be precisely cut to length and mitred. There may be no gaps or leaks. Silicon sealant must also be applied to the mitre join. When fitting the glass, it is a good idea to fix the top of the rubber seal to the frame with a little superglue. First put in the left and right side sections and gently tap them into the rubber seal with a mallet. Then hold the fixings to the lugs but do not fasten them. Then place the bottom of the middle section in the seal and align it so that the distance to the side sections is equal (at least 2 to 3 mm). Using small wooden wedges between the panes makes it easier to align them and attach the fixings. The panes may not touch, even if the cab moves.

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Cab, Heating, Air Conditioning After checking the position of the panes again, apply silicon to the rubber seals to a length of around 15 cm from the corners (outside only). This is necessary because the rubber seals can warp at this point, which can lead to leaks. Then tighten the bolts on the fixings to the right torque and take out the wedges. Finally use an installation tool to insert the beading. Cut it to the right length just before you finish inserting it.

Applying silicon sealant To apply the transparent silicon sealant, use a manually operated or compressed-air sealant gun. Before applying sealant to the panes, clean the edges with acetone or thinners. To avoid smearing the glass while applying sealant, attach masking tape immediately to the left and right of the mounting rubber (inside and outside). Then smooth the mounting rubber outside using a template and inside using your thumb and remove the masking tape. Important: do not touch the silicon sealant until it has dried (around 5 hours depending on the temperature).

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16.1 Instrument panel Important operating, display and control elements are arranged on the instrument panel. Their locations are determined by ergonomic factors. Ergonomic design means that health and safety aspects are taken into account. Features such as the adjustable steering column and seat provide maximum comfort for the driver.

Design

Instrument panel 1 Steering column switch 2 Display unit on the instrument panel 3 Ignition switch 4 LIEBHERR control lever

Adjustable steering column with steering wheel and steering column switch Right-side console (control panel)

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5 Position for additional control lever 6 Electronic controller A1 7 Switches on the side console 8 Fuse and relay box

9 10 11 12

Air flap adjustment lever Heater control panel Round compartment Glove compartment

The display unit 2 on the instrument panel, the switches for the driving lights and floodlights and the switches for the parking brake and hazard lights are built into the steering console. The ignition switch 3 is on the right side of the steering console. The LIEBHERR control lever 4 is in the side cover on the right. To the right of this, an (optional) additional control lever 5 may be installed. Other controls in the side cover 7 include switches and lamps for the equipment, emergency steering, wipers and mode switch. The electronic controller A1 6 is under the side cover. The top part of the side cover can be opened.

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Rear instrument panel

16.1.1

At the back of the side cover there are the controls for the heater, blower and air conditioning 10 (optional). The air flap adjustment lever 9 is to the right of this. Under the lift-up right cover there is the control unit A14 with fuses and relays. The pin assignment of the connectors on the board is described in section 10 on the electrical system. The shelves are at the back of the left side cover.

Display unit The display unit is built into the steering console and is part of the instrument panel. The display shows the operating condition of the machine and warns the driver of various malfunctions. Some malfunctions also trigger an audible beep.

Design

Display unit 1 Fuel supply segment field (black) 2 Coolant temperature segment field (black) 3 Charge control symbol field colour (red) 4 Engine oil pressure symbol field (red) 5 Forward travel direction symbol field (green) 6 Reverse travel direction symbol field (green) 7 Hydraulic oil overheating symbol field (red) 8 Parking brake symbol field (red) 9 Travel speed, service hours and clock LCD (yellow) 10 Travel range I symbol field (green)

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11 Travel range II symbol field (green) 12 Engine overheating symbol field (red) 13 Special function symbol field (red) 14 Safety belt symbol field (yellow) 15 Working hydraulics lockout symbol field (red) 16 Preglow monitor symbol field (yellow) 17 Emergency steering symbol field (red) 18 High beam symbol field (blue) 19 Brake system accumulator symbol field (red) 20 Direction indicator symbol field (green) 21 Air filter contamination symbol field (yellow)

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The display unit comprises segment and symbol fields, as well as an LCD for various warning and indicator functions.

Back view of display unit 1 Plug X4

2 Plug X3

3 Opening for dip switches

The dip switches have the following functions: – Dip switch 1 switches between mph und km/h – Dip switch 2 selects km/h or the time as the display directly after turning on the ignition – Dip switch 3 switches the diesel engine (D504 or D924) – Dip switches 4 and 5 are for switching the frequency, depending on the machine and the gear wheel used – Dip switch 6 has no function and must be set to “OFF” Plug X3 pin 1 2 3 4 5 6 7 8 9 10 11

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Colour/no. white/7100 white/6000 white/6011 white/6025 white/6015 white/6008 white/5931 white/5106 black/6010 black/5102 white/7205

Function Speed sensor B1 frequency input (+) Monitor supply, ignition on (K8) (+) Forward signal input S2 (-) Hydraulic overheating input B6 (+) Monitor backlighting input (+) Parking brake pressure switch input (+) Charge indicator input D+ (-) Engine oil pressure input B7 (+) Reverse signal input S2 (-) Analogue engine temperature input B20 (+) Analogue tank sensor voltage B25

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Display A5 H3 H23 H11 H6 H4 H9 P6 P3

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Plug X4 pin 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21

Colour/no.

white/6009 white/6012 white/6006 white/6020 white/6002 white/6018 white/7119 white/5103 white/6022 red/1006 black (-) white/6023 white/6005 white/7104 white/6016 white/6024

Function Unassigned Unassigned (+) High beam input (+) Emergency steering pump input (+) Working hydraulics lockout input (-) Clock setting input S101 (-) Beeper output B9 (+) Travel range I switch S2 input (-) Accumulator pressure switch (from B19) (-) Hydraulic oil overheating input (from B20) (+) Travel range II switch S2 input (+) Monitor supply (battery terminal 30) Monitor supply (earth) (+) Indicator lamp (from K1) (+) Preglow display input (from K4) (-) Air filter contamination display input (from B4) (-) LCD display input from S101 Not used (special function) Unassigned Unassigned Unassigned

Display H3 H9 H12 H8 H5

H19 H13

H10 H2 H7

Pin assignment of plug X4 on the display unit

Function description The main functions of the display unit are: 1 Displaying the operating conditions 2 Warning function 3 Lamp check 4 Controlling the travel direction 5 Controlling the travel ranges

Lamp check on starting During the lamp check, all the symbol fields and segment fields on the display unit are tested by the electronic controller. The warning buzzer is also tested. (2 x beep) The following symbols and segments are shown during the lamp check (with the ignition key in position I):

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Display unit during the lamp check 1 Battery charge symbol field 2 Engine oil pressure symbol field 3 Hydraulic oil overheating symbol field 4 Parking brake symbol field 5 Travel speed LED 6 Service hours LED 7 Clock LED 8 Travel range II symbol field

9 Travel range I symbol field 10 Preglow monitor symbol field 11 Emergency steering symbol field 12 Brake system accumulator pressure symbol field 13 Air filter contamination symbol field 14 Fuel supply segment field 15 Coolant temperature segment field

Fuel level display This is an LCD bar display element which shows the fuel level. The sensor in the fuel tank sends a voltage signal to the display unit. On the bottom bar, the reserve level is marked in red. If the fuel sensor fails, the middle bars 4 and 5 flash (see also the section on the fuel system).

How the coolant temperature display works This is an LCD bar display element which shows the coolant temperature. The coolant temperature sender unit (B20a) sends a resistance signal to the display unit. The absolute values are listed in the table below. If the indicator sensor (B20a) fails, the middle bars 4 and 5 flash and the electronic controller in the side cover beeps. Temperature (C°)

Input signal from B20 (Ohm) 287.4 - 213

212.9 - 134

50 – 59.9

133.9 – 95.2

60 – 69.9

95.1 – 69.1

70 – 79.9

Bars displayed

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40 – 49.9

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Temperature (C°)

Input signal from B20 (Ohm) 69 – 51.2

6 7 flashes with beep 8 flashes with beep

51.1 – 38.5 38.4 – 33.6 33.5 – 22.7

90 – 99.9 100 – 104.9 105 – 120

Bars displayed

80 – 89.9

Coolant temperature bar display

Travel speed, service hours and clock display This display element 1 is a switchable digital LCD display. The LEDs 2, 3, 4 directly below show the current display status. You can switch to travel speed 2, service hours 3 or the clock 4 by touching the mode switch. It also allows you to set the time.

Display status Lamp test Speed (km/h) Service hours Clock

Display: digital (LCD) All fields are active Digital (LCD) Digital (LCD) Digital (LCD)

Input signal Internal Pulse (PTO sensor) Alternator (D+) Internal

3-way LCD digital display If you switch off the battery main switch or the power supply is interrupted, you must reset the clock. A coding switch on the back of the display unit allows you to switch between km/h and mph. If the speed sensor fails, “OPEN” appears in the display

Battery charge control indicator This display lights up when the alternator fails, for example if the V-ribbed belt tears.

Operating mode Lamp test Ignition ON Engine running Battery not charging

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Display: lamp Lights up Lights up Goes out Lights up

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Input signal Internal (+) (-) Negative from (D+) via X3 pin 7 (+) Positive from (D+) via X3 pin 7 (-) Negative from (D+) via X3 pin 7

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Engine oil pressure indicator The warning function of the symbol field is accompanied by a sound: Operating mode Lamp test Ignition ON Engine running Malfunction: oil pressure too low

Display: lamp, beeper Input signal Lights up Internal (-) Negative via B7 at X3 Lights up pin 8 Goes out None (-) Negative via B7 at X3 Lights up and beeps pin 8

Reverse / forward travel direction indicator If the optional back-up alarm is fitted, it is activated when you reverse the machine. Operating mode Lamp test Ignition ON (unavailable because the brake is engaged) Engine running (unavailable because the brake is engaged) Engine running, brake released, function available

Display: lamp, beeper Input signal Beep Internal (monitor) Beep, because it cannot be selected

Internal (monitor)

Beep, because it cannot be selected

Internal (button S2 not detected)

Selected travel direction is shown

(+) Positive from S2 on X3 pin 3 and 9

See also the section on the LIEBHERR control lever.

Hydraulic oil overheating indicator This indicator lights up when the hydraulic oil overheats above 100 Â°C. The machine switches down to travel range I and the travel range I and II indicators are activated. The hydraulic oil overheating indicator is accompanied by a single beep.

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Operating mode Lamp test

Display: lamp Lights up

Ignition ON

None

Engine running

None

Malfunction: hydr. overheating

Lights up and beeps

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Input signal Internal None (signal from A1 for overheating only) None (signal from A1 for overheating only) (-) Negative from A1 at X3 pin 4

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Parking brake activation indicator The symbol field lights up (with the parking brake engaged) for: – Ignition key position I – Activating the parking brake – Insufficient brake accumulator pressure (the brake cannot be released) Operating mode Lamp test Ignition ON, brake engaged Brake open Malfunction: accumulator pressure too low

Display: lamp, beeper Lights up Lights up Goes out Lights up and beeps

Input signal Internal (+) Positive via B5 at X3 pin 6 None (B5 open) (+) Positive via B5 at X3 pin 6

Travel range indicator

Operating mode Lamp test Ignition ON Ignition on, range selected Engine running, range selected Malfunction: e.g. hydraulic oil overheating

Display: lamp, beeper Travel range I and II both light up Travel range I lights up Selected travel range lights up Selected travel range lights up Travel range I and II both light up and beep

Input signal Internal Internal (+) Positive from S2 on X4 pin 8, 11 (+) Positive from S2 on X4 pin 8, 11 Internal triggered by temperature switch B8 via A1

Engine overheating indicator The indicator lights up if the coolant temperature exceeds 108 °C. At the same time, you will hear a warning beep. If the coolant temperature sensor for fan control fails (B21), the buzzer (B9) on the electronic controller A1 (in the side cover) makes a sound (5x beeps, 3 seconds pause etc.).

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Operating mode Lamp test

Display: lamp, beeper Input signal None None

Ignition ON

None

None (B20 open)

Engine running

None

None (B20 open)

Malfunction: engine overheating

Lights up and beeps

(-) Negative from B20 via X4 pin 4

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Special function This indicator is not assigned. Symbol field colour – red. Reserved for special function. Operating mode Lamp test

Display: lamp, beeper None

Input signal None

Ignition ON

None

Engine running Malfunction: special function

None

Lights up and beeps

(+) Positive via X4 pin 18

Safety belt warning When the ignition is on this indicator flashes until the engine is started. After the engine is started, it flashes another 15 seconds then goes out. Operating mode Lamp test

Display: lamp, beeper None

Input signal

Ignition ON

Flashes

Internal

Engine running

Flashes for 15 seconds Internal

None

Working hydraulics lockout indicator This indicates that the working hydraulics lockout is activated. The working hydraulics lockout can only be activated when the engine is running. Operating mode Lamp test

Display: lamp None

None

Ignition ON, switch ON None

None

Engine running, switch Lights up ON

(+) Positive from S19 on X4 pin 5

Preglow monitoring If the outside temperature is 5 °C or below, the indicator lights up in ignition key position I until the starting temperature is reached. The after-glow function ends after 30 seconds. The symbol field goes out at the end of the preglow and afterglow period and when the engine is started.

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Operating mode

Display: lamp

Input signal

Lamp test

Lights up

Internal

Ignition ON

Lights up at temperatures below +5 °C:

(+) Positive via X3 pin 15

Starting (temperature below +5 °C)

Lights up as long as the starter switch is activated

(+) Positive from K4 to X4 pin 15

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Emergency steering indicator If the engine shuts down or if the working pump fails while the machine is travelling, the emergency steering pump is automatically activated for 50 seconds. The emergency steering pump can be restarted by pressing and holding the emergency steering button until the thermostat switches off the pump (to prevent overheating). Each time the machine is started, the emergency steering pump is tested. This check is indicated on the switch in the side cover. If the emergency steering pump check fails, the lamp remains on until you switch off the ignition. Operating mode Lamp test Ignition ON Engine start (emergency steering pump check) Malfunction: (emergency steering pump is running)

Display: lamp Lights up Lights up as long as the emergency steering button is pressed Lights up briefly Lights up for 50 seconds

Lights up as long as Emergency steering the emergency button ON; emergency steering button is steering pump restart pressed

Input signal Internal (+) Positive from emergency steering pump to X4 pin 4 (+) Positive from emergency steering pump to X4 pin 4 (+) Positive from emergency steering pump to X4 pin 4 (+) Positive from emergency steering pump via X4 pin 4

High beam indicator The high beam indicator signal is taken from the high beam power supply at the fuse F1A. Operating mode Lamp test Ignition ON Switch on (high beam)

Display: lamp None None Lights up

Input signal None None (+) Positive via X4 pin 3

Brake system accumulator pressure indicator This indicator reports low brake accumulator pressure.

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Operating mode

Value

Input signal

Lamp test

Lights up

Internal

Ignition ON Engine running Malfunction: accumulator pressure below 90 bar

None None

Lights up

(-) From pressure switch B19 to X4 pin 9

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Flashing indicator The lamp (H10) is directly activated by a positive signal from the indicator relay (K1). Operating mode Lamp test Ignition ON

Value None None

Indicator switch ON

Flashes

Input signal None None (+) Positive from K1 to X4 pin 14

Air filter contamination indicator This indicator lights up when the air filter is very dirty. The air filter must be serviced. The vacuum switch (B4) on the intake pipe between the engine and the air filter earths the display unit when the vacuum reaches a set level (meaning the filter is very dirty). Operating mode Lamp test Ignition ON Malfunction: dirty air filter

16.1.2

Value Lights up None Flashes

Input signal Internal None (-) negative (earth) from B4 to X4 pin 16

Switches on the instrument panel The switches for operating the machine and ensuring safety are integrated in the steering console. These are on/off switches for the lights and hazard warning system, as well as a spring button with OFF, ON and 0 positions for the parking brake. The travel range and neutral selection on the LH control lever has been integrated in the left switch group on the instrument panel (buttons) since serial number 6871.

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Design

Switches on the instrument panel 1 Hazard warning system switch (S4) 2 Travel range and neutral button (S100) (valid from ser. no. 6871) 3 Parking light/driving light switch (S6)

4 Front working floodlight switch (S7) 5 Rear working floodlight switch (S8, optional) 6 Parking brake switch/button (S17)

Connectors on the switches in the instrument panel K5 Wiper interval relay S6 Parking light/driving light switch

16.1-12 of 20

1 Travel range/neutral switch (from ser. no. 6871) S4 Hazard warning system switch

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S17 Parking brake switch 2 Spare S7 Front working floodlight switch

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

Service Manual

Cab, Heating, Air Conditioning Instrument panel

Function description The hazard warning switch 1, front working floodlight 4, rear working floodlight 5 can only be switched on after the battery main switch is turned on. To activate the driving light on the parking/driving light switch 3, the battery main switch and the ignition must be on.

Travel range and neutral shifting (from ser. no. 6871) – After the ignition has been turned on, travel range II is automatically selected. – Press the tortoise symbol on to shift to travel range I. – Press the hare symbol to shift to travel II. – Press and hold down the button on the tortoise symbol (for three seconds) to switch to neutral.

Releasing and applying the parking brake The parking brake can only be deactivated when the engine is running. The parking brake is automatically engaged when you start the engine. Press the switch to release or engage the parking brake. Function in OFF position – When you press the switch to the OFF position the parking brake is released. – If a travel direction is preselected, the machine shifts to neutral if you touch the switch in the OFF position. Middle position 0: – In this position you can select the travel directions and ranges. Function in ON position – When you switch to the ON position the parking brake is engaged. If a travel direction is preselected, the machine shifts to neutral if you touch the switch in the ON position.

16.1.3

Switches on the side console Design The design and function of the switches are described in this section. A description of operation can be found in the relevant sections in the operating manual.

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

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Service Manual

Instrument panel

Controls on the side console 1 2 3 4 5 6 7 8 9

Lift kick-out switch Float position switch Bucket return-to-dig switch Hydraulic quick-change device switch (optional) Emergency steering button Emergency steering check switch Working hydraulics lockout switch MODE button Rear wiper and washer system switch

10 Ride control switch (optional) 11 Comfort control switch (optional) 12 Dummy plug (spare) 13 Blower motor switch 14 Air conditioning switch (optional) 15 Lamp and button S41 for engine diagnosis L524, L534 (see 1.2.1) 16 Heater knob

Connector names on the switches in the side console (from below)

16.1-14 of 20

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

Service Manual

Cab, Heating, Air Conditioning Instrument panel

1 2 3 4 5 6 7 8

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

Lift kick-out switch S22 Float position switch S18 Bucket return-to-dig switch S14 Hydraulic quick-change device switch S26 (optional) Emergency steering button S10 Emergency steering check indicator lamp Working hydraulics lockout switch S19 MODE button S101

MJFCIFSS

9 Rear windshield wiper and washer system switch S13 10 Ride control switch S16 (optional) 11 Comfort control switch S12 (optional) 12 Spare 13 Blower switch S11 14 Air conditioning switch S14 (optional) 15 Spare 16 Heater knob (mechanical)

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Service Manual

Instrument panel

16.1.4

LH control lever

Valid for:

L524 - 438 / 0101 - 6870; L534 - 434 / 0101 - 6870; L538 - 432 / 0101 - 6870

Design

LH control lever 1 Travel range switch F Forward 2 Travel direction switch (S100) R Reverse The LH control lever contains the controls for the travel range, travel direction and working attachment. The grip of the LH control lever is mechanically linked to the pilot control device directly underneath it. The pilot control device contains a retaining solenoid for the bucket return-todig (optional), lift kick-out and float position functions.

Grip with mechanical/electrical switches 1 2 3 4

Switch Cap Grip section Wiring harness strain relief

5 Microswitch 6 Latch mechanism 7 Lock nut

8 Additional switch roller actuator 9 Wiring harness 10 Latch notch

The grip consists of two halves 3. Each have is fastened with a cheese-head screw at the base of the grip to the linkage. The cap 2 reinforces the grip.

1 6 . 1 - 1 6 o f 20

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Service Manual

Cab, Heating, Air Conditioning Instrument panel

Part of linkage is a rotary mechanism with a latch, stop and return function, held in the lower, fixed part of the linkage by a positioning screw. Two microswitches 5 with an additional actuator (switch roller 8) are attached to the disc of the linkage. The wiring harness 9 is soldered to the microswitches. Some wires on the harness 9 lead to the switch 1 in the middle part of the grip. Spade connectors are used. Important for repairs: – Do not change the default setting of the latch mechanism 6 or the position of the microswitches 5. – If you replace the microswitches or wiring harness, set the position of the microswitches according to the lead and trail table for the additional actuator. – Use strain reliefs ensure that movements of the lever do not affect the wiring harness and microswitches. Microswitch setting Lead (max)

2.7 mm

Trail (min)

1.0 mm

The lead is the path of the additional actuator (switch roller) between the idle position and the switching point. The trail is the patch of the additional actuator for the microswitch after the audible switching has taken place until it reaches the limit stop of the latch mechanism.

Function description The LH control lever has a joystick function where a linkage transfers the movement from the grip to the pilot controller. The linkage includes a switching mechanism, where twisting the grip to the left or right against a return spring (torsion spring) activates the corresponding microswitch. Turning to the left activates the right microswitch (switch to travel range 2). Turning to the right activates the left microswitch (switch to travel range 1, or neutral if held for two seconds). When you let go, the spring returns the grip to the middle, where it is held by a latch mechanism. The spring switch 1 returns to the middle as soon as a travel direction is selected. For more information see the section on operation in the operating manual.

L524 - 438 / 0101 - 8795 L534 - 434 / 0101 - 8961 L538 - 432 / 0101 - 8507

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Service Manual

Instrument panel

LH control lever Valid for:

L524 - 438 / 6871 - 9315; L534 - 434 / 6871 - 9419; L538 - 432 / 6871 - 9436

Design The LH control lever contains the controls for the travel range 1 and the additional working function 2 (optional). Position 3 (left button) is unassigned. The travel range / neutral switch is a touch switch in the middle of the left switch group on the instrument panel. The grip consists of two halves. Each have is fastened with a cheese-head screw 4 at the base of the grip to the linkage 5. The cap and the built-in comfort control 2 (optional) reinforce the grip. The linkage 5 mechanically connects the grip of the LH control lever to the pilot control device underneath it.

1 6 . 1 - 1 8 o f 20

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L524 - 438 / 0101 - 8795 L534 - 434 / 0101 - 8961 L538 - 432 / 0101 - 8507

Service Manual

Cab, Heating, Air Conditioning Instrument panel

LH control lever Valid for:

L524 - 438 / from 9316; L534 - 434 / from 9420; L538 -432 / from 9437

Design

Water- and airtight LH control lever 1 2 3 4

LH control lever Travel direction button Standard version Cover

5 Cover with additional equipment buttons 6 Unassigned 7 Additional equipment button 2 8 Additional equipment button 1 Depending on the machine, the LH control lever is equipped with or without a touch switch. The LH control lever also has the button 2 for the travel direction. The LH control lever is connected by cables to the electronic controller. The LH control lever is linked to the pilot control device directly underneath it. The travel range 1, travel range 2 and neutral switch is a touch switch in the middle of the left switch group on the instrument panel.

Plug assignment LH control lever connector (12-pin male) 1 2 3 4 5 6 7 8 9 10 11 12

L524 - 438 / from 8796 L534 - 434 / from 8962 L538 - 432 / from 8508

Power supply for forward/reverse switch from terminal 15 Permanent output, forward Switch output, reverse Switch output, forward Permanent output, reverse Unassigned Kickdown input (L544 â&#x20AC;&#x201C; L580) Kickdown power supply (L544 â&#x20AC;&#x201C; L580) Control button 1 power supply Control button 1 switch output Control button 2 switch output Control button 2 power supply

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Instrument panel

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L524 - 438 / from 8796 L534 - 434 / from 8962 L538 - 432 / from 8508

Service Manual

Cab, Heating, Air Conditioning Heating and ventilation

16.2 Heating and ventilation (ID 9840506) The driver’s cab is equipped with a warm water heating system. The heating circuit is part of the engine cooling circuit.

Design

Heating circuit 1 Diesel engine 4 Heat exchanger 2 Hot water supply 5 Blower 3 Water valve 6 Return The hot water supply 2 is on the thermostat housing of the engine and is connected by flexible hoses to the heat exchanger 4 in the cab. The supply line contains the water valve 3, which is operated via a bowden cable. This means the heating power can be continuously adjusted. The return line 6 of the heating circuit ends in the lower coolant line. The heater, with the radial blower and the heat exchanger 4, is located under the driver’s seat. A flap in the blower intake duct allows fresh air and circulated air to be selected and mixed as required. The controls are located on the left behind the driver’s seat (blower knob and heater slider). The lever for the fresh/circulated air flap is on the right beside the side cover. There is a serviceable air filter between the fresh/recirculated air flap and the heater blower. This fastened with a clip and pushed onto the seal surface.

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Service Manual

Heating and ventilation

Function description How the heating/ventilation works Part of the thermal energy in the engine coolant is passed through the hot water supply 2, the water valve 3 and the heat exchanger 4 for heating the cabin. The blower 5 supplies fresh or recirculated air to the heat exchanger 4 and takes thermal energy out of the coolant, which means the cab air heats up. Either fresh air from outside or recirculated air from the cab can be passed through the heat exchanger and heated up. When the flap is closed (recirculated air mode), only the air in the cab is passed through the heat exchanger. This increases the heating effect. Even while the engine is warming up, the circulating water is available for the heating circuit (the thermostat in the engine cooling circuit does not affect the heating circuit). The coolant then passes through the return line 6 to the engine coolant circuit to take up more thermal energy for heating. The coolant is circulated in the heating circuit by the pressure (intake) and suction (return) of the coolant pump. The heater knob 2 opens and closes the water valve by means of a bowden cable. This is how to adjust the temperature: turn clockwise = warmer, turn anticlockwise = colder. Thus, the heater power can be smoothly adjusted as required. When the water valve is closed the blower ventilates the cab. More details on operation can be found in the chapter on heating and ventilation in the operating manual.

Technical data 16.2.1

Blower (ID 6905460) The blower is part of the heating and ventilation unit.

Design The blower is a 3-level radial fan for ventilation, heating and air conditioning (optional) in the cab. It is located under the driverâ&#x20AC;&#x2122;s seat cover plate between the air filter element and the heat exchanger.

16.2-2 of 6

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Service Manual

Cab, Heating, Air Conditioning Heating and ventilation

Function description Basic function The blower sucks air (axial intake) 4 through the fresh/recirculated air duct and blows it out of the radial outlet 5 to the heat exchanger. If an air conditioning system is fitted, the air is first blown to the compressor. The air flow is regulated by changing the blower speed. It is operated and regulated using a knob. At level 0 the blower is switched off. Level 3 is maximum air flow.

Technical data 16.2.2

Heat exchanger The heat exchanger is the actual heating element in the heating and ventilation system.

Design The heat exchanger 2 consists of tightly packed, large-surfaced, thin-walled fins 1. These are welded to a snaking copper pipe through which the hot coolant is passed. This design maximises the effective surface, which is essential for efficiently exchanging heat with the cab air. At the same time, the heat exchanger 2 takes up very little space.

Function description Basic function of the heat exchanger Part of the thermal energy in the engine cooling system passes through the supply line and the water valve to the heat exchanger 2. Hot coolant passes through the copper pipe 5, heating it up. The hot copper pipe 5 passes heat to the fins 1 welded to it. The fins 1 of the heat exchanger 2 transfer the thermal energy by convection to the cab air flowing through it. The cab air is heated up. The cooled coolant passes back through the return line 4 to the engine cooling circuit.

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

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Heating and ventilation

16.2.3

Water valve The water valve is part of the heating and ventilation system. It can be accessed by taking off the seat cover. The water valve 5 is to the left of the blower.

Design The water valve 5 is a rotary slide valve. Its individual parts are made of plastic. Flexible hoses 3 in the hot water supply line are connected to the water valve and fastened with clips 4. The rotary slider of the water valve can be continuously adjusted via a bowden cable 2 using the heater knob 1.

Function description The water valve and blower switch the heating on and off and regulate it. The rotary slider of the water valve is adjusted using the heater knob 1 by means of a bowden cable. This regulates the water supply to the heat exchanger or cuts it off completely. When the water valve is closed, the heater/ventilator unit ventilates the cab.

16.2.4

Air filter (ID 7623247) The air filter is located in the fresh/recirculated air duct and can be accessed for servicing from outside the cab on the rear/right.

16.2-4 of 6

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

Service Manual

Cab, Heating, Air Conditioning Heating and ventilation

Design The air filter consists of a metal frame 3, which encloses and supports the paper element 1. The metal frame has a self-adhesive rubber strip 2, which seals the air filter from the filter bracket. A support grille is attached to the opposite (front) side. The air filter is pushed into the bracket and fastened using the housing. Make sure the filter is correctly fitted. The arrow 4 must face the blower.

Function description The air filter removes dust particles and other foreign bodies from the fresh or recirculated air before is reaches the blower. The air filter is a coarse filter for particles larger than 10 Âľm.

Technical data

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

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Heating and ventilation

16.2-6 of 6

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

Service Manual

Cab, Heating, Air Conditioning Air-conditioning system

16.3 Air-conditioning system (ID 9841672, 9841131) This equipment is optional. The air conditioning system is manufactured by LIEBHERR. The intake air is filtered through a serviceable dry filter cartridge and directed into the cab via the evaporator, heat exchanger and adjustable outlet nozzles.

Design

Components of the air conditioning system 1 Air conditioning compressor 2 Condenser 3 Filter / dryer

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

4 Pressure switch 5 Expansion valve 6 Evaporator

MJFCIFSS

7 Coolant hose 8 Thermostat

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Cab, Heating, Air Conditioning

Service Manual

Air-conditioning system

Function description Basic cooling function

Diagram of cooling circuit 1 2 3 4 5 6 7

Air conditioning compressor Magnetic coupling Condenser Fan Pressure switch Dryer collector unit Sight glass

16.3-2 of 4

8 Temperature switch b Liquid/gaseous refrigerant, high 9 Temperature sensor pressure 10 Condensation tray c Liquid/gaseous refrigerant, low 11 Evaporator pressure 12 Blower d Gaseous refrigerant, low 13 Expansion valve pressure a Liquid refrigerant, high pressure The air conditioning compressor 1 draws in the refrigerant in gas form and increases its energy level (pressure and thermal energy). The heat thus generated is transferred to the condenser 3. The heat dissipation lowers the energy potential. The cooled refrigerant liquefies. This change of state further reduces the energy in it. The refrigerant, which still has bubbles in it, passes into the dryer collector unit 6, where it is filtered and dried, and then, with the bubbles removed, through the rising pipe to the expansion valve 13 on the evaporator. The liquid, pressurised refrigerant is sprayed through the expansion valve 13 into the depressurised evaporator 11. This allows the refrigerant to expand. The expansion reduces the pressure energy in the refrigerant and very quickly cools the evaporator. The evaporator 11 is exposed to hot air from the cab and transfers the heat to the refrigerant. This thermal exchange cools the cab air and heats the refrigerant. The heated refrigerant evaporates and turns to gas. This change of state requires additional energy from the (warm) evaporator, which further reduces the temperature.

MJFCIFSS

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

Service Manual

Cab, Heating, Air Conditioning Air-conditioning system

Temperature regulation The temperature is regulated by the cyclical activation and deactivation of the magnetic coupling 2 of the air conditioning compressor during operation, or by mixing hot air from the heater, as for example in reheat mode. The frequency of switching is controlled by the preset thermostat 8 in the evaporator (see the technical data). The temperature is also regulated at the expansion valve. The pressure and temperature are recorded at the evaporator outlet and the injection quantity is precisely metered. These monitoring elements prevent the evaporator from icing up.

Re-heat mode When the windows are misted up, the cab air must be dried. This is done by operating the air conditioning and the heater at the same time. The cab air can absorb more moisture when it is heated. The air flowing past the cool evaporator releases the moisture in the form of condensation. Reheat mode is also recommended to attain a pleasant climate in the cab.

Technical data

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

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Service Manual

Air-conditioning system

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

Service Manual

Cab, Heating, Air Conditioning Windscreen wiper and washer system

16.4 Windscreen wiper and washer system Design

Windscreen wiper and washer system 1 2 3 4 5

Front and rear washer system

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

Star grip screw Cover Washer fluid reservoir Front washer pump Rear washer pump

6 7 8 9 10

Check valve Washer hose Outlet nozzle Front wiper motor Rear wiper motor

The machine has an electric washer and wiper system for the front and rear windscreens. Essentially it consists of the wipers and nozzles, the wiper motor and gear, the reservoir and pumps, and the controls. The front and rear wiper and washer systems have a common washer fluid reservoir. Non-return valves are fitted in the washer hoses to the outlet nozzles. The switches for the front washer and wiper system are on the steering column switch. The switch for the rear washer and wiper system is in the right-hand side console. There is a spring-action button for activating the washer pump. The two washer pumps are fastened to the floor of the shared washer fluid reservoir. This is built into the rear of the cab on the left and can be accessed from outside.

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Service Manual

Windscreen wiper and washer system

Access to the washer reservoir and pump

Function description The washer pump is energised for as long as you press the slider switch in the steering column or the touch switch in the right side cover. The washer pumps deliver the washer fluid from the shared reservoir through hoses to the nozzles on the wipers. Check valves in the hoses prevent washer fluid from flowing back to the reservoir when you let go of the button. This ensures that fluid is immediately supplied to the nozzle the next time the washer is activated. If you loosen the star-grip screw you can take off the cover along with the washer reservoir and tip it out or remove it. This allows you to top up the fluid. For winter operation, top up with antifreeze in good time before the cold weather starts.

16.4-2 of 2

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

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Î»¿¼·²¹ »²¹·²» ¼¿¬¿ òòòòòòòòòòòòòòòòòòòòòòòòòòòòòòòòòòòòòòòòòòòòòòòòòòòòòòòòòòòòòïçóè

MJFCIFSS

19-1 ±º î

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19-2 ±º î

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Ôëîì ó ìíè ñ º®±³ ðïðï Ôëíì ó ìíì ñ º®±³ ðïðï Ôëíè ó ìíî ñ º®±³ ðïðï

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19.1 Malfunctions Warning and error messages Š Ê¿®·±« º¿«´¬ ¿®» ·²¼·½¿¬»¼ ¾§ ¬¸» ½±®®»°±²¼·²¹ §³¾±´ º·»´¼ øª·«¿´´§÷ ±® ¾§ ¼·°´¿§ ·²¬®«³»²¬ ±² ¬¸» ·²¬®«³»²¬ °¿²»´ò Š Í±³» ©¿®²·²¹ º«²½¬·±² ¿®» ¿½½±³°¿²·»¼ ¾§ ¿«¼·¾´» ©¿®²·²¹ ·¹²¿´ò Finding and eliminating errors and malfunctions Š Ú¿«´¬ ½¿² ±º¬»² ¾» ¬®¿½»¼ ¾¿½µ ¬± ·²½±®®»½¬ ±°»®¿¬·±² ±® »®ª·½·²¹ ±º ¬¸» ³¿½¸·²»ò Therefore, carefully read the appropriate section of the operating manual each time a fault occurs. Š Analyse the cause of the fault and correct it immediately.

19.1.1

Service code ÑÐÛ²

Ôëîì ó ìíè ñ º®±³ ðïðï Ôëíì ó ìíì ñ º®±³ ðïðï Ôëíè ó ìíî ñ º®±³ ðïðï

Service code indication on the display

1 Travel speed, service hours and clock LCD Cause Remedy

Effect ÑÐÛ²Œ · ¸±©² ±² ¬¸» ¬®¿ª»´ °»»¼ ÔÝÜ ©¸»² §±« ©·¬½¸ ¬¸» ·¹²·¬·±² ±²ò Ì¸» ¼·°´¿§ «²·¬ ©·¬½¸» ¬± ¬®¿ª»´ ®¿²¹» × ¿²¼ ¿² ·²¬»®ª¿´ ¬±²» ±«²¼ ø«²·²¬»®®«°¬»¼´§÷ò

MJFCIFSS

19-1 ±º ì

Ì®±«¾´»¸±±¬·²¹ ¿²¼ Î»°¿·®

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Ó¿´º«²½¬·±²

19.1.2

Audible and visual warning signals Ì¸» º±´´±©·²¹ ¬¿¾´» ½±²¬¿·² ¬¸» ©¿®²·²¹ ·¹²¿´ ©¸·½¸ ¸¿ª» ¿² ¿¼¼·¬·±²¿´ ¿«¼·¾´» ¬±²» ±® ©¸·½¸ ¿®» ±²´§ ¼·°´¿§»¼ ª·«¿´´§ô ¿´±²¹ ©·¬¸ ¬¸»·® ½¿«» ¿²¼ ®»³»¼·»ò Ì¸»®» ¿®» ¬¸®»» ¼·ºº»®»²¬ ¿«¼·¾´» ©¿®²·²¹ ·¹²¿´æ Š ×²¬»®ª¿´ ¬±²» øïñç÷æ ï »½±²¼ ¬±²» º±´´±©»¼ ¾§ ç »½±²¼ °¿«» Š ×²¬»®ª¿´ ¬±²» ©·¬¸±«¬ °¿«» Š Ý±²¬·²«±« ¬±²»

Warning signal Ø§¼®¿«´·½ ±·´ ¿²¼ ½±±´¿²¬ ±ª»®¸»¿¬·²¹ §³¾±´ º·»´¼ Øîí º´¿¸»ò Ì¸» ³¿½¸·²» ¿«¬±³¿¬·½¿´´§ ©·¬½¸» ¬± ¬®¿ª»´ ®¿²¹» × ¿º¬»® êð »½±²¼ò Ì¸» ¬®¿ª»´ ®¿²¹» × ¿²¼ ×× §³¾±´ º·»´¼ º´¿¸ ¿´¬»®²¿¬»´§ò ×²¬»®ª¿´ ¬±²» ±«²¼ ø»¯«»²½»æ ï ¬±²» º±´´±©»¼ ¾§ ç »½±²¼ °¿«»÷ò Ø§¼®¿«´·½ ±·´ ¿²¼ ½±±´¿²¬ ±ª»®¸»¿¬·²¹ §³¾±´ º·»´¼ Øîí ´·¹¸¬ «°ò Ì¸» ³¿½¸·²» ¿«¬±³¿¬·½¿´´§ ©·¬½¸» ¬± ¬®¿ª»´ ®¿²¹» × ¿º¬»® êð »½±²¼ò Ì¸» ¬®¿ª»´ ®¿²¹» × ¿²¼ ×× §³¾±´ º·»´¼ º´¿¸ ¿´¬»®²¿¬»´§ò ×²¬»®ª¿´ ¬±²» ±«²¼ ø»¯«»²½»æ ï ¬±²» º±´´±©»¼ ¾§ ç »½±²¼ °¿«»÷ò Û²¹·²» ±ª»®¸»¿¬·²¹ §³¾±´ º·»´¼ øØïí÷ ´·¹¸¬ «°ò

19-2 ±º ì

Cause

Remedy

Ñ² Ôëîì ¿²¼ Ôëíì ó ½±±´¿²¬ ¬»³°»®¿¬«®» øÞîï÷ ¿¾±ª» ïðí pÝ Ñ² Ôëíè ó ½±±´¿²¬ ¬»³°»®¿¬«®» øÞîï÷ ¿¾±ª» ïðð pÝ

Ý´»¿² ¬¸» ½±±´·²¹ §¬»³ ±® ±°»®¿¬» ¬¸» ³¿½¸·²» ¿¬ ²± ´±¿¼ «²¬·´ ¬¸» ½±±´¿²¬ ¬»³°»®¿¬«®» º¿´´ ¿¹¿·²ò

Ú¿«´¬ ·² ¬¸» ½±±´·²¹ §¬»³

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Ý¸»½µ ¬¸» ¬»³°»®¿¬«®» »²±® Þîï øïïïî ¿¬ îð pÝ÷

Ø§¼®¿«´·½ ±·´ ¬»³°»®¿¬«®» øÞè÷ ¿¾±ª» ïðð pÝ

Ý´»¿² ¬¸» ½±±´·²¹ §¬»³ ±® ±°»®¿¬» ¬¸» ³¿½¸·²» ¿¬ ²± ´±¿¼ «²¬·´ ¬¸» ¸§¼®¿«´·½ ±·´ ¬»³°»®¿¬«®» º¿´´ ¿¹¿·²ò

Ú¿«´¬ ·² ¬¸» ¸§¼®¿«´·½ §¬»³

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Ý¸»½µ ¬¸» ¬»³°»®¿¬«®» »²±® Þèæ øïïïî ¿¬ îð pÝ÷

Ý±±´¿²¬ ¬»³°»®¿¬«®» øÞîð÷ ¿¾±ª» ïðð pÝ

Ý¸»½µ ¬¸» ±°»²·²¹ °±·²¬ ±º ¬¸» ¬¸»®³±¬¿¬æ øÔëîìô Ôëíì ¿°°®±¨ò èî pÝ÷ øÔëíè ¿°°®±¨ò éç pÝ÷

MJFCIFSS

Ôëîì ó ìíè ñ º®±³ ðïðï Ôëíì ó ìíì ñ º®±³ ðïðï Ôëíè ó ìíî ñ º®±³ ðïðï

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Ì®±«¾´»¸±±¬·²¹ ¿²¼ Î»°¿·® Ó¿´º«²½¬·±²

Warning signal Û²¹·²» ±·´ °®»«®» §³¾±´ º·»´¼ øØì÷ ´·¹¸¬ «°ò

Þ¿¬¬»®§ ½¸¿®¹» §³¾±´ º·»´¼ øØê÷ ´·¹¸¬ «°ò

Û³»®¹»²½§ ¬»»®·²¹ §³¾±´ º·»´¼ ´·¹¸¬ «°ò

Cause

Remedy

Ú¿«´¬ ·² ¬¸» »´»½¬®·½¿´ §¬»³

Ì±®² Êó¾»´¬

Î»°´¿½» ¬¸» Êó¾»´¬ Ý¸»½µ ¬¸» ¿´¬»®²¿¬±® ¿²¼ ®»°´¿½» ·º ²»½»¿®§

Ü»º»½¬·ª» ¿´¬»®²¿¬±® Ú¿«´¬ ·² ¬¸» »´»½¬®·½¿´ §¬»³

Û³»®¹»²½§ ¬»»®·²¹ °«³° ½¸»½µ ²±¬ «½½»º«´´§ ½±³°´»¬»¼

Ý¸»½µ ¬¸» »³»®¹»²½§ ¬»»®·²¹ °«³°

Ú¿«´¬ ·² ¬¸» »´»½¬®·½¿´ §¬»³

Ú¿«´¬ ·² ¬¸» ¸§¼®¿«´·½ §¬»³

Ý¸»½µ ¬¸» »³»®¹»²½§ ¬»»®·²¹ °«³° °®»«®»æ øÐ®»«®» ®»´·»º ª¿´ª» ëëoë ¾¿®÷

Û³»®¹»²½§ ¬»»®·²¹ º«²½¬·±² ¿½¬·ª¿¬»¼ ¼«» ¬± º¿·´«®» ±º ¬»»®·²¹ °«³°

Ý¸»½µ ¬¸» ¬»»®·²¹ °«³°

Ú¿«´¬ ·² ¬¸» »´»½¬®·½¿´ §¬»³ øÞí÷ É¿®²·²¹ ¾«¦¦»®æ ×²¬»®ª¿´ ¬±²» ©·¬¸±«¬ °¿«»ò ß½½«³«´¿¬±® ½¸¿®¹» °®»«®» §³¾±´ º·»´¼ øØïç÷ ´·¹¸¬ «°ò

Ôëîì ó ìíè ñ º®±³ ðïðï Ôëíì ó ìíì ñ º®±³ ðïðï Ôëíè ó ìíî ñ º®±³ ðïðï

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Ú¿«´¬ ·² ¬¸» »´»½¬®·½¿´ §¬»³

Ý¸»½µ ¬¸» °®»«®» ©·¬½¸ Þïç øÍ©·¬½¸·²¹ °®»«®» çðoë ¾¿®÷ Ý¸»½µ ¬¸» °®»«®» ©·¬½¸ Þë øÍ©·¬½¸·²¹ °®»«®» ïððoë ¾¿®÷ Ý¸»½µ ¬¸» ©·®·²¹ ¬± ¬¸» ³±²·¬±® Ý¸»½µ ©·®·²¹ º±® »´»½¬®±²·½ ½±²¬®±´´»® ßï

Ú¿«´¬ ·² ¬¸» ¸§¼®¿«´·½ §¬»³

Ý¸»½µ ¬¸» ¿½½«³«´¿¬±® ½¸¿®¹» ª¿´ª»æ øÝ«¬ó·² °®»«®» ïìëoë ¾¿®÷ øÝ«¬ó±«¬ °®»«®» ïéëoë ¾¿®÷ Ý¸»½µ ¬¸» ¹»¿® °«³°

MJFCIFSS

19-3 ±º ì

Ì®±«¾´»¸±±¬·²¹ ¿²¼ Î»°¿·®

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Warning signal

Cause

Remedy

É¿®²·²¹ ¾«¦¦»® ¿½½±³°¿²·»¼ ¾§ ½±²¬·²«±« ¬±²»ò

Þ®¿µ» ¬¸» ³¿½¸·²»ò

Ì®¿ª»´ °»»¼ ±º ìïòé µ³ñ¸ »¨½»»¼»¼

Ì¸» ¬®¿ª»´ ¼·®»½¬·±² §³¾±´ º·»´¼ ¹± ±«¬ò Ì¸» ¬®¿ª»´ ¼·®»½¬·±² ½¿²²±¬ ¾» »´»½¬»¼ò ×³°´¿«·¾´» ·²°«¬ ·¹²¿´ º®±³ ¬®¿ª»´ ¼·®»½¬·±² ©·¬½¸

Ô»ª»´ »²±® º¿·´«®»

Ì»³°»®¿¬«®» ·²¼·½¿¬±® º¿·´«®»

ÔÛÜ Øïî ±² ¬¸» »´»½¬®±²·½ ½±²¬®±´´»® ßï ´·¹¸¬ «°ò

19-4 ±º ì

MJFCIFSS

Ôëîì ó ìíè ñ º®±³ ðïðï Ôëíì ó ìíì ñ º®±³ ðïðï Ôëíè ó ìíî ñ º®±³ ðïðï

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Ì®±«¾´»¸±±¬·²¹ ¿²¼ Î»°¿·® Û²¹·²» ¼·¿¹²±·

19.2 Engine diagnosis Ì¸»®» ¿®» ¬©± ©¿§ ¬± ®»¿¼ ¬¸» »®ª·½» ½±¼»æ Š Ü·¿¹²±· ©·¬¸ ¬¸» ¾«¬¬±² Íìï ±² ¬¸» ®·¹¸¬ ½±²¬®±´ °¿²»´ Š Ü·¿¹²±· ©·¬¸ ¬¸» ÓËÎÐØÇóÙßÙÛ ¼·¿¹²±¬·½ ¬±±´ Ü·¿¹²±· «·²¹ ¬¸» ¾«¬¬±² Íìïæ ×º §±« °®» ¬¸» ¾«¬¬±² Íìï ¿²¼ ¿¬ ¬¸» ¿³» ¬·³» ©·¬½¸ ±² ¬¸» ·¹²·¬·±²ô ¬¸» »®ª·½» ½±¼» ¿®» ¸±©² ¿ ¿ º´¿¸·²¹ ·¹²¿´ ±² ¬¸» ¾«¬¬±² Íìïò Ü·¿¹²±· ©·¬¸ ¬¸» ÓËÎÐØÇóÙßÙÛ ¼·¿¹²±¬·½ ¬±±´æ Ç±« ½¿² ®»¿¼ ¿´´ ¬¸» »®ª·½» ½±¼» ©¸»² ¬¸» ·¹²·¬·±² · ±²ò ß´±ô §±« ½¿² »´»½¬ ¿´´ ¬¸» ®»´»ª¿²¬ ·²º±®³¿¬·±² º®±³ ¬¸» ½±²¬®±´ §¬»³ ©¸·´» ¬¸» »²¹·²» · ®«²²·²¹ò

19.2.1

Diagnosis using the button S41 Ú±® ·³°´» ¼·¿¹²±·ô «» ¬¸» ¾«¬¬±² Íìï ·² ¬¸» ®·¹¸¬ ½±²¬®±´ °¿²»´ò

Button S41 with service code lamp ï Þ«¬¬±² Íìï º±® »®ª·½» ½±¼»

î Í»®ª·½» ½±¼» ·¹²¿´ ´¿³°

Ð®» ¬¸» ¾«¬¬±² Íìï ¿²¼ ¿¬ ¬¸» ¿³» ¬·³» ©·¬½¸ ±² ¬¸» ·¹²·¬·±² ¬± ¿½¬·ª¿¬» ¬¸» »®ª·½» ½±¼» ±«¬°«¬ò Ì¸» »®ª·½» ½±¼» ¿®» ¼·°´¿§»¼ ¾§ º´¿¸·²¹ »¯«»²½»ò Ì¸» ·²¼·½¿¬·±² »¯«»²½» · ¿ º±´´±©æ Š Ú·®¬ô ¬¸» ¿½¬·ª» »®ª·½» ½±¼» ¿®» ¸±©²ô ¬¿®¬·²¹ ©·¬¸ ¬¸» º´¿¸·²¹ ·¹²¿´ íî Š Ì¸»²ô ¬¸» ¬±®»¼ »®ª·½» ½±¼» ¿®» ¸±©²ô ¬¿®¬·²¹ ©·¬¸ ¬¸» º´¿¸·²¹ ·¹²¿´ íí Ì¸· ³±¼» · ®»°»¿¬»¼ «²¬·´ §±« ©·¬½¸ ±ºº ¬¸» ·¹²·¬·±²ò øÛ¨¿³°´» ãâ 3îÁÈÈÁÈÈ› ííÁÈÈÁÈÈ› íîÁÈÈ›÷ É¸»² ¬¸» »®ª·½» ½±¼» ³»³±®§ · »³°¬§ô ¬¸» ¼·°´¿§ · »²¼»¼ ©·¬¸ ¬¸» º´¿¸·²¹ ·¹²¿´ èèò øÛ¨¿³°´» ãâ 3îÁèèÁííÁèèÁíîÁèè››ò÷ ÒÑÌÛæ É¸»² ¬¸» »®ª·½» ½±¼» ¼·°´¿§ · ¿½¬·ª¿¬»¼ô ¬¸» º·®¬ í º´¿¸·²¹ ·¹²¿´ ¿®» ²±¬ ¸±©²ò Ì¸»§ ¿®» ¸±©² ©¸»² ¬¸» ¼·°´¿§ · ®»°»¿¬»¼ò

Procedure Ì¸» ·¹²·¬·±² ³«¬ ¸¿ª» ¾»»² ©·¬½¸»¼ ±ºº º±® ¿¬ ´»¿¬ ë »½±²¼ ¾»º±®» ¬¸· °®±½»¼«®» ¬¿®¬ô ¬± »²«®» ¬¸¿¬ ¬¸» »´»½¬®±²·½ ½±²¬®±´´»® ÛÝË ßïì ¸¿ ¸«¬ ¼±©²ò Ð®» ¬¸» ¾«¬¬±² Íìï ¿²¼ ©·¬½¸ ±² ¬¸» ·¹²·¬·±²ô ¸±´¼·²¹ ·¬ º±® îóí »½±²¼ò É®·¬» ¼±©² ¬¸» º´¿¸·²¹ ½±¼»ò Ý¸»½µ ¬¸» º´¿¸·²¹ ½±¼» ±² ¬¸» »®ª·½» ½±¼» ´·¬ò

Ôëîì ó ìíè ñ º®±³ èéçê Ôëíì ó ìíì ñ º®±³ èçêî

MJFCIFSS

19-1 ±º è

Ì®±«¾´»¸±±¬·²¹ ¿²¼ Î»°¿·®

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Active service code display

Stored service code display Ú±® ¿ ´·¬ ±º º´¿¸·²¹ ½±¼» ¿²¼ ©¸¿¬ ¬¸»§ ³»¿²ô »» ¬¸» º´¿¸·²¹ ½±¼» ½±´«³² ±º ¬¸» »®ª·½» ½±¼» ´·¬ò

19.2.2

Diagnosis with the MURPHY-GAGE diagnostic tool Ð´«¹ ¬¸» ÓËÎÐØÇ ÙßÙÛ ·²¬± ¬¸» ¼·¿¹²±¬·½ °´«¹ Èïìï ±² ¬¸» ¬±° ±º ¬¸» »²¹·²» ¿¬ ¬¸» ®»¿®ò

Old X141 diagnostic plug Deutsch DT 04 4-pin L524-438 from 8796 - 11926 L534-434 from 8796 - 12091

New diagnostic plug X141 Deutsch DT 04 10 9-pin L524-438 from 11927 L534-434 from 12092

Èïìï °·² ¿·¹²³»²¬ ï î í ì

19-2 ±º è

MJFCIFSS

ë ê é è

Ôëîì ó ìíè ñ º®±³ èéçê Ôëíì ó ìíì ñ º®±³ èçêî

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Ì®±«¾´»¸±±¬·²¹ ¿²¼ Î»°¿·® Û²¹·²» ¼·¿¹²±·

MURPHY GAGE diagnostic tool with cables and adapter ï ÓËÎÐØÇ ÙßÙÛ ¼·¿¹²±¬·½ ¬±±´ ©·¬¸ ½¿¾´» î îì Ê Š ïî Ê ¬®¿²º±®³»® º±® ¼·°´¿§ ¾¿½µ´·¹¸¬ í Ü·°´¿§ ¾¿½µ´·¹¸¬ ½±²²»½¬±® ì Ü·¿¹²±¬·½ ¬±±´ ÔÛÜ ë Ü·¿¹²±¬·½ ¬±±´ ¼·°´¿§ ê Ô»º¬ ¾«¬¬±² ø«°÷

é Î·¹¸¬ ¾«¬¬±² ø¼±©²÷ è Ò»© ÓËÎÐØÇ ÙßÙÛ ¼·¿¹²±¬·½ °´«¹ô çó°·² Ü»«¬½¸ ç Ü·¿¹²±¬·½ °´«¹ ¿¼¿°¬»® ½¿¾´» çó°·² Ü»«¬½¸ ïð ß¼¿°¬»® ½¿¾´» º±® ³¿½¸·²» Ôëîì º±® èéçê Š ïïçîê Ôëíì º±®ò Ò®ò èéçê Š ïîðçï ïï Ñ´¼ ¼·¿¹²±¬·½ °´«¹ ¿¼¿°¬»® ½¿¾´» ìó°·² Ü»«¬½¸

Procedure Selecting the active service codes “ServCode” Ì± ®«² ¬¸®±«¹¸ ¬¸» ³¿·² »²¹·²» °¿®¿³»¬»® ³»²«ô °®» either ¬¸» ®·¹¸¬ ±® ´»º¬ ¾«¬¬±²ò Ì± »´»½¬ ¬¸» Í»®ªÝ±¼»Œ «¾³»²«ô °®» both ¬¸» ´»º¬ ¿²¼ ®·¹¸¬ ¾«¬¬±²ò Ì± ®«² ¬¸®±«¹¸ ¬¸» Í»®ªÝ±¼»Œ «¾³»²«ô °®» either ¬¸» ´»º¬ ±® ®·¹¸¬ ¾«¬¬±² «²¬·´ §±« ¸¿ª» »»² ¿´´ ¬¸» ½±¼»ò NOTE: ×º Ò± Ü¿¬¿Œ ¿°°»¿® ·² ¬¸» ¼·°´¿§ô ²± ½±¼» ¿®» ¬±®»¼ò Ì± ¯«·¬ ¬¸» Í»®ªÝ±¼»Œ «¾³»²«ô °®» both ¬¸» ´»º¬ ¿²¼ ®·¹¸¬ ¾«¬¬±²ò

Ôëîì ó ìíè ñ º®±³ èéçê Ôëíì ó ìíì ñ º®±³ èçêî

MJFCIFSS

19-3 ±º è

Ì®±«¾´»¸±±¬·²¹ ¿²¼ Î»°¿·®

Í»®ª·½» Ó¿²«¿´

Û²¹·²» ¼·¿¹²±·

Selecting the stored service codes “StorCode” Ì± ®«² ¬¸®±«¹¸ ¬¸» ³¿·² »²¹·²» °¿®¿³»¬»® ³»²«ô °®» either ¬¸» ®·¹¸¬ ±® ´»º¬ ¾«¬¬±²ò Ì± »´»½¬ ¬¸» Í¬±®Ý±¼»Œ «¾³»²«ô °®» both ¬¸» ´»º¬ ¿²¼ ®·¹¸¬ ¾«¬¬±²ò Ì± ®«² ¬¸®±«¹¸ ¬¸» Í¬±®Ý±¼»Œ «¾³»²«ô °®» either ¬¸» ´»º¬ ±® ®·¹¸¬ ¾«¬¬±² «²¬·´ §±« ¸¿ª» »»² ¿´´ ¬¸» ½±¼»ò NOTE: ×º Ò± Ü¿¬¿Œ ¿°°»¿® ·² ¬¸» ¼·°´¿§ô ²± ½±¼» ¿®» ¬±®»¼ò Ì± ¯«·¬ ¬¸» Í¬±®Ý±¼»Œ «¾³»²«ô °®» both ¬¸» ´»º¬ ¿²¼ ®·¹¸¬ ¾«¬¬±²ò

Deleting the stored service codes “StorCode” Ì± ®«² ¬¸®±«¹¸ ¬¸» ³¿·² »²¹·²» °¿®¿³»¬»® ³»²«ô °®» either ¬¸» ®·¹¸¬ ±® ´»º¬ ¾«¬¬±²ò Ì± »´»½¬ ¬¸» Í¬±®Ý±¼»Œ «¾³»²«ô °®» both ¬¸» ´»º¬ ¿²¼ ®·¹¸¬ ¾«¬¬±²ò NOTE: ×º Ò± Ü¿¬¿Œ ¿°°»¿® ·² ¬¸» ¼·°´¿§ô ²± ½±¼» ¿®» ¬±®»¼ò Ì± ¼»´»¬» ¿´´ ¬¸» ¬±®»¼ »®ª·½» ½±¼»ô °®» both ¬¸» ®·¹¸¬ ¿²¼ ´»º¬ ¾«¬¬±² º±® ¿¬ ´»¿¬ è »½±²¼ò NOTE: ×º §±« ¸±´¼ ¼±©² ¬¸» ¾«¬¬±² º±® ´» ¬¸¿² è »½±²¼ô §±« ©·´´ ¯«·¬ ¬¸» ³»²«ò É¸»² §±« »» öööööööööööŒ ±² ¬¸» ¼·°´¿§ ±º ¬¸» ¼·¿¹²±¬·½ ¬±±´ô ´»¬ ¹± ±º ¬¸» ´»º¬ ¾«¬¬±² ¿²¼ continue °®»·²¹ ¬¸» ®·¹¸¬ ¾«¬¬±² º±® ¿¬ ´»¿¬ è »½±²¼ò É¸»² §±« »» öÍ»²¼öööÜÓíöŒ ±² ¬¸» ¼·°´¿§ô ¿´´ ¬¸» »®ª·½» ½±¼» ¸¿ª» ¾»»² ¼»´»¬»¼ò Ì± ¯«·¬ ¬¸» Í¬±®Ý±¼»Œ «¾³»²«ô °®» both ¬¸» ´»º¬ ¿²¼ ®·¹¸¬ ¾«¬¬±²ò

19-4 ±º è

MJFCIFSS

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19.2.3

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19.2.4

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19-8 ±º è

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