Liebherr Wheel loaders L 509-1581 Service manual – PDF DOWNLOAD

Liebherr Wheel loaders L 509-1581 Service manual – PDF DOWNLOAD

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FILE DETAILS:

Liebherr Wheel loaders L 509-1581 Service manual – PDF DOWNLOAD

Language : English
Pages :730
Downloadable : Yes
File Type : PDF
Size:106 MB

DESCRIPTION:

Liebherr Wheel loaders L 509-1581 Service manual – PDF DOWNLOAD

PrefaceNotes for users

• This service manual is designed for trained specialist staff of the Liebherr organisation and their dealers.
• This service manual contains specialist knowledge for repairing Liebherr construc- tion machines. Basic specialist knowledge on electronics, hydraulics, mechanics and engine technology is not contained in this service manual. Therefore special- ized training and qualifications are necessary. Liebherr recommends participating in the Liebherr training program for construction machines.

In this service manual you will find information on:

— Special tools— Technical data— Maintenance intervals and maintenance tasks— Adjustment procedures— Structure and function descriptions— Removal and installation tasks— Circuit diagrams, hydraulic plans and technical drawings

• You will find information on controls and operation in the operator’s manual. Information on spare parts are in the spare parts catalogue. Please observe the local accident prevention laws.
• You can find information on repairs of machine parts in the service documentation under “Wheel loader – repair instructions”.

Introduction:

Intended Use:1.1. Laws, Rules, Guidelines and Safety Regulations

To ensure safe operation:

• Consult with the worksite manager about safety regulations at the place of use.
• Adhere to safety regulations at the place of use.
• Follow traffic regulations.
• Adhere to valid guidelines provided by insurers (for example, employers’ professional liability insurance companies, accident insurance, etc.).
• Avoid working methods that can endanger safety.
• Follow all intervals specified for recurrent checks and inspections as outlined in this operator’s manual.

1.2. Intended Use of Wheel Loader

The wheel loader is used to pick up, move, and dump the following materials:

• Soil
• Stones
• Broken rocks
• Bulk materials

This applies to a standard machine under normal operating conditions. Special applications are described in a separate options operator’s manual.

To ensure the intended use:

• Adhere to the operator’s manual.
• Follow maintenance intervals.
• Carry out inspection and maintenance tasks.
• Follow the specifications in the technical data.
• When using the machine on public roads, ensure it complies with applicable national regulations.
• Only lift loads with intended working attachments (fork prongs, crane boom), which must be properly fitted and functioning.
• Ensure that machines used underground (for mining and tunnel construction) are fitted with systems to reduce exhaust emissions (such as diesel particulate filters).
• Adhere to the requirements of each individual country for underground operation.
• For special uses, use special working attachments and, if necessary, special safety equipment.
• Exclusively mount and use special working attachments with approval and as per the stipulations of the manufacturer of the basic machine.

TABLE OF CONTENTS:

Liebherr Wheel loaders L 509-1581 Service manual – PDF DOWNLOAD

Contents010 Introduction 010-1
010.1 Safety instructions 010-4
010.1.1 Information on these instructions 010-4
010.1.1.1 Representation of warning messages 010-4
010.1.1.2 Graphic symbols in these instructions 010-4
010.1.2 Intended use 010-5
010.1.2.1 Laws, rules, guidelines and safety regulations 010-5
010.1.2.2 Intended use 010-5
010.1.2.3 Foreseeable misuse 010-6
010.1.2.4 Operating conditions 010-6
010.1.2.5 Disposal 010-7
010.1.3 Description of staff 010-7
010.1.3.1 Personal protective equipment 010-7
010.1.3.2 Requirements for staff 010-8
010.1.3.3 Operating company 010-8
010.1.3.4 Operator 010-9
010.1.3.5 Maintenance staff 010-9
010.1.3.6 Refrigeration technician 010-10
010.1.3.7 Slinger 010-11
010.1.3.8 Spotter 010-12
0101.4 Protective devices on the machine 010-12
010.1.4.1 Operator’s cab 010-12
010.1.4.2 Roll over protective structure (ROPS) 010-13
010.1.4.3 Falling object protective structures (FOPS) 010-13
0101.5 Emergency equipment on the machine 010-13
010.1.5.1 Emergency exit (standard) 010-13
010.1.5.2 Fire extinguisher (option) 010-14
010.1.6 Safe operation 010-14
010.1.6.1 Intoxicants 010-14010.1.6.2 Dangerous fuels and operating fluids 010-14
010.1.6.3 Transporting machine 010-15
010.1.6.4 Access to machine 010-15
010.1.6.5 Machine danger zone 010-16
010.1.6.6 Visibility 010-16
010.1.6.7 Protection against vibration 010-17
010.1.6.8 Operation of machine 010-18
010.1.7 Safe maintenance 010-21
010.1.7.1 Spare parts 010-21
010.1.7.2 Heavy parts 010-21
010.1.7.3 Regular checks 010-22
010.1.8 Modifications to the machine 010-22
010.1.8.1 Modifications, add-ons and retrofittings 010-22
Special tools for maintenance and repair work 010-23
010.21 Special tools, general 010-23
010.2.2 Special tools for diesel engine 010-25
010.2.3 Special tools for lift cylinders 010-26
010.2.4 Special tools for tilt cylinders 010-26
010.2.5 Special tools for quick coupler locking hydraulic cylinder 010-27
010.2.6 Special tools for steering wheel 010-27
010.2.7 Special tools for steering cylinders 010-28
010.2.8 Special tools for the electrical system 010-28
010.2.9 Special tools for front axle 010-30
010.2.10 Special tools for rear axle 010-30
010.2.11 Special tools for air conditioning system 010-31
010.2.12 Special tools for cab glazing 010-32
010.2.13 Special tools for the central lubrication system (Liebherr) 010-32Standards and regulationsPrestressing forces and tightening torques for bolts with metricstandard and fine threads as per DIN ISO 261010.3.1.1 Range of application and purpose010.3.1.2 Other applicable documents010.3.1.3 Modifications and descriptions010.3.1.4 Tightening torquesService manual Contents010.4 Preservation guidelines 010-42
010.4.1 General information 010-42
0104.2 Machine out of service for an unknown period of time 010-42
0104.3 Putting the machine out of service 010-43010.4.3.1 Out of service for up to 2 months 010-43
010.4.3.2 Out of service for up to 12 months 010-44
010.4.3.3 Out of service for longer than 12 months 010-45
010.44 Putting back into service 010-45
010.4.4.1 After being out of service for 2 months 010-45
010.4.4.2 After being out of service for 12 months 010-46010.4.4.3 After being out of service for longer than 12 months 010-46020 Technical data 020-1
020.1 Overall machine 020-4
0201.1 Complete machine with bucket (z-bar kinematics)
L509-1581; 020-4
020.1.2 Working attachment: light material bucket
L509-1581; 020-5
020.1.3 Working attachment: 4 in 1 bucket
L509-1581; 020-6
020.14 Working attachment: forklift
L509-1581; 020-8
020.2 Drive group 020-10
020.2.1 Diesel engine
L509-1581/0-53994; 020-10
020.2.2 Diesel engine
L509-1581/53995-; 020-11
020.2.3 Fuel tank
L509-1581; 020-12
020.2.4 Fuel level sensor
L509-1581; 020-13
020.3 Cooling system 020-14
020.3.1 Fan pump
L509-1581; 020-14
0203.2 Fan motor
L 509-1581; 020-14
020.3.3 Hydraulic oil temperature sensor B8
L509-1581; 020-14
020.4 Working hydraulics 020-15020.41 Working pumpL509-1581; 020-15
020.4.2 Control block1509-1581; 020-15
020.4.3 Pilot control unitL509-1581; 020-15
020.4.4 Pilot control hydro accumulator1509-1581; 020-15
020.4.5 Stabilisation moduleL509-1581; 020-16
020.46 Ride control hydro accumulator1509-1581; 020-16
020.4.7 Lift cylinderL509-1581; 020-16
020.4.8 Tilt cylinder1509-1581; 020-16
020.49 Working pumpL509-1581; 020-17
Travel hydraulics 020-18
020.5.1 Travel pumpL 509-1581; 020-18
020.5.2 Pressure sensor for high pressure of travel pump B1021509-1581; 020-18
020.5.3 Travel motor1509-1581; 020-18
Hydraulic components 020-20
020.6.1 Return suction filter1509-1581; 020-20
020.6.2 Breather filter with filler strainer1509-1581; 020-20
Steering system 020-21
020.7.1 ServostatL 509-1581; 020-21
020.7.2 Steering cylinderL509-1581; 020-21
Brake system 020-22
020.8.1 Drum brakeL509-1581; 020-22
020.8.2 Inch/brake unitL509-1581; 020-22
020.8.3 Brake light pressure switch B121509-1581; 020-22
020.8.4 Spring accumulator cylinder for parking brakeL509-1581; 020-23020.9 Electrical system 020-24
020.9.1 Central control unit (Master 4)
L509-1581/0-60029; 020-24
020.9.2 Central control unit (Master5-Mini)
L509-1581/60030-; 020-24
020.9.3 Compact module
L509-1581; 020-24
020.9.4 Battery
L509-1581; 020-25
020.9.5 Voltage transformer
L509-1581; 020-25
020.10 Gearbox 020-26
020.10.1 Transmission
L509-1581; 020-26
020.11 Axles and drive shafts 020-27
020.11.1 Front axle
L509-1581; 020-27
020.11.2 Rear axle
L509-1581; 020-27
020.11.3 Drive shaft
L509-1581; 020-27
020.114 Tyres
L509-1581; 020-27
020.11.4.2 Special tyres 020-28
020.12 Working attachment 020-30
020.12.1 Quick coupler locking hydraulic cylinder
L509-1581; 020-30
020.13 Operator’s cab, heating and air conditioning 020-31
020.13.1 Dryer
L509-1581; 020-31
020.13.2 Pressure switches
L509-1581; 020-31
$ 020.14 Lubrication system 020-32
g 020.14.1 Central lubrication pump EP1
g L509-1581; 020-3030 Maintenance 030-1
030.1 Maintenance and inspection schedule 030-9
030.2 Filling quantities and lubrication chart 030-14030.2.1 Lubricant filling quantityL509-1581; 030-14
030.2.2 Recommended operating fluids1509-1581; 030-14030.3 Lubricants and fuels 030-15030.3.1 General information on lubricants and fuels 030-15030.3.1.1 General questions 030-15030.3.1.2 Safety data sheets 030-15030.3.1.3 Technical data sheets 030-15030.3.1.4 Specific Liebherr standards 030-15
030.3.2 General information on changing lubricants and fuels 030-15
030.3.3 Converting hydraulic system from mineral oils to biodegradablehydraulic fluids 030-16
030.3.4 Diesel fuelsL509-1581/0-53994; 030-16030.3.4.1 Minimum quality requirement 030-16030.3.4.2 Operating temperatures of diesel fuels 030-16030.3.4.3 Minimum quality requirement 030-17
030.3.5 Diesel fuelsL509-1581/53995-; 030-17030.3.5.1 Minimum quality requirement 030-17030.3.5.2 Operating temperatures of diesel fuels 030-17030.3.5.3 Minimum quality requirement 030-17
030.3.6 Engine oilsL509-1581; 030-18030.3.6.1 Liebherr recommendation 030-18030.3.6.3 Minimum quality requirement 030-18
030.3.7 RefrigerantL509-1581; 030-18
030.3.8 Coolant1509-1581; 030-19030.3.8.1 Requirements for the water used 030-19030.3.8.2 Antifreeze and corrosion inhibitor 030-19030.3.8.3 Minimum quality requirement 030-19
030.3.9 Hydraulic oil030.3.9.1 Liebherr recommendation 030-19
030.3.9.2 Minimum quality requirement 030-20
030.3.9.3 Qil analysis 030-20
030.3.9.4 Qil change 030-20
030.3.10 Transmission
L 509-1581; 030-21
030.3.10.1 Liebherr recommendation 030-21
030.3.10.2 Minimum quality requirement 030-21
0303.11 Axle oil
L 509-1581; 030-21
030.3.11.1 Liebherr recommendation 030-21
030.3.11.2 Minimum quality requirement 030-21
030.3.12 Brake oil
L509-1581; 030-22
030.3.12.1 Liebherr recommendation 030-22
030.3.13 Lubrication grease
L509-1581; 030-22
030.3.13.1 Liebherr recommendation 030-22
030.3.13.2 Minimum quality requirement 030-22
030.3.14 Windscreen washer fluid
L509-1581; 030-22
030.3.14.1 Liebherr recommendation 030-22
030.3.14.2 Minimum quality requirement 030-23
030.3.15 Refrigerant oil for air conditioning compressor
L509-1581; 030-23
030.3.15.1 Liebherr recommendation 030-23
030.4 Maintenance tasks 030-24
0304.1 Safety precautions
L509-1581; 030-24
0304.2 Preparatory tasks for maintenance 030-24
030.421 Maintenance positions
L 509-1581; 030-25
030.4.2.2 Opening service hatches
L509-1581; 030-26
030.423 Turning off battery main switch
L 509-1581; 030-27
0304.3 Overall machine 030-28030.4.3.1 Checking machine is in proper condition
L 509-1581; 030-28copyright ® Liebherr-Werk Bischofshofen GmbH 2021L509-1581 LIEBHERR 1″
Contents Service manual
030.4.3.2 Removing loose parts, dirt, ice and snow from
machine
L509-1581; 030-30
0304.33 Cleaning machine
1509-1581; 030-30
030.4.3.4 Replacing VCI capsules
L509-1581; 030-33
0304.3.5 Operating fluid analysis: General specifications
1509-1581; 030-36
0304.36 Operating fluid analysis: filling out sample information
form
1509-1581; 030-39
030.4.3.7 Fuel and operating fluid analysis: scope of analysis
L509-1581; 030-45
030.4.3.8 Analysis of lubricants and fuels
L509-1581; 030-49
030.4.4 Drive group 030-56
030.4.4.1 Checking diesel engine oil level
1509-1581; 030-56
030.4.4.2 Diesel engine: changing diesel engine oil
L509-1581; 030-57
030.443 Diesel engine: changing oil filter
1509-1581; 030-59
030.4.4.4 Diesel engine: checking V-belt
1509-1581; 030-61
030.4.4.5 Diesel engine: changing V-belt
L509-1581; 030-63
030.446 Diesel engine: checking valve clearance
L509-1581; 030-64
030.447 Draining condensate and sediment from the fuel tank
1509-1581; 030-68
030.4.4.8 Draining off condensate from fuel pre-filter
L509-1581; 030-69
030.4.4.9 Changing fuel pre-filter element
L509-1581; 030-70
030.4.4.10 Changing fuel fine filter element
L509-1581; 030-72
030.4.4.11 Cleaning service cover and dust discharge valve of
air filter system
L509-1581; 030-73
030.4.4.12 Checking air filter vacuum switch function
L509-1581; 030-74
030.4.4.13 Cleaning or changing main element of air filter
system
L509-1581; 030-76
copyright © Liebher-Werk Bischofshofen GmbH 2021
12 LIEBHERR 508-1581LBH/M2234435/12/211-20210126_075215/en
LBH/M2234435/12/211-20210126_075215/enService manualContents030.4.4.14 Changing safety element of air filter system
L509-1581; 030-78
030.4.4.15 Checking that diesel engine intake and exhaust
system is in good condition and not loose or leaking
1509-1581; 030-79
030.4.4.16 Cleaning or changing diesel particulate filter
L509-1581; 030-82
0304.5 Cooling system 030-88
030.4.5.1 Checking coolant level in cooling system
1509-1581; 030-88
030.4.5.2 Coolant: checking anti-freeze and corrosion protec-
tion agent concentration
L509-1581; 030-90
030.4.5.3 Cleaning cooling system
1509-1581; 030-97
030.4.5.4 Cooling system: changing coolant
1509-1581; 030-98
030.46 Working hydraulics 030-101
030.46.1 Cleaning and lubricating the pilot control unit
1509-1581; 030-101
030.4.7 Hydraulic components 030-101
030.4.7.1 Checking oil level in hydraulic tank
L 509-1581; 030-101
030.4.7.2 Draining off condensate and sediment from hydraulic
tank
1509-1581; 030-103
030.4.7.3 Hydraulic tank: changing filter cartridge in return-
suction filter
1509-1581; 030-104
030.4.7.4 Changing the hydraulic tank breather filter
1509-1581; 030-106
030.4.7.5 Hydraulic tank: changing oil
L509-1581; 030-106
0304.8 Steering system 030-109
030.4.8.1 Test steering
L509-1581; 030-109
030.4.8.2 Steering cylinder: lubricating bearing
L 509-1581; 030-109
0304.9 Brake system 030-110
030.4.9.1 Testing service brake and parking brake
1509-1581; 030-110
030.4.9.2 Checking the oil level in the brake system
L509-1581; 030-110
copyright ® Liebherr-Werk Bischofshofen GmbH 2021
1509-1581 LIEBHERR 13
Contents Service manual
030.4.9.3 Checking gap and wear on service brake linings
L509-1581; 030-112
030.4.10 Electrical system 030-115
030.4.10.1 Checking function of lighting and horn
L509-1581; 030-115
030.4.10.2 Checking battery fluid levels and terminals
L509-1581; 030-116
030.4.10.3 Use the control lever to change the travel direction
switch rocker and cap.
1509-1581; 030-118
030.4.11 Gearbox 030-121
030.4.11.1 Transmission: checking oil level
L509-1581; 030-121
0304.11.2 Changing transmission oil
L509-1581; 030-122
030.4.12 Axles and drive shafts 030-123
030.4.12.1 Checking axle oil levels
L509-1581; 030-123
030.4.12.2 Changing axle oil
L509-1581; 030-125
030.4.12.3 Lubricating rear axle kingpin bearings
L509-1581; 030-127
0304.12.4 Checking fitting of rear axle kingpin bearings and
steering rod taper connections
L509-1581; 030-128
030.4.12.5 Checking tightening torque of front axle fastening
bolts
L509-1581; 030-129
030.4.12.6 Checking and lubricating drive shaft
L509-1581; 030-130
030.4.12.7 Tyres: checking tyre pressure
L509-1581; 030-131
030.4.12.8 Checking wheel tightness
1509-1581; 030-131
030.4.13 Steel parts of the basic machine 030-132
030.4.13.1 Lubricating articulated bearing
L509-1581; 030-132
030.4.13.2 Lubricating articulation stops
L509-1581; 030-133
030.4.13.3 Engine bonnet: lubricating moving parts with pene-
trating oil
1509-1581; 030-133
030.4.13.4 Service hatches: cleaning and maintaining seals030.4.14 Working attachment 030-135
030.4.14.1 Lubricating the lift arms and working attachment
1509-1581; 030-135
030.4.14.2 Checking lift arm bucket bearing bushings
L509-1581; 030-136
030.4.14.3 Checking the lift arm bucket stops
L 509-1581; 030-136
030.4.14.4 Quick coupler: checking function
1509-1581; 030-137
030.4.15 Operator’s cab, heating and air conditioning 030-138
030.4.15.1 Cleaning operator’s cab air filter
1509-1581; 030-138
030.4.15.2 Changing operator’s cab air filter
L509-1581; 030-138
030.4.15.3 Safety belt: checking condition and function
1509-1581; 030-139
030.4.154 Windscreen washer system: testing
L509-1581; 030-140
030.4.15.5 Windscreen washer system: filling windscreen
washer fluid
L 509-1581; 030-140
030.4.15.6 Operator’s cab: lubricating locking mechanism and
cylinder with penetrating oil
1509-1581; 030-141
030.4.15.7 Operator’s cab: cleaning and maintaining seals
L 509-1581; 030-141
030.4.15.8 Air conditioning: checking V-belt
1509-1581; 030-142
030.4.15.9 Air conditioning: changing V-belt
1509-1581; 030-144
030.4.15.10 Checking the indicator bead in the air conditioning
dryer-collector unit
L509-1581; 030-146
030.4.15.11 Heating and air conditioning unit: Testing function
L 509-1581; 030-147
030.4.16 Lubrication system 030-148
030.4.16.1 Central lubrication system: checking level in grease
reservoir
L509-1581; 030-148
030.4.16.2 Central lubrication system: checking pipes, hoses
and lubrication points for leaks and damage.
1509-1581; 030-149
030.4.16.3 Central lubrication system: checking lubrication of
bearings
1509-1581; 030-150L509-1681copyright ® Liebherr-Werk Bischofshofen GmbH 2021LIEBHERR 15
ContentsService manual030.5 Testing and adjustment checklistL509-1581; 030-151
030.6 Testing and adjustment tasks 030-155
030.6.1 Safety precautions
L509-1581; 030-155
030.6.2 Overall machine 030-155
030.6.2.1 Preparing for adjustment procedures
1509-1581; 030-155
0306.2.2 Hydraulic oil and coolant: operating temperature
L509-1581; 030-157
030.6.3 Drive group 030-158
030.6.3.1 Pedals: calibration
L509-1581; 030-158
030.6.3.2 Diesel engine speed
1509-1581; 030-159
030.6.3.3 Reading the diesel engine service files
1509-1581; 030-160
030.6.3.4 Performing a service regeneration on diesel particu-
late filter
L509-1581; 030-162
030.6.3.5 Diesel engine: changing engine control unit (ECU)
L509-1581; 030-163
030.6.4 Cooling system 030-173
030.6.4.1 Fan motor: fan speed proportional solenoid
L509-1581; 030-173
030.6.5 Working hydraulics 030-176
030.6.5.1 Control valve block: secondary pressure relief valves
1509-1581; 030-176
030.6.5.2 Control valve block: primary pressure relief valve
L509-1581; 030-178
030.6.5.3 Control block: reduction of tilt-out speed (option)
L509-1581; 030-180
030.6.5.4 Stabilisation module (option), safety valve
1509-1581; 030-181
030.6.5.5 Ride control hydro accumulator (option): nitrogen
filling
1509-1581; 030-183
030.6.6 Hydraulic components 030-185
030.6.6.1 Checking the hydraulic lines for damage
1509-1581; 030-185
030.6.7 Travel hydraulics 030-190030.6.7.1 Travel pump high pressure sensor B102: Deviatio030.6.7.2 Travel pump replenishing pressure relief valve030.6.7.3 Travel pump: high pressure relief valves030.6.7.4 Travel pump: pressure cut-off030.6.7.5 Travel pump: manual block curve calibration (up tosoftware version (Masterd) 013, from softwareversion (Master4) 017 or from serial number 60030)030.6.7.6 Travel pump: automatic block curve calibration (fromsoftware version (Master4) 020 or from serial number Travel motor: manual calibration (maximum swivel
030.6.8.1 Inching brake pedal: basic settingL509-1581; 030-202
030.6.8.2 Angle sensor for inching function: checking basicsettingL 509-1581; 030-204
Electrical system 030-205
030.6.9.1 Central control unit (Master4) Creating a ServicefileL509-1581/0-600029; 030-205
030.6.9.2 Central control unit (Master5): creating service file1 509-1581/600030-; 030-208
030.6.9.3 Updating the central controller softwareL509-1581/0-60029; 030-209
030.6.9.4 Central control unit (Master5): software updateL509-1581/60030-; 030-211
030.6.9.5 Setting the IP addresses of the central control unit(Master4)L509-1581; 030-215
030.6.9.6 Resetting the central control unit (Master4)L509-1581/0-60029; 030-217
030.6.9.7 Central control unit (Master5): resetting to factorysettingsL509-1581/60030-; 030-219
030.6.9.8 Central control unit (Master5): connecting Sculi diag-nostic softwareL509-1581/60030-; 030-220
030.6.9.9 Central control unit (Master5): connecting LiFT func-tion
L509-1581/60030-; 030-224L509-1681copyright ® Liebherr-Werk Bischofshofen GmbH 2021LIEBHERR 17
ContentsService manual030.6.9.10 Addressing CAN module and checking system infor-mation
L509-1581; 030-225
030.6.10 Axles and drive shafts 030-227
030.6.10.1 Tyres: setting radius
1509-1581; 030-227
030.6.11 Options 030-228
030.6.11.1 LiDAT: connecting to LIDAT module
1509-1581; 030-228
030.6.11.2 LiDAT: software update for LIDAT module
1509-1581; 030-230
030.6.11.3 LiDAT: creating report and snapshot
L509-1581; 030-232
040 Drive group 040-1
040.1 Engine 040-2
040.1.1 Diesel engine overview
1509-1581; 040-2
040.1.2 Electrical components of diesel engine
L509-1581; 040-10
040.1.3 Fuel system 040-11
040.1.3.1 Overview of fuel system
1509-1581; 040-12
040.1.3.2 Fuel level sensor
L509-1581; 040-14
040.1.3.3 Fuel pre-filter
1509-1581; 040-15
040.1.3.4 Fuel fine filter
L509-1581; 040-16
040.1.4 Air filter system 040-17
040.1.4.1 Air filter
L509-1581; 040-17
040.1.4.2 Vacuum switch for air filter
1509-1581; 040-18
040.1.5 Exhaust system 040-18
040.1.5.1 Overview of diesel particulate filter
L509-1581; 040-19
050 Cooling system 050-1
050.1 Overview of cooling system
L509-1581; 050-2
050.2 Cooling system hydraulics 050-318copyright © Liebher-Werk Bischofshofen GmbH 2021LIEBHERR L509-1581LBH/M2234435/12/211-20210126_075215/en
LBH/M2234435/12/211-20210126_075215/enService manualContents050.2.1 Overview of cooling system hydraulicsL509-1581; 050-3
050.2.2 Fan pump
L509-1581; 050-6
0502.3 Fan motor
L509-1581; 050-7
050.3 Cooling system electronics 050-9
050.3.1 General overview of electronic control system
L509-1581; 050-9
050.3.2 Hydraulic oil temperature sensor
L509-1581; 050-12
050.4 Cooler 050-14
0504.1 Cooler unit
L509-1581; 050-14
050.5 Reversible fan drive 050-15
050.5.1 Overview of reversible fan drive
L509-1581; 050-15
050.5.2 Fan reversal valve block
L509-1581; 050-18
060 Working hydraulics 060-1
060.1 Overview of working hydraulics
L509-1581; 060-3
060.2 Working pump
L509-1581; 060-9
060.3 Control block
L509-1581; 060-12
060.4 Pilot control 060-21
060.4.1 Overview of pilot control unit
L509-1581; 060-21
060.4.2 Pilot control unit
L509-1581; 060-25
0604.3 Pilot pressure for solenoid valve
L509-1581; 060-27
060.5 Ride control 060-29
060.5.1 Overview of ride control system
L509-1581; 060-29
060.5.2 Stabilisation module
L509-1581; 060-33
060.6 Regulated flow rate 060-38
0606.1 Regulated flow rate: total overview
L509-1581; 060-38
copyright ® Liebherr-Werk Bischofshofen GmbH 2021
L509-1581 LIEBHERR 19
Contents Service manual
060.6.2 Valve block for regulated flow rate
L509-1581; 060-40
060.7 Pipe break protection 060-42
060.7.1 Pipe break protection: overview
L509-1581; 060-42
060.7.2 Valve block for pipe break protection
L 509-1581; 060-44
060.7.3 Solenoid valve for release of the ride control
1509-1581; 060-45
060.8 High flow 060-47
060.8.1 High Flow: total overview
1509-1581; 060-47
060.8.2 High Flow pump
L509-1581; 060-50
060.8.3 Solenoid valve for High Flow
1509-1581; 060-51
070 Travel hydraulics 070-1
070.1 Overview of travel hydraulics
L509-1581; 070-2
070.2 Travel pump
L509-1581; 070-8
070.3 Travel motors 070-24
070.3.1 Travel motor
1509-1581; 070-24
080 Hydraulic components 080-1
080.1 Hydraulic system: overview
L509-1581; 080-2
080.2 Hydraulic tank 080-4
080.2.1 Overview of the hydraulic tank
1509-1581; 080-4
080.2.2 Return suction filter
1509-1581; 080-6
080.2.3 Breather filter
1509-1581; 080-12
090 Steering system 090-1
090.1 Steering system overview
L509-1581; 090-2
090.2 ServostaService manualContents100 Brake system 100-1
100.1 Overview of brake system
1509-1581; 100-2
100.2 Service brake and parking brake 100-6
100.2.1 Drum brake
1509-1581; 100-6
100.3 Service brake 100-11
100.3.1 Inch/brake unit
L509-1581; 100-11
100.3.2 Inching function angle sensor
L509-1581; 100-12
100.3.3 Brake light pressure switch
L509-1581; 100-14
100.4 Parking brake 100-16
100.4.1 Parking brake solenoid valve
L509-1581; 100-16
100.4.2 Spring accumulator cylinder for parking brake
L509-1581; 100-17
110 Electrical system 110-1
110.1 Overview of electrical system
L509-1581; 110-2
110.2 Lighting
L509-1581; 110-5
110.3 Circuit diagrams
1509-1581; 110-7
110.4 Electronic control unit 110-9
110.4.1 General overview of electronic control system
L509-1581/0-60029; 110-9
110.4.2 General overview of electronic control system
L509-1581/60030-; 110-11
110.4.3 Central control unit (Master4)
L509-1581/0-60029; 110-12
110.4.4 Central control unit (Master5 Mini)
L509-1581/60030-; 110-17
110.4.5 Modules 110-19
1104.51 Compact module: overview
L509-1581; 110-19
110.4.5.2 Compact module
1509-1581; 110-21
110.5 Electrical components of the driver’s cab 110-27
110.5.1 Fuse boards
L509-1581; 110-27110.5.2 Door contact switchL509-1581; 110-29
110.6 Electrical components in the rear section 110-30
110.6.1 Battery installation
L509-1581; 110-30
120 Gearbox 120-1
120.1 Overview of transmission
L509-1581; 120-2
120.2 Transmission electronics 120-3
120.2.1 Output speed sensor
1509-1581; 120-3
130 Axles and drive shafts 130-1
130.1 Axles 130-2
130.1.1 Front axle
L509-1581; 130-2
130.1.2 Rear axle
L509-1581; 130-4
130.2 Cardan shafts 130-6
130.2.1 Drive shaft
L509-1581; 130-6
140 Steel parts of the basic machine 140-1
140.1 Vehicle frame 140-2
140.1.1 Articulation bearing
L509-1581; 140-2
140.1.2 Articulation lock
L509-1581; 140-3
150 Working attachment 150-1
150.1 Lift arms for Z kinematics 150-2
150.1.1 Lift arms for Z kinematics
L509-1581; 150-2
150.2 Quick coupler 150-4
150.2.1 Quick coupler
1509-1581; 150-4
160.2.2 Quick coupler hydraulics 150-5
1560.2.2.1 Overview of quick coupler hydraulics
L509-1581; 150-6
150.2.2.2 Opening solenoid valve for quick coupler
L509-1581; 150-8
160 Operator’s cab, heating and air conditioning 160-1
160.1 Overview of operator’s cab, heating and air conditioning unit
1509-1581; 160-2
160.2 Display and control elements 160-4
160.2.1 Display
L509-1581; 160-4
160.2.2 Control lever
L509-1581; 160-4
160.2.3 Accelerator pedal
L509-1581; 160-6
160.3 Heating, ventilation, air conditioning 160-8
160.3.1 Overview of heating, ventilation and air conditioning system
L509-1581; 160-8
160.3.2 Heating and air conditioning unit 160-14
160.3.2.1 Heating and air conditioning unit
L509-1581; 160-14
160.3.2.2 Blower
1509-1581; 160-17
160.4 Air conditioning 160-18
160.4.1 Air conditioning (optional)
L509-1581; 160-18
1604.2 Compressor magnetic coupling
L509-1581; 160-19
160.4.3 Air conditioning condenser
L509-1581; 160-21
160.4.4 Dryer-collector unit
L509-1581; 160-21
160.4.5 Air conditioning pressure switch
L509-1581; 160-23
170 Lubrication system 170-1
170.1 Liebherr automatic central lubrication system 170-2
170.1.1 Automatic central lubrication system: overview
L509-1581; 170-2
170.1.2 Central lubrication pump EP-1
L509-1581; 170-6
170.1.3 Progressive distributor MX-F
L509-1581; 170-9
190 Options 190-1
190.1 LIiDAT 190-2
190.1.1 Overview of LiDAT
L509-1581; 190-2
190.1.2 LiDAT on machine
L509-1581/0-50943; 190-4
190.1.3 LiDAT on machine
L509-1581/50944-; 190-5
190.1.4 LiDAT module (LiTU2)
L509-1581/0-50943; 190-7
190.1.5 LiDAT module (LiTU3)
L509-1581/50944-; 190-9
200 Diagnosis 200-1
200.1 Malfunctions 200-2
200.1.1 Warning symbols 200-2
200.1.2 Warning symbols 200-2
200.1.3 Service code indicator in the display 200-3
200.2 Troubleshooting 200-6
200.2.1 Replacing fuses 200-6
200.2.1.1 Fuses on the fuse board in the cab 200-6
200.2.1.2 Fuses in right of engine compartment 200-9010.1 Safety instructions 010-4010.1.1 Information on these instructions 010-4010.1.1.1 Representation of warning messages 010-4010.1.1.2 Graphic symbols in these instructions 010-4010.1.2 Intended use 010-5010.1.2.1 Laws, rules, guidelines and safety regulations 010-5010.1.2.2 Intended use 010-5010.1.2.3 Foreseeable misuse 010-6010.1.2.4 Operating conditions 010-6010.1.2.5 Disposal 010-7010.1.3 Description of staff 010-7010.1.3.1 Personal protective equipment 010-7010.1.3.2 Requirements for staff 010-8010.1.3.3 Operating company 010-8010.1.3.4 Operator 010-9010.1.3.5 Maintenance staff 010-9010.1.3.6 Refrigeration technician 010-10010.1.3.7 Slinger 010-11010.1.3.8 Spotter 010-12010.1.4 Protective devices on the machine 010-12010.1.4.1 Operator’s cab 010-12010.1.4.2 Roll over protective structure (ROPS) 010-13010.1.4.3 Falling object protective structures (FOPS) 010-13010.1.5 Emergency equipment on the machine 010-13010.1.5.1 Emergency exit (standard) 010-13010.1.5.2 Fire extinguisher (option) 010-14010.1.6 Safe operation 010-1010.1.6.1 Intoxicants 010-14010.1.6.2 Dangerous fuels and operating fluids 010-14010.1.6.3 Transporting machine 010-15010.1.6.4 Access to machine 010-15010.1.6.5 Machine danger zone 010-16010.1.6.6 Visibility 010-16010.1.6.7 Protection against vibration 010-17010.1.6.8 Operation of machine 010-18010.1.7 Safe maintenance 010-21010.1.7.1 Spare parts 010-21010.1.7.2 Heavy parts 010-21010.1.7.3 Regular checks 010-22010.1.8 Modifications to the machine 010-22010.1.8.1 Modifications, add-ons and retrofittings 010-22010.2 Special tools for maintenance and repair work 010-23010.2.1 Special tools, general 010-23010.2.2 Special tools for diesel engine 010-25010.2.3 Special tools for lift cylinders 010-26010.24 Special tools for tilt cylinders 010-26010.2.5 Special tools for quick coupler locking hydraulic cylinder 010-27010.2.6 Special tools for steering wheel 010-27010.2.7 Special tools for steering cylinders 010-28010.2.8 Special tools for the electrical system 010-28010.2.9 Special tools for front axle 010-30010.2.10 Special tools for rear axle 010-30010.2.11 Special tools for air conditioning system 010-31010.2.12 Special tools for cab glazing 010-32010.2.13 Special tools for the central lubrication system (Liebherr) 010-32010.3 Standards and regulations 010-34
010.3.1 Prestressing forces and tightening torques for bolts with metricstandard and fine threads as per DIN ISO 261 010-34010.3.1.1 Range of application and purpose 010-34010.3.1.2 Other applicable documents 010-34010.3.1.3 Modifications and descriptions 010-35010.3.1.4 Tightening torques 010-35010.3.2 Liebherr standards for assembly instructions and tightening torques010-41Preservation guidelines 010-42
0104.1 General information 010-42
010.4.2 Machine out of service for an unknown period of time 010-42
0104.3 Putting the machine out of service 010-43
010.4.3.1 Out of service for up to 2 months 010-43
010.4.3.2 Out of service for up to 12 months 010-44
010.4.3.3 Out of service for longer than 12 months 010-45
010.44 Putting back into service 010-45
010.4.4.1 After being out of service for 2 months 010-45
010.4.4.2 After being out of service for 12 months 010-46010.4.4.3 After being out of service for longer than 12 months 010-46