Liebherr L524-438 Wheel Loader Service Repair Manual SN 0101 PDF

en
Service Manual
(20
Wheel Loader
(10 points)
L524 / L534 / L538(10
en
Service Manual
(20
Wheel Loader
(10 points)
L524 / L534 / L538
(10
Address
LIEBHERR-WERK BISCHOFSHOFEN GMBH
Dr. Hans Liebherr – Straße 4

A – 5500 BISCHOFSHOFEN
Product ID
Manufacturer: LIEBHERR-WERK BISCHOFSHOFEN GMBH
Product group: Wheel loader
Type: L524 L534 L538
Production number: 438 434 432
Serial number: from 0101 from 0101 from 0101
Document ID
Order number: 8450818
Author: LBH / T-DOK department
Document version: 02
Manual number:
Owner:
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 mecha-
nics 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, descrip-
tion of maintenance tasks, testing and adjustment tasks and specifications of
fuel and lubricants.
The technical description of the machine is in the following chapters,
structured according to fifteen function groups. The layout, function and
technical data of the groups, components and parts are explained.
Instructions on use This manual describes several types and versions of machines. The
information generally applies to the types and serial numbers stated at the
bottom of the page. The exception to this is information which only applies to
specific types and serial numbers, which are stated at the beginning of the
section concerned (for example technical data of parts).
Where possible, the ID numbers of parts and components are stated in
the heading.
This manual is available in German, English and French.
Working instructions Always follow the safety regulations whenever you work on the machine.
You will find a reference to this in the “General Information” section.
In order to perform these tasks you need a complete set of basic tools
and certain special tools, all in perfect working order. All tasks require
absolute cleanliness.
Replace seals such as O-rings and surface seals during repairs.
DVD edition Please note that this manual is not only available in printed form, but is also
available as electronic documentation on DVD (Lidos).
General information 1
Product description 2
Maintenance 3
Diesel engine 4
Cooling system 5
Travel hydraulics 6
Working hydraulics 7
Steering system 8
Brake system 9
Electrical system 10
Transfer gear 11
Axles and cardan shaft 12
Machine frame and ballast weight 13
Central lubrication system 14
Coverings and access 15
Cab, heating and air-conditioning 16
Lift arms and quick-change device 17
Equipment and accessories 18
Repairs and troubleshooting 19
Options 20
1 General Information
1.0
Chapter contents
1 General Information ............................................................ 1.0-1
1.1 Safety regulations ...........................................................................1.1-1

1.1.1 Introduction...........................................................................1.1-1
1.1.2 Overview of the safety regulations .......................................1.1-2
1.2 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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MJFCIFSS 1.0-1 of 2
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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 Danger
Warning that without appropriate precautions, certain procedures could
result in fatal accidents.
Warning
Warning
result in severe physical injuries.
Caution
Caution
result in minor physical injuries or damage to the machine.
2. Observance of these instructions does not exempt you from following

any additional rules and guidelines that may apply
The following should also be observed:
– The safety rules in force at the operating site
– Legally enforceable road traffic regulations
– Guidelines issued by trade associations
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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 Introduction
2 General safety regulations
3 Proper use
4 Decals on the machine
5 Instructions on preventing crushing injuries and burns
6 Instructions on preventing fires and explosions
7 Safety instructions for start-up
8 Safety precautions during start-up
9 Instructions for safe working
10 Safety instructions for driving on slopes
11 Parking safely
12 Transporting the machine safely
13 Towing the machine safely
14 Measures for ensuring safe maintenance
15 Safety instructions for working on machines with hydro accumulators
16 Safety instructions for welding work on the machine
17 Instructions for working safely on the working attachment
18 Safety instructions for transporting the machine by crane
19 Safe maintenance of hydraulic hoses and hose lines
20 Attachments and accessories
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Special tools for maintenance and repair work
1.2 Special tools for maintenance and

repair work
1.2.1 Special tools in general
Description ID no. Use Remarks
For measuring temperature
Digital thermometer 7020372 All wheel loaders
during adjustments
For testing the DCA4 and
DCA 4 water testing kit 5608459 All wheel loaders
antifreeze content
For checking the acid concentration
Anti-freeze and battery tester 7408922 All wheel loaders
(battery charging state) and anti-freeze
24 volt vacuum pump 7408148 All wheel loaders For preventing oil loss
Filling and testing device
8145359 All wheel loaders For checking the hydro accumulator
with case
Manometer 0-40 bar 7361288 All wheel loaders For checking the hydraulic pressure
Manometer connection 7002436 All wheel loaders Connection for the manometer
High pressure hose 1500 mm 7002475 All wheel loaders High pressure hose for manometer
High pressure hose 4000 mm 7009134 All wheel loaders High pressure hose for manometer
Screw connection M 10 x 1 5005180 All wheel loaders For checking the hydraulic pressure
Draining hose 7005660 All wheel loaders For draining oil via a drain valve
Drain piece 7402657 All wheel loaders For the drain hose
For securing the valves on the variable
Safety cap SW 10 7009315 All wheel loaders
adjustment motor
Safety cap SW 13 7615515 All wheel loaders For securing the valves on the pumps
For securing the valves on the
Safety cap SW 17 7622068 All wheel loaders
control block
1.2.2 Special tools for Liebherr diesel engines

Compression tester 8008782 L524 - L538 engine For checking the compression
Nozzle tester 7361236 L524 - L538 engine For checking the injection valves
Adapter for compression tester 0524044 L538 engine Instead of the injection valve
Adapter for compression tester 7090397 L524 - L534 engine Instead of the injection valve
Injection valve extraction tool 0524072 L538 engine For removing the injection valves
Extraction tool adapter 0524029 L538 engine For use with the extraction tool
For pushing the piston rings together
Piston ring tensioning belt 8000952 All wheel loaders
during installation of the pistons
Krikit 2 V-belt tester 8042829 L524 - L538 engine For testing the V-belt tension
Flywheel cranking device 0524045 L538 engine For cranking the engine via the flywheel
For adjusting the start of delivery of the
Stopwatch 7022418 L538 engine
distributor injection pump
Measuring device 7022420 L538 engine
Adapter 7022419 L538 engine
L524 - 438 / from 0101

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For cranking the engine via the V-belt
Crankshaft turning device 0541887 L524, L534 engine
pulley
For cranking the engine via the
Crankshaft turning device 9183785 L538 engine
crankshaft
Installation pin 7090360 L524, L534 engine For fixing the engine at UDC
Adjusting pin for injection L524, L534 engine with For static adjustment when installing
7090592
pump DE10 electronic injection the injection pump
For removing the drive gearwheel of the
Extractor 7090374 L524, L534 engine
Stanadyne injection pump
For installing the front crankshaft oil
Shaft seal ring installation tool 7090373 L524, L534 engine
seal
Extractor tool 7090377 L524, L534 engine For removing the front wear ring
Extractor tool 7090395 L524, L534 engine For removing the front wear ring
Seal remover 7090372 L524, L534 engine For removing the front crankshaft oil seal
For dynamically adjusting the start of
Adjusting device 7090384 L524, L534 engine
delivery of the distributor injection pump
For removing Stanadyne injection
Extractor tool 7090364 L524, L534 engine
nozzles
For inserting the carbon seal in the
Installation tool 7090382 L524, L534 engine
injection nozzle groove
For cleaning the injection nozzle bore
Cleaning tool 7090375 L524, L534 engine
hole in the cylinder head
For installing the rear oil seal ring and
Installation set 7090378 L524, L534 engine
wear ring
For measuring the valve depth in the
Depth gauge 7090370 L524, L534 engine 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
Angle wrench 0524062 L538 engine
bearing and big end bearing
MURPHY GAGE diagnostic L524, L534 engine with For diagnosing controls and ECU (A14)
10030461
tool with cable electronic injection engine controller
L524, L534 engine with
Adapter cable 9067863 For diagnosis with the MURPHY GAGE
electronic injection

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1.2.3 Special tools for hydraulic cylinders

L524 P kinematics tilt
Assembly sleeve 80 mm 9227165 For fitting the seals
cylinder
L524 - L538 steering
cylinder
L534, L538 P kinematics
tilt cylinder
Assembly sleeve 100 mm 9998626 L524 lift cylinder For fitting the seals
Assembly sleeve 110 mm 9170509 L534, L538 lift cylinder For fitting the seals
L524 Z kinematics tilt
cylinder
L534, L538 P Z
kinematics tilt cylinder
L524 P kinematics tilt
Expansion sleeve 80 mm 9227166 For fitting the seals
cylinder
cylinder
L534, L538 P kinematics
tilt cylinder
Expansion sleeve 100 mm 9110405 L524 lift cylinder For fitting the seals
Expansion sleeve 110 mm 9170511 L534, L538 lift cylinder For fitting the seals
cylinder
L534, L538 P Z
kinematics tilt cylinder
Piston spanner 9211967 For fitting the piston
cylinder
Piston spanner 80/12 mm 8007364 L524 - L538 lift cylinder For fitting the piston
L524 - L538 P kinematics
Piston spanner 4002681 For fitting the piston
tilt cylinder
Piston spanner 88/12 mm 8007365 For fitting the piston
cylinder
L534, L538 Z kinematics
Piston spanner 100/14 mm 8007366 For fitting the piston
tilt cylinder
1.2.4 Special tools for electronics

For measuring voltage, current,
Digital multimeter 8502956 All wheel loaders
resistance and frequency
Test probe, red 884191214 All wheel loaders For testing DEUTSCH connectors
Test probe, black 884191114 All wheel loaders For testing DEUTSCH connectors
Magnet tester 8145743 All wheel loaders For checking solenoid valves
Stripping and crimping pliers
8460263 All wheel loaders For MATE-N-LOK connectors
0.5 - 6.0 mm2
Insertion tool 8145432 All wheel loaders For MATE-N-LOK connectors
Extractor tool 7366655 All wheel loaders For MATE-N-LOK connectors
Crimping pliers 8503647 All wheel loaders For DEUTSCH connectors
Wedge extractor tool 7026267 All wheel loaders For DEUTSCH connectors
Extraction tool size 12 for pin
8145674 All wheel loaders For DEUTSCH connectors
and bushing
Extraction tool size 16 for pin
8145673 All wheel loaders For DEUTSCH connectors
and bushing
Extraction tool size 20 for pin 8503630 All wheel loaders For DEUTSCH connectors
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and bushing
Plug-in fuse tester 8145834 All wheel loaders For checking the fuses
Wide METRI-PACK extractor For removing terminals on the main
7091022 L524, L534
tool connector of the ECU engine controller
Narrow METRI-PACK For removing terminals on the main
7091023 L524, L534
extractor tool connector of the ECU engine controller
1.2.5 Special tools for axles

L524 - L538 front axle For measuring wear on the service
Measuring tool 8145535
L524 - L538 rear axle brake discs
1.2.6 Central lubrication system

Filling press 10009239 All wheel loaders For quickly filling the
Filling connection 7029283 All wheel loaders reservoir
BEKA MAX central lubrication For inspecting the
10008427 All wheel loaders
data cable + software central lubrication system
Gröneveld central lubrication For inspecting the
data cable central lubrication system
plug adapter central lubrication system
As below All wheel loaders
software 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 Special tools for the air conditioning system

For evacuating the air conditioning
Vacuum pump 7027552 All wheel loaders
system
For testing, evacuating and filling the air
4-valve test fitting 7027558 All wheel loaders
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

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2 Product Description
2.0
Chapter contents
2 Product Description............................................................. 2.0-1
2.1 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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Service Manual Product Description
Technical data
2.1 Technical data

2.1.1 Complete machine
Wheel loader with Z lift arms 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 Value Unit

Bucket capacity as per ISO 7546 2.0 m³
Bucket width 2500 mm
Specific material weight 1.8 t/m³
A Dump height at maximum lifting height 2850 mm
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 4840 mm
F Reach at maximum lifting height and 42° 870 mm
tilt-out angle
G Digging depth 80 mm
H Height above the cab 3150 mm
I Height above exhaust 3090 mm
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Product Description Service Manual
Technical data

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) 40 °
Swing angle (to each side) 6 °
Operating weight 10100 kg
Tractive force 76.2 daN
Travel speed in travel range 1, forward 0 - 8 km/h
and reverse
Travel speed in travel range 2, forward 0 - 33 km/h
and reverse
Sound pressure level in the cab LpA 75 dB (A)
Wheel loader with P lift arms Valid for: L524 - 438 / from 0101

With P lift arms (2400 mm) and hydraulic quick-change device.
tipping load.
Dimensions - machine with P lift arms

L534 - 434 / from 0101
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Technical data

tilt-out angle
Tractive force 76.2 kN
Travel speed in travel range 1, forward 0 - 8.0 km/h
and reverse
and reverse
tipping load.
L524 - 438 / from 0101

L534 - 434 / from 0101
L538 - 432 / from 0101
Technical data

tilt-out angle

L534 - 434 / from 0101
L538 - 432 / from 0101
Technical data

and reverse
and reverse
tipping load.

tilt-out angle
L524 - 438 / from 0101

L534 - 434 / from 0101
L538 - 432 / from 0101
Technical data

and reverse
and reverse

L534 - 434 / from 0101
L538 - 432 / from 0101
Technical data
tipping load.

tilt-out angle
L524 - 438 / from 0101

L534 - 434 / from 0101
L538 - 432 / from 0101
Technical data

Tractive force 87.8 daN
and reverse
and reverse
tipping load.


L534 - 434 / from 0101
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Technical data

tilt-out angle
Travel speed in travel range 1 0 - 8.0 km/h
forward and reverse
Travel speed in travel range 2 0 - 36.0 km/h
forward and reverse
2.1.2 Diesel engine and pump distributor gear
Diesel engine
Valid for: L524 - 438 / 0101 - 8795; ID no. 9739010
Engine model D 504 T
Number of cylinders 4
Capacity 4500 cm³
Rated power as per ISO 9249 81 / 110 kW / PS
Rated speed 2400 min-1
Maximum torque at 1400 min-1 424 Nm
Lower idle speed 850 50
min-1
Upper idle speed 2500 +80 min-1
Inlet valve play (cold) 0.35 mm
Outlet valve play (cold) 0.45 mm
Control thermostat opening temperature 82 °C
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Technical data

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 EU RL 97/68 EC Stage I
Valid for: L524 - 438 / from 8796; ID no. 9739021

Engine model D 504 TI - 02
Firing order 1-3-4-2
Capacity 4500 cm³
Cylinder bore 106.5 mm
Stroke 127 mm
min-1
Combustion pressure 24 +3 bar
Injection nozzle pressure 241 ±6 bar
Injection nozzles, maximum pressure 7 bar
difference between cylinders
Direction of rotation, looking at flywheel Anticlockwise
Number of teeth on flywheel gear 129
Control thermostat opening 82 °C
temperature
Longitudinal / traverse inclinability 30 / 30 °
Auxiliary power take-off transmission 1:1.0333
Weight 387 kg
Emission thresholds comply with EU RL 97/68/EC Stage II
Valid for: L534 - 434 / 0101 - 8961; ID no. 9739011

Engine model D 504 TI
Capacity 4500 cm³

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Technical data

min-1

Engine model D 504 TI - 02
Capacity 4500 cm³
Cylinder bore 106.5 mm
Stroke 127 mm
Lower idle speed 850±50 min-1
Upper idle speed 2550+80 min-1
Combustion pressure min. 24+3 bar
Injection nozzle pressure 241±6 bar
Control thermostat 82 °C
Weight 396 kg
Emission thresholds comply with EU RL 97/68/EC Stage II
L524 - 438 / from 0101

L534 - 434 / from 0101
L538 - 432 / from 0101
Technical data
Valid for: L538 - 432 / 0101 -8507; ID no. 9880051

Engine model D924T-E-A1
Capacity 6640 cm³
min-1
Control thermostat 79 °C

Engine model D 924TI-E-A1
Capacity 6640 cm³
Cylinder bore 122 mm
Stroke 142 mm
min-1
Upper idle speed 2100+80 min-1
Start of delivery 1.4 0.05 mm
Compression ratio 17.2:1
Combustion pressure 20 - 26 bar
Injection nozzle pressure 225±6 bar
Control thermostat opening temperature 79 °C

L534 - 434 / from 0101
L538 - 432 / from 0101
Technical data

Weight 740 kg
Emission levels comply with 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
Tank capacity, FULL 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
Filtration grade min. 0.6 mm
max. 0.8 mm
Valid for: L538 - 432 / 0101 -8507; ID no. 7381876

Filtration grade 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
Filtration grade 10 µm

Fuel fine filter (stage I)

Valid for: L538 - 432 / 0101 - 8507; ID no. 7381643

L524 - 438 / from 0101

L534 - 434 / from 0101
L538 - 432 / from 0101
Technical data
Fuel fine filter (stage II)


Vacuum switch
Valid for: L524 - 438 / from 0101; L534 -434 / from 0101; L538 - 432 / from 0101;
ID no. 6906001
Air filter contamination vacuum switch 50 mbar
activation point
Coupling
Valid for: L524 - 438 / from 0101; L534 - 434 / from 0101; ID no. 5717325, 10010559
Glue for torsion 8 absorber bolts 241 Loctite
Tightening torque for 8 torsion 49 Nm
absorber bolts
Hub star fastening screw tightening torque 50 Nm

Glue for torsion 8 absorber bolts 241 Loctite
Tightening torque for 8 torsion 68 Nm
absorber bolts

2.1.3 Cooling system
Cooling system
Gear pump
Valid for: L524 - 438 / 0101 -6316; ID no. 5717137
Capacity 14 cm³

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L538 - 432 / from 0101
Technical data
Capacity 16 cm³

Capacity 14 cm³
Gear motor
Valid for: L524 - 438 / from 0101; L534 - 434 / from 0101;
L538 - 432 / from 0101; ID no. 5717099
Gear motor displacement 16 cm³
5
Pressure relief valve 175 bar
Temperature sensor
Valid for: L524 - 438 / from 0101; L534 - 434 / from 0101;
L538 - 432 / from 0101; ID no. 5717099
Measuring range -30 to +30 °C
Resistance at 20°C 1112
2.1.4 Travel hydraulics
Variable displacement pump

Valid for: L524 - 438 / from 0101
Control type DA
Maximum capacity 90 cm³
Flow rate at rated speed 212 l/min
Power 72 kW
Replenishing pump capacity 19.6 cm³
Weight 60 kg
5
Pressure cut-off 430 bar
Valid for: L534 - 434 / from 0101

Control type DA
Power 90 kW
Weight 60 kg
5
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L538 - 432 / from 0101
Technical data
Valid for: L538 - 432 / from 0101

Control type DA
Power 90 kW
Weight 80 kg
5
Variable displacement motor 1

Valid for: L524 - 438 / from 0101
Control type DA
Maximum displacement 107 cm³
Minimum displacement 43 cm³
Maximum speed 5490 min-1
Torque (Dp 400 bar) 594 Nm
Weight 47 kg
5
Control range while driving 230 bar
Valid for: L534 - 434 / from 0101

Control type DA
Weight 60 kg
5
Valid for: L538 - 432 / from 0101

Control type DA
Weight 60 kg
5

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Technical data
Variable displacement motor 2

Valid for: L524 - 438 / from 0101; L538 - 432 / from 0101
Control type HD1D
Weight 64 kg
1
Control pressure start of regulation 6.0 bar
5
High pressure start of regulation 260 bar
Valid for: L534 - 434 / from 0101

Control type HD1D
Weight 64 kg
1
Control pressure start of regulation 6.0 bar
5
High pressure start of regulation 290 bar
Motor scavenging pump

Flow rate at rated speed 32.5 l
Speed at rated speed 2322 min -1
Valid for: L538 - 432 / from 0101

Flow rate at rated speed 35.7 l
2.1.5 Working hydraulics
Working hydraulics pump

Valid for: L524 - 438 / from 0101
Control type DFLR
Power 40 kW
1
Flow regulator (delta p) 28 bar
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L538 - 432 / from 0101
Technical data

1
Weight 215 bar
Valid for: L534 - 434 / from 0101

Control type DFLR
Power 57 kW
1
1
Weight 215 bar
Valid for: L538 - 432 / from 0101

Control type DFLR
Power 57 kW
1
1
Weight 215 bar
Control block
Valid for: L524 - 438 / from 0101
Piston diameter 14.3 mm
5
LS working hydraulics pressure cut-off 305 bar
5
LS steering pressure cut-off 210 bar
Piston diameter 18 mm
5
LS pressure relief valve 305 bar
Pilot control hydro accumulator

Hydro accumulator volume 320 cm³
Preload pressure (nitrogen filling) 15 bar
Float position pressure switch

Switch type Normally open
2
Switch point, rising 23 bar

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Technical data
Stabilisation module
2
Cut-off valve 150 cm³
Valid for: L524 - 438 / from 0101

Rod diameter 60 mm
Stroke length 735 mm
Lift cylinder
Valid for: L524 - 438 / from 0101
Rod diameter 60 mm
Z kinematics tilt cylinder

Valid for: L524 - 438 / from 0101
Rod diameter 70 mm
Rod diameter 80 mm
P kinematics tilt cylinder

Valid for: L524 - 438 / from 0101
Rod diameter 50 mm
Rod diameter 50 mm
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Technical data
Return suction filter

Return strainer
Bleeder filter
Inlet opening pressure 0.03 bar
Outlet opening pressure 0.5 bar
2.1.6 Steering system
Servostat
Displacement 462 cm³
Secondary pressure relief 285 ±10 bar
Volume flow boost 1 : 1.6
Steering cylinder
Rod diameter 40 mm
Emergency steering pump

Capacity 11 cm²
Pressure relief valve 55 ±5 bar
Emergency steering pump pressure switch

Switch point, rising 10 ±1 bar
Emergency steering check pressure switch

Switch point, rising 5 ±0.5 bar

L534 - 434 / from 0101
L538 - 432 / from 0101
Technical data
2.1.7 Brake system
Brake system gear pump

Valid for: L524 - 438 / to 6316
Flow rate at rated speed 32.5 l/min
Valid for: L538 - 432 / from 0101

Compact brake valve

Accumulator charge valve 145 ±5 bar
activation pressure
Accumulator charge valve 175 ±5 bar
deactivation pressure
Maximum service brake pressure 65 ±5 bar
Service brake hydro accumulator

Brake light pressure switch

Switching point, falling 90 ±5 bar
Disc brake
Brake pad gap 1.0 ±0.5 mm
Brake lining thickness, new 4.5 mm
Minimum brake lining thickness 1.0 mm
L524 - 438 / from 0101

L534 - 434 / from 0101
L538 - 432 / from 0101
Technical data
Parking brake hydro accumulator

Parking brake pressure switch

Switch type Change-over
switch
Switching point, falling 100 ±5 bar
2.1.8 Electrical system
Electrical system with circuit diagrams

System voltage 24 V
Battery
Battery voltage 12 V
Battery capacity 100 Ah
Acid density of charged battery 1.26 - 1.28 kg/l
Valid for: L538 - 432 / from 0101

Battery voltage 12 V
Battery capacity 110 Ah
Acid density of charged battery 1.26 - 1.28 kg/l
2.1.9 Transfer gear
Transfer gear
Valid for: L524 - 438 / from 0101
Variable displacement motor 1 transmission 1.829 -
Cardan speed at 34 km/h 2640 min-1
Speed sensor Inductive

L534 - 434 / from 0101
L538 - 432 / from 0101
Technical data

Cardan speed at 34 km/h 2895 min -1
Speed sensor Inductive
Speed sensor
Type Inductive sensor -
Distance to spur gear A min. 1.2 mm
max. 1.8 mm
2.1.10 Axles and tyres
Front axle
Valid for: L524 - 438 / from 0101
Self-locking differential level 45 %
Width 1900 mm
Wheel lug tightening torque 650 Nm
Wheel lug spanner size 30 mm
Weight 490 kg
Width 1900 mm
Weight 600 kg
Rear axle
Valid for: L524 - 438 / from 0101
Width 1900 mm
Weight 600 kg
Width 1900 mm
L524 - 438 / from 0101

L534 - 434 / from 0101
L538 - 432 / from 0101
Technical data

Weight 680 kg
2.1.11 Machine frame and ballast weight
Ballast weight
Valid for: L524 - 438 / from 0101
Left ballast weight 570 kg
Right ballast weight 650 kg
Valid for: L534 - 434 / from 0101

Valid for: L538 - 432 / from 0101

2.1.12 Cab, heating and air-conditioning
Heating and ventilation

Blower speeds 3
Heating power 4.0 kW
Blower
Air flow 630 m³/h
Blower speeds 3
Voltage 24 V
Current consumption (max) free blowing 10.5 A
Power consumption (min) free blowing 245 W
Air filter
Filter class EU3
Filtration grade 10 µ
Filter surface (effective) 1.8 m²

L534 - 434 / from 0101
L538 - 432 / from 0101
Technical data
Air-conditioning system
Coolant oil 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
2.1.13 Lift arms and quick-change device
Lift arms with Z kinematics

Valid for: L524 - 438 / from 0101
L - length 2400 mm
L - length 2500 mm
Lift arms with P kinematics

Valid for: L524 - 438 / from 0101
L - length 2400 mm
Valid for: L534 -434 / from 0101; L538 - 432 / from 0101
L - length 2600 mm
Hydraulic quick-change device for Z lift arms

(hydraulic actuation)
A system connection size 1000 mm
Weight 300 kg
Hydraulic quick-change device for Z lift arms

(electrohydraulic actuation)
Weight 300 kg
L524 - 438 / from 0101

L534 - 434 / from 0101
L538 - 432 / from 0101
Technical data
Hydraulic quick-change device for P lift arms

(electrohydraulic actuation)
Weight 230 kg
2.1.14 Equipment and accessories
Bucket
Valid for: L524 - 438 / from 0101
B bucket width 2500 mm
Heaped bucket capacity (ISO 7546) 2.0 m³
Valid for: L534 - 434 / from 0101

Valid for: L538 - 432 / from 0101

Forklift
Fork carrier prong size FEM III
Prong length 1200 mm
High dump bucket (optional)

(L524-438 with P kinematics)
Maximum operating pressure for 250 bar
attachment hydraulics

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
3.4.4 Lubrication chart ...................................................................3.4-3
3.5 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
L524 - 438 / from 0101

MJFCIFSS 3.0-1 of 4
L534 - 434 / from 0101
L538 - 432 / from 0101
Maintenance 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
(L534)................................................................................. 3.5-38
(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

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 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
L524 - 438 / from 0101

MJFCIFSS 3.0-3 of 4
L534 - 434 / from 0101
L538 - 432 / from 0101
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 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

L534 - 434 / from 0101
L538 - 432 / from 0101
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for your reading.
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Dr. Hans Liebherr – Straße 4

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

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

L524 - 438 / from 0101

1.1 Safety regulations

2. Observance of these instructions does not exempt you from following

L524 - 438 / from 0101

1.1.2 Overview of the safety regulations

1.1-2 of 2 MJFCIFSS L524 - 438 / from 0101

1.2 Special tools for maintenance and

1.2.2 Special tools for Liebherr diesel engines

L524 - 438 / from 0101

Description ID no. Use Remarks

1.2-2 of 4 MJFCIFSS L524 - 438 / from 0101

1.2.3 Special tools for hydraulic cylinders

1.2.4 Special tools for electronics

L524 - 438 / from 0101

Description ID no. Use Remarks

1.2.5 Special tools for axles

1.2.6 Central lubrication system

1.2.7 Special tools for the air conditioning system

1.2-4 of 4 MJFCIFSS L524 - 438 / from 0101

2.1 Technical data ................................................................................2.0-1

L524 - 438 / from 0101

2.1 Technical data

The values stated refer to the standard version of the machine:

Dimensions - machine with Z lift arms

Description Value Unit

L524 - 438 / from 0101

Description Value Unit

The values stated refer to the standard version of the machine:

Dimensions - machine with P lift arms

Description Value Unit

L524 - 438 / from 0101

Dimensions - machine with Z lift arms

Description Value Unit

2.0-4 of 26 MJFCIFSS L524 - 438 / from 0101

Description Value Unit

Dimensions - machine with P lift arms

Description Value Unit

L524 - 438 / from 0101

Description Value Unit

2.0-6 of 26 MJFCIFSS L524 - 438 / from 0101

Dimensions - machine with Z lift arms

Description Value Unit

L524 - 438 / from 0101

Description Value Unit

Dimensions - machine with P lift arms

2.0-8 of 26 MJFCIFSS L524 - 438 / from 0101

Description Value Unit

2.1.2 Diesel engine and pump distributor gear

L524 - 438 / from 0101

Description Value Unit

Valid for: L524 - 438 / from 8796; ID no. 9739021

Valid for: L534 - 434 / 0101 - 8961; ID no. 9739011

2.0-10 of 26 MJFCIFSS L524 - 438 / from 0101

Description Value Unit

Valid for: L534 - 434 / from 8962; ID no. 9739022

L524 - 438 / from 0101

Valid for: L538 - 432 / 0101 -8507; ID no. 9880051

Valid for: L538 - 432 / from 8508; ID no. 9076608

2.0-12 of 26 MJFCIFSS L524 - 438 / from 0101