Liebherr Wheel loaders L 576-1759 Service manual – PDF DOWNLOAD

Liebherr Wheel loaders L 576-1759 Service manual – PDF DOWNLOAD

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Liebherr Wheel loaders L 576-1759 Service manual – PDF DOWNLOAD

Language : English
Pages : 964
Downloadable : Yes
File Type : PDF
Size:213 MB

DESCRIPTION:

Liebherr Wheel loaders L 576-1759 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 576-1759 Service manual – PDF DOWNLOAD

010 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
010.1.4 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
010.1.5 Emergency equipment on the machine 010-13 iil
010.1.5.1 Emergency exit (standard) 010-13 “‘ I~D 010.1.5.2 Fire extinguisher (option) 010-14
010.1.6 Safe operation 010-14
010.1.6.1 Intoxicants 010-14
010.1.6.2 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
010.2 Special tools for maintenance and repair work 010-23
010.2.1 Special tools, general 010-23
010.2.2 Special tools for the diesel engine 010-25
010.2.3 Special tools for lift cylinders with Z kinematics 010-29
010.2.4 Special tools for tilt cylinders with Z kinematics 010-29
010.2.5 Special tools for steering wheel 010-30
010.2.6 Special tools for steering cylinders 010-31
010.2.7 Special tools for brake system 010-31
010.2.8 Special tools for the electrical system 010-32
010.2.9 Special tools for front axle 010-33
010.2.10 Special tools for rear axle 010-33
010.2.11 Special tools for the air conditioning system 010-33
010.2.12 Special tools for Grammer driver’s seat 010-35
010.2.13 Special tools for cab glazing 010-35 C: i CD
010.2.14 Special tools for the central lubrication system (Liebherr) 010-35
010.3 Standards and regulations 010-37 ‘
010.3.1 Prestressing forces and tightening torques for bolts with metric ~
standard and fine threads as per DIN ISO 261 010-37 ~ iil
010.3.1.1 Range of application and purpose 010-37
010.3.1.2 Other applicable documents 010-37 ~ ID
010.3.1.3 Modifications and descriptions 010-38
010.3.1.4 Tightening torques 010-38
010.3.2 Liebherr standards for assembly instructions and tightening torqueso10-44
010.4 Preservation guidelines 010-45
010.4.1 General information 010-45
010.4.2 Machine out of service for an unknown period of time 010-45
010.4.3 Putting the machine out of service 010-46
010.4.3.1 Out of service for up to 2 months 010-46
010.4.3.2 Out of service for up to 12 months 010-47
010.4.3.3 Out of service for longer than 12 months 010-48
010.4.4 Putting back into service 010-48
010.4.4.1 After being out of service for 2 months 010-48
010.4.4.2 After being out of service for 12 months 010-49
010.4.4.3 After being out of service for longer than 12 months 010-49
010.5 Preservation guidelines for the SCR system 010-50
010.5.1 Putting out of service for longer than 2 months 010-50
010.5.2 Starting up after being out of service for longer than 2 months 010-50
020 Technical data 020-1
020.1 Overall machine 020-5
020.1.1 Complete machine with bucket (Z lift arms)
020.2 Drive group 020-7
020.2.1 Diesel engine
020.2.2 Fuel tank
020.2.3 Fuel level sensor
020.2.4 Fuel pre-filter (separator filter)
020.2.5 Compressed air system ;;;, L576-1759; 020-9
020.3 Cooling system
020.3.1 Fan pump ~
020.3.2 Fan motor
020.3.3 Hydraulic oil temperature sensor B8
020.4 Working hydraulics 020-11
Working pump
020.4.2 Control valve block for Z kinematics
020.4.3 Pilot control valve block
020.4.4 Pilot control hydro accumulator
020.4.5 Stabilisation module
020.4.6 Ride control hydro accumulator
020.4.7 Z-bar kinematics lift cylinder
020.4.8 Z kinematics tilt cylinder
020.4.9 Pressure sensors for lift cylinders and tilt cylinders B90, B91, B92,
020.5 Hydraulic components 020-14
020.5.1 Return filter
020.5.2 Breather filter
020.6 Steering system 020-15
020.6.1 Steering pump
020.6.2 Servostat
020.6.3 Steering cylinder
020.6.4 Steering damper hydro accumulator
020.6.5 Emergency steering pump C:’
020.6.6 Emergency steering pressure switch B3 ;;;,
020.6.7 Emergency steering check pressure switch B3a ~’
020.6.8 Joystick steering control valve block
020.7 Brake system 020-18
020.7.1 Brake pump
020.7.2 Compact brake valve
L576-1759; 020-18
020.7.3 Service brake hydro accumulator
L576-1759; 020-18
020.7.4 Brake light pressure switch B12
L576-1759; 020-18
020.7.5 Brake accumulator pressure sensor B19
L576-1759; 020-19
020.7.6 Parking brake hydro accumulator
L576-1759; 020-19
020.8 Electrical system 020-20
020.8.1 Central control unit (Master5-Premium)
L576-1759; 020-20
020.8.2 Input module
L576-1759; 020-20
020.8.3 Output module
L576-1759; 020-20
020.8.4 Battery
L576-1759; 020-21
020.8.5 Voltage transformer
L576-1759; 020-21
020.8.6 Reversing camera
L576-1759; 020-21
020.9 Gearbox 020-22
020.9.1 Transmission
L576-1759; 020-22
020.9.2 Filter bypass switch B85
L576-1759; 020-22
020.9.3 Proportional solenoid for gear shifting Y1, Y2, Y3, Y 4, Y5, Y6
L576-1759; 020-22
020.9.4 Pressure sensor for hydrostat B80, B81
L576-1759; 020-23
020.9.5 Speed sensor B82, B83, B84
C: L576-1759; 020-23 i “.C.D.’ 020.9.6 Transmission oil temperature sensor B86 ;;;,
~
L576-1759; 020-23
0
0 “0 ‘ 020.9.7 Proportional solenoid for position control Y7
~ L576-1759; 020-24
~
iil 020.10 Axles and drive shafts 020-25 “”” “”” “‘ 020.10.1 Front axle ~ ID L576-1759; 020-25 …J
020.10.2 Rear axle
L576-1759; 020-25
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L576-1759 llEBHERR 9
Contents
10
020.10.3 Drive shaft between diesel engine and transmission
L576-1759;
020.10.4 Drive shaft between transmission and front axle
L576-1759;
020.10.5 Drive shaft between transmission and rear axle
L576-1759;
020.10.6 Tyres
L576-1759;
020.10.6.2 Tyres for timber work
020.10.6.3 Special tyres
Service manual
020-25
020-26
020-26
020-26
020-27
020-28
——————-
020. 11 Steel parts of the basic machine
020.11.1 Ballast weights
L576-1759;
020.11.1.1 Standard (z-bar kinematics) and industrial lift arms
020.11.1.2 Foam-filled tyres or tracks
020.12 Working attachment
020.12.1 Quick coupler locking hydraulic cylinder
L576-1759;
020.13 Operator’s cab, heating and air conditioning
020.13.1.1 Air conditioning compressor
020.13.2 Air conditioning pressure switch
L576-1759;
020.14 Lubrication system
020.14.1 Central lubrication system (Liebherr)
L576-1759;
020.14.1.1 Central lubrication pump
020.14.1.2 Progressive distributor
020.14.2 Progressive distributor
L576-1759;
020.14.2.1 MX-F
020-29
020-29
020-29
020-29
020-30
020-30
020-31
020-31
020-31
020-32
020-32
020-32
020-32
020-33
020-33 ——————–
020.14. 2. 2 MX-F 25 020-33
——————–
020.14. 2. 3 MX-F 45 020-34
——————–
020.14. 2 .4 MX-F 75 020-34
——————–
020.14. 2. 5 MX-F105
020.14.3 Progressive distributor SXE-2
L576-1759;
020.14.3.1 SXE-2 / MX-F
020-34
020-34
020-34 ——————-
020.14. 3. 2 SXE-2 100 020-34
——————-
020.14. 3. 3 SXE-2 150 020-35
copylight © Liebherr-Werk Bischofshofen GmbH 2020
llEBHERR L576-1759
C: i “.C.D.’ ;;;,
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C: i “.C.D.’ ;;;,
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“”” “”” “‘ ~ ID
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Service manual Contents
020.14.3.4 SXE-2 220 020-35
——————–
020.14. 3. 5 SXE-2 400 020-35
020.14.3.6 SXE-2 760 020-35
030 Maintenance 030-1
L576-1759
030.1 Maintenance and inspection schedule
030.2 Filling quantities and lubrication chart
030.2.1 Lubricant filling quantity
L576-1759;
030.2.2 Fuel and operating fluid filling quantity
L576-1759;
030.3 Lubricants and fuels
030.3.1 General information on lubricants and fuels
030.3.1.1
030.3.1.2
030.3.1.3
030.3.1.4
General questions
Safety data sheets
Technical data sheets
Specific Liebherr standards
030-11
030-16
030-16
030-16
030-17
030-17
030-17
030-17
030-17
030-17
030.3.2 General information on changing lubricants and fuels 030-17
030.3.3 Converting hydraulic system from mineral oils to biodegradable
hydraulic fluids 030-18
030.3.4 Diesel fuels
L576-1759; 030-18
030.3.4.1
030.3.4.2
030.3.4.3
Minimum quality requirement
Operating temperatures of diesel fuels
Minimum quality requirement
030.3.5 Diesel exhaust fluid
L576-1759;
030.3.5.1 Liebherr recommendation
030.3.5.2 Minimum quality requirement
030.3.6 Engine oils
L576-1759;
030.3.6.1 Liebherr recommendation
030.3.6.2 Minimum quality requirement
030.3.6.3 Changing intervals
030.3.6.4 Complicating factors
030.3.7 Refrigerant
L576-1759;
030.3.8 Coolant
L576-1759;
copylight © Liebherr-Werk Bischofshofen GmbH 2020
llEBHERR
030-18
030-19
030-19
030-19
030-19
030-19
030-20
030-20
030-20
030-20
030-21
030-21
030-22
11
Contents Service manual
030.3.8.1 Requirements for the water used 030-22
030.3.8.2 Antifreeze and corrosion inhibitor 030-22
030.3.8.3 Minimum quality requirement 030-22
030.3.9 Hydraulic oil
L576-1759; 030-22
030.3.9.1 Liebherr recommendation 030-22
030.3.9.2 Minimum quality requirement 030-23
030.3.9.3 Oil analysis 030-23
030.3.9.4 Oil change 030-23
030.3.10 Splitter box oil
L576-1759; 030-24
030.3.10.1 Liebherr recommendation 030-24
030.3.10.2 Minimum quality requirements 030-24
030.3.11 Gear oil
L576-1759; 030-24
030.3.11.1 Liebherr recommendation 030-24
030.3.11.2 Minimum quality requirement 030-24
030.3.12 Axle oil
L576-1759; 030-25
030.3.12.1 Liebherr recommendation 030-25
030.3.12.2 Minimum quality requirement 030-25
030.3.13 Lubrication grease
L576-1759; 030-25
030.3.13.1 Liebherr recommendation 030-25
030.3.13.2 Minimum quality requirement 030-25
030.3.14 Windscreen washer fluid
L576-1759; 030-26
030.3.14.1 Liebherr recommendation 030-26
030.3.14.2 Minimum quality requirement 030-26
C:
030.3.15 Refrigerant oil for air conditioning compressor i
L576-1759; 030-26 “.C.D.’ ;;;,
030.3.15.1 Liebherr recommendation 030-26 !:j
0
0 “0 ‘
030.4 Maintenance tasks 030-27 ~
~
030.4.1 Safety precautions iil
L576-1759; 030-27 “”” “”” “‘
030.4.2 Preparatory tasks for maintenance 030-27 ~ ID
…J
030.4.2.1 Maintenance positions
L576-1759; 030-28
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Service manual Contents
030.4.2.2 Opening the service hatches
L576-1759; 030-29
030.4.2.3 Turning off the battery main switch
L576-1759; 030-33
030.4.3 Overall machine 030-34
030.4.3.1 Checking machine is in proper condition
L576-1759; 030-34
030.4.3.2 Removing loose parts, dirt, ice and snow from
machine
L576-1759; 030-36
030.4.3.3 Cleaning machine
L576-1759; 030-36
030.4.3.4 Changing the VCl-capsules
L576-1759; 030-39
030.4.3.5 Oil analyses
L576-1759; 030-42
030.4.4 Drive group 030-49
030.4.4.1 Checking diesel engine oil level
L576-1759; 030-49
030.4.4.2 Diesel engine: changing diesel engine oil
L576-1759; 030-52
030.4.4.3 Diesel engine: changing oil filter
L576-1759; 030-55
030.4.4.4 Checking diesel engine belt drive
L576-1759; 030-56
030.4.4.5 Changing diesel engine belt drive
L576-1759; 030-57
030.4.4.6 Checking fastening of diesel engine control units and
sensor cable connections
L576-1759; 030-58
030.4.4.7 Checking diesel engine valve clearance
L576-1759; 030-59
030.4.4.8 Diesel engine: changing oil separator filter cartridge
L576-1759; 030-61
C: i “.C.D.’ 030.4.4.9 LD5ie7s6e-l1 e7n5g9i;n e: Changing the heating flange 030-62 ;;;,
~ 0 030.4.4.10 Fuel tank: Draining off condensate and sediment
0 “0 ‘ L576-1759; 030-62 ~
~ 030.4.4.11 Fuel pre-filter: Draining off condensate iil
“”” L576-1759; 030-63 “”” “‘ ~ 030.4.4.12 Changing fuel pre-filter cartridge
ID …J L576-1759; 030-64
030.4.4.13 Changing fuel fine filter element
L576-1759; 030-67
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L576-1759 llEBHERR 13
Contents Service manual
030.4.4.14 Diesel exhaust fluid tank: checking ventilation
L576-1759; 030-70
030.4.4.15 Air filter system: Cleaning the service cover and dust
discharge valve
L576-1759; 030-71
030.4.4.16 Cleaning or changing the main element of the air
filter system
L576-1759; 030-72
030.4.4.17 Air filter system: Changing the safety element
L576-1759; 030-75
030.4.4.18 Dust protection for alternator (option): cleaning or
replacing filter element
L576-1759; 030-76
030.4.4.19 Splitter box: Checking the oil level
L576-1759; 030-79
030.4.4.20 Splitter box: Changing the oil
L576-1759; 030-80
030.4.4.21 Checking that the diesel engine intake and exhaust
system is in good condition and not loose or leaking
L576-1759; 030-82
030.4.4.22 Checking the diesel engine for leaks, contamination
and damage
L576-1759; 030-84
030.4.4.23 Diesel engine: checking profile clamps
L576-1759; 030-85
030.4.4.24 Diesel particulate filter: Cleaning filter module
L576-1759; 030-87
030.4.4.25 Changing the compressed air dryer
L576-1759; 030-90
030.4.4.26 Checking compressed air system
L576-1759; 030-91
030.4.5 Cooling system 030-92
030.4.5.1 Cooling system: Checking the coolant level
L576-1759; 030-92
030.4.5.2 Coolant: checking anti-freeze and corrosion protec- C:
tion agent concentration i CD
L576-1759; 030-93 “…’ ;;;,
030.4.5.3 Cleaning the cooling system !:j
0
0
L576-1759; 030-100 “0 ‘
~
030.4.5.4 Changing coolant in cooling system ~
L576-1759; 030-101 iil
“”” “”” 030.4.6 Hydraulic components 030-104 “‘ ~ ID
030.4.6.1 Hydraulic tank: Checking the oil level …J
L576-1759; 030-104
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14 llEBHERR L576-1759
Service manual Contents
030.4.6.2 Draining off condensate and sediment from the
hydraulic tank
L576-1759; 030-106
030.4.6.3 Change the return filter insert in the hydraulic tank.
L576-1759; 030-107
030.4.6.4 Changing the hydraulic tank breather filter
L576-1759; 030-108
030.4.6.5 Hydraulic tank: analysing the oil
L576-1759; 030-109
030.4.6.6 Changing the oil in the hydraulic tank
L576-1759; 030-110
030.4.7 Steering system 030-114
030.4.7.1 Steering: Checking the function
L576-1759; 030-114
030.4.7.2 Steering cylinders: Lubricating the bearings
L576-1759; 030-114
030.4.8 Brake system 030-115
030.4.8.1 Service brake: checking function and effectiveness
L576-1759; 030-115
030.4.8.2 Checking service brake discs for wear
L576-1759; 030-116
030.4.8.3 Checking the gap and wear on the parking brake
linings
L576-1759; 030-120
030.4.8.4 Emergency actuation of parking brake: checking the
seal
L576-1759; 030-126
030.4.8.5 Checking emergency parking brake actuation
L576-1759; 030-126
030.4.9 Electrical system 030-127
030.4.9.1 Checking function of the lighting and horn
L576-1759; 030-127
030.4.9.2 Batteries: Checking the acid level and terminals
C:
L576-1759; 030-128
i “.C.D.’ 030.4.9.3 Control lever: Change the travel direction switch ;;;, rocker and cap.
~ L576-1759; 030-130 0
0 “0 ‘ ~ 030.4.9.4 Personnel detection: cleaning sensor
~ L576-1759; 030-133
iil
“”” 030.4.10 Gearbox 030-133 “”” “‘ ~ 030.4.10.1 Transmission: checking the oil level
ID …J L576-1759; 030-133
030.4.10.2 Changing gear oil and gear oil filter
L576-1759; 030-136
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L576-1759 llEBHERR 15
Contents Service manual
030.4.10.3 Change the transmission hydrostat oil filter.
L576-1759; 030-140
030.4.11 Axles and drive shafts 030-141
030.4.11.1 Axles Changing the oil
L576-1759; 030-141
030.4.11.2 Checking drive shafts
L576-1759; 030-143
030.4.11.3 Checking the tyre pressure
L576-1759; 030-145
030.4.11.4 Checking the wheel tightness
L576-1759; 030-147
030.4.12 Steel parts of the basic machine 030-147
030.4.12.1 Lubricating the articulation bearing and the rear axle
oscillating bearing
L576-1759; 030-147
030.4.12.2 Cooler hood: Lubricating moving parts with penetrating
oil
L576-1759; 030-148
030.4.12.3 Engine hood: Lubricating moving parts with penetrating
oil
L576-1759; 030-149
030.4.12.4 Right cab access: Lubricating moving parts with
penetrating oil
L576-1759; 030-150
030.4.12.5 Service hatches: cleaning and maintaining seals
L576-1759; 030-150
030.4.13 Working attachment 030-151
030.4.13.1 Lubricating the lift arms and working attachment
L576-1759; 030-151
030.4.13.2 Lift arms: Checking the bucket bearing seals
L576-1759; 030-153
030.4.13.3 Lift arms: checking bucket bearing bushings
L576-1759; 030-154
030.4.13.4 Checking the lift arm bucket stops
C: L576-1759; 030-155 i CD 030.4.13.5 Bucket: Check the teeth or undercut blade for wear “‘ … ;;;,
and replace if necessary !:j
0
L576-1759; 030-157 0 “0 ‘
~
030.4.13.6 Lubricate and test the bearings on the quick coupler. ~
L576-1759; 030-160 iil
“”” 030.4.13.7 High dump bucket: Lubricating the bearing “”” “‘ L576-1759; 030-161 ~ ID
…J
030.4.14 Operator’s cab, heating and air conditioning 030-161
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Service manual
030.5
030.6
C: i “.C.D.’ ;;;,
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“”” “”” “‘ ~ ID
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L576-1759
Contents
030.4.15
030.4.14.1 Operator’s cab: cleaning the fresh and recirculated
air filters
L576-1759;
030.4.14.2 Operator’s cab: changing fresh air filter and recirculated
air filters
L576-1759;
030.4.14.3 Safety belt: Checking the condition and function
L576-1759;
030.4.14.4 Testing the windscreen washer system
L576-1759;
030.4.14.5 Windscreen washer system: filling windscreen
washer fluid
L576-1759;
030.4.14.6 Cab: Lubricating the lock and cylinder with penetrating
oil
L576-1759;
030.4.14.7 Operator’s cab: cleaning and maintaining seals
L576-1759;
030.4.14.8 Heating and air conditioning: Checking the function
L576-1759;
Lubrication system
030.4.15.1 Checking the level in the grease reservoir of the
central lubrication system
L576-1759;
030.4.15.2 Central lubrication system: Checking the pipes,
hoses and lubrication points for leaks and damage
030-161
030-162
030-164
030-165
030-165
030-166
030-166
030-167
030-168
030-168
L576-1759; 030-169
030.4.15.3 Central lubrication system: Checking the lubrication
of the bearings
L576-1759; 030-170
Testing and adjustment checklist
L576-1759; 030-171
Testing and adjustment tasks 030-177
030.6.1 Safety precautions
L576-1759; 030-177
030.6.2 Overall machine 030-177
030.6.2.1 Preparing for adjustment procedures
L576-1759; 030-177
030.6.2.2 Hydraulic oil: operating temperature
L576-1759; 030-179
030.6.2.3 Gear oil operating temperature
L576-1759; 030-180
030.6.2.4 Service management
L576-1759; 030-180
030.6.3 Drive group 030-181
copylight © Liebherr-Werk Bischofshofen GmbH 2020
llEBHERR 17
Contents Service manual
030.6.3.1 Pedals: calibration
L576-1759; 030-181
030.6.3.2 Reading the diesel engine service files
L576-1759; 030-183
030.6.4 Cooling system 030-184
030.6.4.1 Fan speed proportional solenoid valve
L576-1759; 030-184
030.6.5 Working hydraulics 030-186
030.6.5.1 Multi-lever control (optional): Calibration
L576-1759; 030-186
030.6.5.2 Calibrating working hydraulics angle sensors
L576-1759; 030-188
030.6.5.3 Proportional solenoids in the control valve block: calibration
L576-1759; 030-191
030.6.5.4 Pilot control valve block: pressure reducing valve
L576-1759; 030-195
030.6.5.5 Working pump: flow regulator (standby pressure)
L576-1759; 030-196
030.6.5.6 Working pump flow regulator (differential pressure)
L576-1759; 030-197
030.6.5.7 Working pump: power regulator
L576-1759; 030-199
030.6.5.8 Z-bar kinematics control valve block: secondary pressure
relief valves
L576-1759; 030-201
030.6.5.9 Z-bar kinematics control valve block: primary pressure
relief valve
L576-1759; 030-203
030.6.5.10 Z-bar kinematics control valve block: LS-pressure
cut-off
L576-1759; 030-205
030.6.5.11 Stabilisation module cut-out function
L576-1759; 030-206
030.6.5.12 Ride control hydro accumulator nitrogen filling C: i
L576-1759; 030-207 “.C.D.’
030.6.6 Hydraulic components 030-208
;;;,
!:j
0
0 030.6.6.1 Hydro accumulator: checking and topping up “‘ 0
~
nitrogen filling ~
L576-1759; 030-208 iil
“”” 030.6.6.2 Checking the hydraulic lines for damage “”” “‘ L576-1759; 030-210 ~ ID
…J
030.6.7 Steering system 030-215
030.6.7.1 Joystick for joystick steering (option): calibration
L576-1759; 030-215
copylight © Liebherr-Werk Bischofshofen GmbH 2020
18 llEBHERR L576-1759
Service manual
L576-1759
030.6.7.2
030.6.7.3
030.6.7.4
030.6.7.5
030.6.7.6
030.6.7.7
030.6.7.8
030.6.7.9
030.6.8 Brake system
030.6.8.1
030.6.8.2
030.6.8.3
030.6.8.4
Contents
Angle sensor for articulation angle (option): calibration
(machine with steering wheel steering)
L576-1759; 030-215
Angle sensor for articulation angle (option): calibration
(machine without steering wheel steering)
L576-1759; 030-217
Control block for joystick steering (option): calibration
L576-1759; 030-218
Steering pump: LS pressure cut-off valve
L576-1759; 030-220
Steering pump flow regulator (standby pressure)
L576-1759; 030-221
Steering pump: flow regulator (differential pressure)
L576-1759; 030-223
Steering damper hydro accumulator nitrogen filling
L576-1759; 030-224
Control block for joystick steering: determining installation
position of position sensors
L576-1759; 030-225
030-226
Brake accumulator pressure sensor B19: deviation
L576-1759; 030-226
Compact brake valve hydro accumulator charging
function
L576-1759; 030-227
Service brake pressure
L576-1759; 030-228
Service brake hydro accumulator capacity
L576-1759; 030-229
030.6.9 Electrical system 030-231
030.6.9.1 Central control unit (Master5): creating service file
L576-1759; 030-231
030.6.9.2 Central control unit (Master5): software update
L576-1759; 030-232
030.6.9.3 Central control unit (Master5): resetting to factory
settings
L576-1759; 030-235
030.6.9.4 Central control unit (Master5): connecting Sculi diagnostic
software
L576-1759; 030-237
030.6.9.5 Central control unit (Master5): connecting LiFT function
L576-1759; 030-240
030.6.9.6 Addressing CAN module and checking system information
L576-1759; 030-241
copyright© Liebherr-Werk Bischofshofen GmbH 2020
llEBHERR 19
Contents
030.6.10
030.6.11
030.6.12
Service manual
Gearbox
030.6.10.1 Gearbox: basic calibration
L576-1759;
030.6.10.2 Gearbox: service calibration
L576-1759;
030.6.10.3 Transmission control unit: software update
L576-1759;
Axles and drive shafts
030.6.11.1 Tyres: setting radius
L576-1759;
Working attachment
030.6.12.1 Valve block for quick coupler (option): Pressure
reducing valve
L576-1759;
030.6.12.2 Parameters for lift arm geometry
L576-1759;
030-245
030-245
030-247
030-250
030-251
030-251
030-252
030-252
030-253
030.6.12.3 Working attachment: automatic return of 3rd function
L576-1759; 030-254
030.6.13 Operator’s cab, heating and air conditioning 030-255
030.6.13.1 Checking the pressure and temperature conditions of
the air conditioning unit
L576-1759; 030-255
030.6.14 Options 030-256
030.6.14.1 LiDAT: connecting to LiDAT module
L576-1759;
030.6.14.2 LiDAT: software update for LiDAT module
L576-1759;
030.6.14.3 LiDAT: creating report and snapshot
L576-1759;
030-256
030-258
030-260
030.6.14.4 Liebherr weighing device with Truck Payload Assist:
calibration
L576-1759; 030-264
030.6.14.5
030.6.14.6
Skyview 360°: calibration
L576-1759;
Personnel detection: transmitting configuration files
030-264 I
ill
L576-1759; 030-271
040 Drive group
040.1 Engine
030.6.14.7 Tyre pressure monitoring: changing and programming
pressure sensor
L576-1759; 030-275
040-1
040-3
—————————-
040. 1. 1 Diesel engine overview
L576-1759; 040-3
copylight © Liebherr-Werk Bischofshofen GmbH 2020
… ;;;,
!:j
~
I
I ~
ID
…J
20 llEBHERR L576-1759
Service manual Contents
040.1.2 Electrical components of diesel engine
L576-1759; 040-7
040.1.3 Ambient temperature sensor
L576-1759; 040-10
040.1.5 Fuel system 040-16
040.1.5.2 Fuel level sensor
L576-1759; 040-19
040.1.5.3 Separ fuel pre-filter
L576-1759; 040-21
040.1.6 Air filter system 040-21
040.1.6.1 Air filter
L576-1759; 040-22
040.1.6.2 Vacuum switch
L576-1759; 040-23
040.1.7 Exhaust system 040-23
040.1.7.1 Exhaust gas treatment (stage V): overview
L576-1759; 040-24
040.1.7.2 Exhaust gas treatment (stage IV/ tier 4f): overview
L576-1759
L576-1759;
040.1.7.3 Metering unit
L576-1759;
040.1.7.4 Sampling module
L576-1759;
040.1.7.5 Exhaust treatment sensors
L576-1759;
040.1.8 Compressed air system
040.1.8.1 Overview of the compressed air system
L576-1759;
040.1.8.2 Compressor
L576-1759;
040.1.8.3 Air dryer
L576-1759;
040.1.8.4 SCR system air supply valve
L576-1759;
040.2 Clutch
L576-1759;
040.3 Splitter box
L576-1759;
050 Cooling system
050.1 Cooling system: General overview
L576-1759;
050.2 Cooling system hydraulics
copyright© Liebherr-Werk Bischofshofen GmbH 2020
llEBHERR
040-33
040-38
040-41
040-42
040-43
040-44
040-46
040-47
040-48
040-49
040-51
050-1
050-2
050-3
21
Contents Service manual
050.2.1 Overview of cooling system hydraulics
L576-1759; 050-4
050.2.2 Fan pump
L576-1759; 050-8
050.2.3 Fan motor
L576-1759; 050-9
050.3 Cooling system electronics 050-13
050.3.1 Overview of electrical controls of cooling system
L576-1759; 050-13
050.3.2 Hydraulic oil temperature sensor
L576-1759; 050-16
050.4 Cooler 050-18
050.4.1 Cooler unit
L576-1759; 050-18
050.5 Reversible fan drive 050-19
050.5.1 Overview of reversible fan drive
L576-1759; 050-19
050.5.2 Fan reversal valve block
L576-1759; 050-21
060 Working hydraulics 060-1
060.1 Overview of Z-bar kinematics working hydraulics
L576-1759; 060-2
060.2 Working pump
L576-1759; 060-11
060.3 Control block for Z-bar kinematics
L576-1759; 060-19
060.4 Pilot control 060-28
060.4.1 Pilot control valve block
L576-1759; 060-28
060.5 Ride control 060-30
060.5.1 Overview of ride control system
L576-1759; 060-30 C: i 060.5.2 Stabilisation module “.C.D.’
L576-1759; 060-33
;;;,
!:j
0
0
060.5.3 Electric ride control unit “0 ‘
L576-1759; 060-36 ~
~
060.6 Electronics of the working hydraulics 060-38 iil
“”” “””
060.6.1 Overview of electrical controls the working hydraulics “‘ ~
L576-1759; 060-38 ID
…J
060.6.2 Working hydraulics angle sensors
L576-1759; 060-40
copylight © Liebherr-Werk Bischofshofen GmbH 2020
22 llEBHERR L576-1759
Service manual
L576-1759
060.6.3 Pressure sensors for lift cylinders and tilt cylinders
L576-1759;
060. 7 Pipe break protection
060.7.1 Pipe break protection: overview
L576-1759;
060.7.2 Valve block for pipe break protection
L576-1759;
060.7.3 Ride control release solenoid valve
L576-1759;
080 Hydraulic components
080.1 Hydraulic system: overview
L576-1759;
080.2 Hydraulic tank
080.2.1 Overview of hydraulic tank
L576-1759;
080.2.2 Steel tank
L576-1759;
080.2.3 Return filter
L576-1759;
080.2.4 Leak oil strainer
L576-1759;
080.2.5 Breather filter
L576-1759;
090 Steering system
090.1 Steering system overview
L576-1759;
090.2 Steering pump
L576-1759;
090.3 Servostat
L576-1759;
090.4 Steering cylinder
090.4.1 Steering cylinder
L576-1759;
090.4.2 Steering stabilisation valve block
L576-1759;
090.4.3 Valve block for steering stabilisation (without steering wheel
steering)
L576-1759;
090.5 Emergency steering
090.5.1 Emergency steering overview
L576-1759;
copyright© Liebherr-Werk Bischofshofen GmbH 2020
llEBHERR
Contents
060-42
060-44
060-44
060-47
060-48
080-1
080-2
080-5
080-5
080-7
080-9
080-10
080-10
090-1
090-3
090-8
090-14
090-17
090-17
090-20
090-21
090-23
090-23
23
Contents
24
Service manual
090.5.2 Emergency steering pump
L576-1759;
090.5.3 Emergency steering electronics
090.5.3.1 Overview of electrical controls of emergency steering
system
090-25
090-27
L576-1759; 090-27
090.5.3.2 Emergency steering pressure switch
L576-1759; 090-32
090.5.3.3 Emergency steering check pressure switch
L576-1759; 090-33
090.6 Joystick steering 090-35
090.6.1 Joystick steering: overview (combined with steering wheel steering)
L576-1759; 090-35
090.6.2 Joystick steering: overview (without steering wheel steering)
L576-1759;
090.6.3 Joystick steering control block
L576-1759;
090.6.4 Joystick steering electrical system
090-39
090-42
090-48
090.6.4.1 Electronic control unit for joystick steering: overview
L576-1759; 090-48
090.6.4.2
090.7 2in1 steering
Joystick with position tracking
L576-1759;
090.7.1 2in1 steering: total overview
L576-1759;
090.7.2 Servostat for 2in1 steering
L576-1759;
100 Brake system
100.1 Overview of brake system
L576-1759;
100.2 Service brake and parking brake
100.2.1 Brake pump
L576-1759;
100.2.2 Compact brake valve
L576-1759;
100.3 Parking brake
100.3.1 Parking brake
L576-1759;
11 0 Electrical system
110.1 Overview of electrical system
Service manual Contents
110.2 Lighting
L576-1759; 110-6
110.3 Circuit diagrams
L576-1759; 110-7
110.4 Electronic control unit 110-9
110.4.1 General overview of electronic control system
L576-1759; 110-9
110.4.2 Central control unit (Master5-Premium)
L576-1759; 110-11
110.4.3 Modules 110-14
110.4.3.1 Overview of the input and output modules
110.4.3.2 Input modules
110.4.3.3 Output modules
110.5 Electrical components of the driver’s cab 110-21
110.5.1 Fuse and relay boards
110.5.2 Door contact switch (inductive sensor)
110.6 Electrical components in the rear section 110-27
110.6.1 Battery installation
110.6.2 Electric battery main switch
120.1 Overview of transmission
120.2 Transmission hydraulics 120-16
120.2.1 Overview of transmission hydraulics
120.2.3 Transmission control valve block
120.2.4 Hydrostat module “”” “”” L576-1759; 120-24 “‘ ~ ID 120.3 Transmission electronics 120-29
120.3.1 Overview of electrical control system of transmission
120.3.2 Filter bypass switch
L576-1759; 120-30
120.3.3 Gear shifting proportional solenoid
L576-1759; 120-31
120.3.4 Pressure sensor for hydrostat
L576-1759; 120-32
120.3.5 Engine speed sensor
L576-1759; 120-33
120.3.6 Temperature sensor
L576-1759; 120-34
120.3.7 Proportional solenoid for position control
L576-1759; 120-34
130 Axles and drive shafts 130-1
130.1 Axles 130-2
130.1.1 Front axle
L576-1759; 130-2
130.1.2 Rear axle
L576-1759; 130-7
130.2 Cardan shafts 130-9
130.2.1 Drive shaft between diesel engine and transmission
L576-1759; 130-9
130.2.2 Drive shaft between transmission and front axle
130.2.3 Drive shaft between transmission and rear axle
140 Steel parts of the basic machine 140-1
140.1 Vehicle frame 140-2
140.1.1 Articulation bearing
140.1.2 Articulation lock
140.2 Covering i’
140.2.1 Linear motor for opening the engine hoo
150 Working attachment 150-1 iil
150.1 Lift arms for Z kinematics 150-2 “~’ ID
150.1.1 Z kinematics
150.2 Quick coupler 150-4
150.2.1 Quick coupler
L576-1759;
150.2.2 Quick coupler hydraulics
150.2.2.1
150.2.2.2
Overview of quick coupler hydraulics
L576-1759;
Valve block for quick coupler
L576-1759;
150.2.3 Quick coupler electrics
150.2.3.1 Quick coupler electric control unit
L576-1759;
160 Operator’s cab, heating and air conditioning
L576-1759
160.1 Overview of operator’s cab, heating and air conditioning unit
L576-1759;
160.2 Display and control elements
160.2.1 Control lever
L576-1759;
160.2.2 Accelerator pedal
L576-1759;
160.3 Heating, ventilation, air conditioning
160.3.1 Heating, ventilation, air conditioning: General overview
L576-1759;
160.3.2 Heating and air conditioning unit
Heating and air conditioning unit
Blower
160.3.3 Air conditioning controller
160.4 Air conditioning
160.4.1 Basic function of the air conditioning unit
160.4.2 Air conditioning compressor
160.4.3 Condenser
160.4.4 Dryer
160.4.5 Air conditioning pressure switch
Contents Service manual
170 Lubrication system 170-1
170.1 Liebherr automatic central lubrication system 170-2
170.1.1 Liebherr automatic central lubrication system: overview
L576-1759; 170-2
170.1.2 Liebherr central lubrication pump
L576-1759; 170-6
170.1.3 Progressive distributor MX-F
L576-1759; 170-10
170.1.4 Progressive distributor SXE-2
L576-1759; 170-12
190 Options 190-1
190.1 LiDAT 190-2
190.1.1 Overview of LiDAT
L576-1759; 190-2
190.1.2 LiDAT on machine
L576-1759; 190-4
190.1.3 LiDAT module (LiTU3)
L576-1759; 190-6
190.2 Liebherr weighing device with Truck Payload Assist
L576-1759; 190-10
190.3 Skyview 360° 190-12
190.3.1 Skyview 360°: complete overview
L576-1759; 190-12
190.3.2 Skyview 360° on machine
L576-1759; 190-16
190.4 Remote control for door lock
L576-1759; 190-17
190.5 Personnel detection
L576-1759; 190-20
190.6 Entfall des Lenkstockschalters 190-23
190.6.1 Elimination of steering-column switch: overview
L576-1759; 190-23 C: i CD
190.6.2 Additional controller (HY-TTC-30S) “…’
200.1 Malfunctions 200-2 “”””’ “””
200.1.1 Warning symbols 200-2 ~ ID
200.1.2 SCR system warning symbols 200-3
200.1.3 Service code indicator in display 200-4
copylight © Liebherr-Werk Bischofshofen GmbH 2020
28 llEBHERR L576-1759
Service manual
200.2 Troubleshooting
200.2.1 Replacing fuses
Fuses on fuse board A4 in the operator’s cab 200-6
Fuses on fuse board A4a in the left ballast weight 200-9
Fuses on fuse board A4b in the operator’s cab 200-11