Liebherr L 509 1582 Wheel Loader Service Manual – PDF DOWNLOAD
FILE DETAILS:
Liebherr L 509 1582 Wheel Loader Service Manual – PDF DOWNLOAD
Language : English
Pages : 790
Downloadable : Yes
File Type : PDF
Size: 160 MB
DESCRIPTION:
Liebherr L 509 1582 Wheel Loader Service Manual – PDF DOWNLOAD
Preface
Notes 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:
– Ask work site manager for safety regulations at place of use.
– Adhere to safety regulations at place of use.
-Adhere to traffic regulations.
-Adhere to valid guidelines from insurers (for example employers’ professional liability insurance companies, accident insurance et cetera).
-Avoid working methods that can endanger safety.
-Adhere to all intervals specified for recurrent checks and inspections in this
operator’s manual.
Intended use:
Wheel loader is used to pick up, move and dump following materials:
– Soil
– Stones
– Broken rocks
– Bulk materials
This applies to a standard machine in normal operating conditions. Special applications are described in a separate options operator’s manual.
To ensure intended use:
– Adhere to operator’s manual.
– Adhere to maintenance intervals.
– Observe inspection and maintenance tasks.
– Adhere to specifications in the technical data.
– When using machine on public roads, make sure it complies with applicable national regulations.
– Only lift loads with intended working attachments (fork prongs, crane boom), which must be fitted and functioning.
– Make sure that machines used underground (mining and tunnel construction) are fitted with systems to reduce exhaust emissions (such as diesel particulate filters).
– Adhere to individual country’s requirements 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 stipulations of manufacturer of basic machine.
– Only use approved tyres.
– A suitably equipped workshop is absolutely essential for performing repair work.
TABLE OF CONTENTS:
Liebherr L 509 1582 Wheel Loader 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 warming 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 010-14
010.1 Safety instructions 010-4
010.1.1 Information on these instructions 010-4
010.1.1.1 Representation of warming 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 010-14
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
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 service brake 010-28
010.2.8 Special tools for the electrical system 010-29
010.2.10 Special tools for front axle 010-30
010.2.11 Special tools for rear axle 010-30
010.2.12 Special tools for air conditioning system 010-31
010.2.13 Special tools for cab glazing 010-32
010.2.14 Special tools for the central lubrication system (Liebherr) 010-32
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 service brake 010-28
010.2.8 Special tools for the electrical system 010-29
010.2.10 Special tools for front axle 010-30
010.2.11 Special tools for rear axle 010-30
010.2.12 Special tools for air conditioning system 010-31
010.2.13 Special tools for cab glazing 010-32
010.2.14 Special tools for the central lubrication system (Liebherr) 010-32
Standards and regulations
Prestressing forces and tightening torques for bolts with metric
standard and fine threads as per DIN ISO 261 010-34
010.3.1.1 Range of application and purpose 010-34
010.3.1.2 Other applicable documents 010-34
010.3.1.3 Modifications and descriptions 010-35
010.3.1.1 Range of application and purpose 010-34
010.3.1.2 Other applicable documents 010-34
010.3.1.3 Modifications and descriptions 010-35
010-35
010.3.1.4 Tightening torques
010.3.2 Liebherr standards for assembly instructions and tightening torques010-41
010.4 Preservation guidelines 010-42
010.4.1 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 010-46
010.4.4.3 After being out of service for longer than 12 months 010-46
020 Technical data 020-1
020.1 Overall machine 020-4
020.1.1 Complete machine with bucket (z-bar kinematics)
L509-1582; 020-4
020.1.2 Working attachment: 4 in 1 bucket
L509-1582; 020-5
0201.3 Working attachment: light material bucket
L509-1582; 020-7
020.1.4 Working attachment: forklift
L509-1582; 020-8
020.2 Drive group 020-10
020.2.1 Diesel engine
L509-1582/0-53994; 020-10
0202.2 Diesel engine
L509-1582/53995-; 020-11
020.2.3 Fuel tank
L509-1582; 020-12
020.2.4 Fuel level sensor
L 509-1582; 020-13
020.3 Cooling system 020-14
020.3.1 Fan pump
L509-1582; 020-14
020.3.2 Fan motor
L509-1582; 020-14
020.3.3 Hydraulic oil temperature sensor B8
L509-1582; 020-14
020.4 Working hydraulics 020-15
copyright ® Liebherr-Werk Bischofshofen GmbH 2021
L509-1582 LIEBHERR 7
Contents
010.4 Preservation guidelines 010-42
010.4.1 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 010-46
010.4.4.3 After being out of service for longer than 12 months 010-46
020 Technical data 020-1
020.1 Overall machine 020-4
020.1.1 Complete machine with bucket (z-bar kinematics)
L509-1582; 020-4
020.1.2 Working attachment: 4 in 1 bucket
L509-1582; 020-5
0201.3 Working attachment: light material bucket
L509-1582; 020-7
020.1.4 Working attachment: forklift
L509-1582; 020-8
020.2 Drive group 020-10
020.2.1 Diesel engine
L509-1582/0-53994; 020-10
0202.2 Diesel engine
L509-1582/53995-; 020-11
020.2.3 Fuel tank
L509-1582; 020-12
020.2.4 Fuel level sensor
L 509-1582; 020-13
020.3 Cooling system 020-14
020.3.1 Fan pump
L509-1582; 020-14
020.3.2 Fan motor
L509-1582; 020-14
020.3.3 Hydraulic oil temperature sensor B8
L509-1582; 020-14
020.4 Working hydraulics 020-15
copyright ® Liebherr-Werk Bischofshofen GmbH 2021
L509-1582 LIEBHERR 7
Contents
Service manual
020.41 Working pump
L509-1582/0-61222; 020-15
020.4.2 Working pump
L509-1582/61223-; 020-15
020.4.3 Control block
L509-1582; 020-15
020.4.4 Pilot control unit
1509-1582; 020-15
020.4.5 Pilot control hydro accumulator
L509-1582; 020-16
020.4.6 Stabilisation module
1509-1582; 020-16
020.4.7 Ride control hydro accumulator
L509-1582; 020-16
020.4.8 Lift cylinder
L 509-1582; 020-16
020.4.9 Tilt cylinder
L509-1582; 020-17
020.4.10 Working pump
L 509-1582; 020-17
020.5 Travel hydraulics 020-18
020.5.1 Travel pump
L 509-1582; 020-18
020.5.2 Pressure sensor for high pressure of travel pump B102
1509-1582; 020-18
020.5.3 Travel motor
L509-1582; 020-18
020.6 Hydraulic components 020-20
020.6.1 Return suction filter
1509-1582; 020-20
020.6.2 Breather filter with filler strainer
1509-1582; 020-20
020.7 Steering system 020-21
020.7.1 Servostat
L509-1582; 020-21
020.7.2 Steering cylinder
1509-1582; 020-21
020.8 Brake system 020-22
020.8.1 Drum brake
L 509-1582; 020-22
020.8.2 Inch/brake unit
1509-1582; 020-22
020.8.3 Brake light pressure switch B12
L509-1582; 020-22
copyright © Liebher-Werk Bischofshofen GmbH 2021
8 LIEBHERR L509-1582
L509-1582/0-61222; 020-15
020.4.2 Working pump
L509-1582/61223-; 020-15
020.4.3 Control block
L509-1582; 020-15
020.4.4 Pilot control unit
1509-1582; 020-15
020.4.5 Pilot control hydro accumulator
L509-1582; 020-16
020.4.6 Stabilisation module
1509-1582; 020-16
020.4.7 Ride control hydro accumulator
L509-1582; 020-16
020.4.8 Lift cylinder
L 509-1582; 020-16
020.4.9 Tilt cylinder
L509-1582; 020-17
020.4.10 Working pump
L 509-1582; 020-17
020.5 Travel hydraulics 020-18
020.5.1 Travel pump
L 509-1582; 020-18
020.5.2 Pressure sensor for high pressure of travel pump B102
1509-1582; 020-18
020.5.3 Travel motor
L509-1582; 020-18
020.6 Hydraulic components 020-20
020.6.1 Return suction filter
1509-1582; 020-20
020.6.2 Breather filter with filler strainer
1509-1582; 020-20
020.7 Steering system 020-21
020.7.1 Servostat
L509-1582; 020-21
020.7.2 Steering cylinder
1509-1582; 020-21
020.8 Brake system 020-22
020.8.1 Drum brake
L 509-1582; 020-22
020.8.2 Inch/brake unit
1509-1582; 020-22
020.8.3 Brake light pressure switch B12
L509-1582; 020-22
copyright © Liebher-Werk Bischofshofen GmbH 2021
8 LIEBHERR L509-1582
LBH/M2234436/13/211-20211019_122128/en
Service manual Contents
Service manual Contents
020.9 Electrical system 020-23
020.9.1 Central control unit (Master 4)
L509-1582/0-60029; 020-23
020.9.2 Central control unit (Master5-Mini)
L509-1582/60030-; 020-23
020.9.3 Compact module
L509-1582; 020-23
020.9.4 Battery
1509-1582; 020-24
020.9.5 Voltage transformer
L509-1582; 020-24
020.10 Gearbox 020-25
020.10.1 Transmission
L509-1582; 020-25
020.10.2 Output B101 speed sensor
L509-1582; 020-25
020.10.3 Hydro accumulator for external servo pressure and service brake
L509-1582; 020-25
020.11 Axles and drive shafts 020-26
020.11.1 Front axle with engageable differential lockout
L509-1582; 020-26
020.11.2 Rear axle when front axle has engageable differential lockout
L509-1582; 020-26
020.11.3 Drive shaft
L509-1582; 020-26
020.11.4 Tyres
L509-1582; 020-26
020.11.4.2 Special tyres 020-27
020.12 Working attachment 020-29
020.12.1 Quick coupler locking hydraulic cylinder
L509-1582; 020-29
020.13 Operator’s cab, heating and air conditioning 020-30
g 020.13.1 Dryer
§ L509-1582; 020-30
g 020.13.2 Pressure switches
§ L509-1582; 020-30
§ 020.14 Lubrication system 020-31
3
3 020.14.1 Central lubrication pump EP1
8 1509-1582; 020-31
ES
3 020.14.2 Progressive distributor
L509-1582; 020-31
020.1421 MX-F 020-31
020.9.1 Central control unit (Master 4)
L509-1582/0-60029; 020-23
020.9.2 Central control unit (Master5-Mini)
L509-1582/60030-; 020-23
020.9.3 Compact module
L509-1582; 020-23
020.9.4 Battery
1509-1582; 020-24
020.9.5 Voltage transformer
L509-1582; 020-24
020.10 Gearbox 020-25
020.10.1 Transmission
L509-1582; 020-25
020.10.2 Output B101 speed sensor
L509-1582; 020-25
020.10.3 Hydro accumulator for external servo pressure and service brake
L509-1582; 020-25
020.11 Axles and drive shafts 020-26
020.11.1 Front axle with engageable differential lockout
L509-1582; 020-26
020.11.2 Rear axle when front axle has engageable differential lockout
L509-1582; 020-26
020.11.3 Drive shaft
L509-1582; 020-26
020.11.4 Tyres
L509-1582; 020-26
020.11.4.2 Special tyres 020-27
020.12 Working attachment 020-29
020.12.1 Quick coupler locking hydraulic cylinder
L509-1582; 020-29
020.13 Operator’s cab, heating and air conditioning 020-30
g 020.13.1 Dryer
§ L509-1582; 020-30
g 020.13.2 Pressure switches
§ L509-1582; 020-30
§ 020.14 Lubrication system 020-31
3
3 020.14.1 Central lubrication pump EP1
8 1509-1582; 020-31
ES
3 020.14.2 Progressive distributor
L509-1582; 020-31
020.1421 MX-F 020-31
copyright ® Liebherr-Werk Bischofshofen GmbH 2021
L509-1582 LIEBHERR 9
Contents Service manual
020.14.22 MX-F 25 020-31
020.14.2.3 MX-F 45 020-31
020.1424 MX-F75 020-32
020.1425 MX-F105 020-32
030 Maintenance 030-1
030.1 Maintenance and inspection schedule 030-10
030.2 Filling quantities and lubrication chart 030-15
030.2.1 Lubricant filling quantity
1509-1582; 030-15
030.22 Recommended operating fluids
1509-1582; 030-15
030.3 Lubricants and fuels 030-16
030.3.1 General information on lubricants and fuels 030-16
030.3.1.1 General questions 030-16
030.3.1.2 Safety data sheets 030-16
030.3.1.3 Technical data sheets 030-16
030.3.1.4 Specific Liebherr standards 030-16
030.3.2 General information on changing lubricants and fuels 030-16
030.3.3 Converting hydraulic system from mineral oils to biodegradable
hydraulic fluids 030-17
030.3.4 Diesel fuels
L509-1582/0-53994; 030-17
030.3.4.1 Minimum quality requirement 030-17
030.3.4.2 Operating temperatures of diesel fuels 030-17
030.3.43 Minimum quality requirement 030-18
030.3.5 Diesel fuels
L509-1582/53995-; 030-18
030.3.5.1 Minimum quality requirement 030-18
030.3.5.2 Operating temperatures of diesel fuels 030-18
030.3.5.3 Minimum quality requirement 030-18
030.3.6 Engine oils
1509-1582; 030-19
030.3.6.1 Liebherr recommendation 030-19
030.3.6.3 Minimum quality requirement 030-19
030.3.7 Refrigerant
1509-1582; 030-19
030.3.8 Coolant
L509-1582; 030-20
copyright © Liebherr-Werk Bischofshofen GmbH 2021
10 LIEBHERR 1509-1582
Contents Service manual
020.14.22 MX-F 25 020-31
020.14.2.3 MX-F 45 020-31
020.1424 MX-F75 020-32
020.1425 MX-F105 020-32
030 Maintenance 030-1
030.1 Maintenance and inspection schedule 030-10
030.2 Filling quantities and lubrication chart 030-15
030.2.1 Lubricant filling quantity
1509-1582; 030-15
030.22 Recommended operating fluids
1509-1582; 030-15
030.3 Lubricants and fuels 030-16
030.3.1 General information on lubricants and fuels 030-16
030.3.1.1 General questions 030-16
030.3.1.2 Safety data sheets 030-16
030.3.1.3 Technical data sheets 030-16
030.3.1.4 Specific Liebherr standards 030-16
030.3.2 General information on changing lubricants and fuels 030-16
030.3.3 Converting hydraulic system from mineral oils to biodegradable
hydraulic fluids 030-17
030.3.4 Diesel fuels
L509-1582/0-53994; 030-17
030.3.4.1 Minimum quality requirement 030-17
030.3.4.2 Operating temperatures of diesel fuels 030-17
030.3.43 Minimum quality requirement 030-18
030.3.5 Diesel fuels
L509-1582/53995-; 030-18
030.3.5.1 Minimum quality requirement 030-18
030.3.5.2 Operating temperatures of diesel fuels 030-18
030.3.5.3 Minimum quality requirement 030-18
030.3.6 Engine oils
1509-1582; 030-19
030.3.6.1 Liebherr recommendation 030-19
030.3.6.3 Minimum quality requirement 030-19
030.3.7 Refrigerant
1509-1582; 030-19
030.3.8 Coolant
L509-1582; 030-20
copyright © Liebherr-Werk Bischofshofen GmbH 2021
10 LIEBHERR 1509-1582
LBH/M2234436/13/211-20211019_122128/en
LBH/M2234436/13/211-20211019_122129/en
LBH/M2234436/13/211-20211019_122129/en
Service manual
Contents
030.4
030.3.8.1 Requirements for the water used 030-20
030.3.8.2 Antifreeze and corrosion inhibitor 030-20
030.3.8.3 Minimum quality requirement 030-20
030.3.9 Hydraulic oil
030.3.9 Hydraulic oil
L 509-1582; 030-20
030.3.9.1 Liebherr recommendation 030-20
030.3.9.2 Minimum quality requirement 030-21
030.3.9.3 Qil analysis 030-21
030.3.9.4 Qil change 030-21
030.3.10 Transmission
030.3.10 Transmission
1509-1582; 030-22
030.3.10.1 Liebherr recommendation 030-22
030.3.10.2 Minimum quality requirement 030-22
030.3.11 Axle oil
030.3.11 Axle oil
L 509-1582; 030-22
030.3.11.1 Liebherr recommendation 030-22
030.3.11.2 Minimum quality requirement 030-22
030.3.12 Brake oil
030.3.12 Brake oil
L 509-1582; 030-23
030.3.12.1 Liebherr recommendation 030-23
030.3.13 Lubrication grease
030.3.13 Lubrication grease
L509-1582; 030-23
030.3.13.1 Liebherr recommendation 030-23
030.3.13.2 Minimum quality requirement 030-23
030.3.14 Windscreen washer fluid
030.3.14 Windscreen washer fluid
L509-1582; 030-23
030.3.14.1 Liebherr recommendation 030-23
030.3.14.2 Minimum quality requirement 030-24
030.3.15 Refrigerant oil for air conditioning compressor
030.3.15 Refrigerant oil for air conditioning compressor
L509-1582; 030-24
030.3.15.1 Liebherr recommendation 030-24
Maintenance tasks 030-25
0304.1 Safety precautions
Maintenance tasks 030-25
0304.1 Safety precautions
L509-1582; 030-25
0304.2 Preparatory tasks for maintenance 030-25
0304.2 Preparatory tasks for maintenance 030-25
030.421 Maintenance positions
L 509-1582; 030-26
030.4.2.2 Opening service hatches
L 509-1582; 030-27
030.4.2.2 Opening service hatches
L 509-1582; 030-27
L509-1682
copyright ® Liebherr-Werk Bischofshofen GmbH 2021
LIEBHERR 1
Contents Service manual
0304.23 Turning off battery main switch
L509-1582; 030-28
030.4.3 Overall machine 030-29
030.4.3.1 Checking machine is in proper condition
L509-1582; 030-29
030.4.3.2 Removing loose parts, dirt, ice and snow from
machine
L509-1582; 030-31
0304.3.3 Cleaning machine
1509-1582; 030-31
030.4.3.4 Replacing VCI capsules
L509-1582; 030-34
0304.3.5 Operating fluid analysis: General specifications
1509-1582; 030-37
030.4.3.6 Operating fluid analysis: filling out sample information
form
1509-1582; 030-40
030.4.3.7 Fuel and operating fluid analysis: scope of analysis
1509-1582; 030-46
0304.3.8 Analysis of lubricants and fuels
L509-1582; 030-50
030.4.4 Drive group 030-56
030.4.4.1 Checking diesel engine oil level
L509-1582; 030-56
0304.4.2 Diesel engine: changing diesel engine oil
L509-1582; 030-58
030.4.4.3 Diesel engine: changing oil filter
1509-1582; 030-60
0304.4.4 Diesel engine: checking V-belt
1509-1582; 030-62
0304.45 Diesel engine: changing V-belt
1509-1582; 030-64
0304.46 Diesel engine: checking valve clearance
L509-1582; 030-65
030.4.4.7 Draining condensate and sediment from the fuel tank
1509-1582; 030-69
0304.4.8 Draining off condensate from fuel pre-filter
L509-1582; 030-70
0304.49 Changing fuel pre-filter element
1509-1582; 030-71
030.4.4.10 Changing fuel fine filter element
L509-1582; 030-73
030.4.4.11 Cleaning service cover and dust discharge valve of
air filter system
L509-1582; 030-74
copyright © Liebher-Werk Bischofshofen GmbH 2021
12 LIEBHERR 1509-1582
Contents Service manual
0304.23 Turning off battery main switch
L509-1582; 030-28
030.4.3 Overall machine 030-29
030.4.3.1 Checking machine is in proper condition
L509-1582; 030-29
030.4.3.2 Removing loose parts, dirt, ice and snow from
machine
L509-1582; 030-31
0304.3.3 Cleaning machine
1509-1582; 030-31
030.4.3.4 Replacing VCI capsules
L509-1582; 030-34
0304.3.5 Operating fluid analysis: General specifications
1509-1582; 030-37
030.4.3.6 Operating fluid analysis: filling out sample information
form
1509-1582; 030-40
030.4.3.7 Fuel and operating fluid analysis: scope of analysis
1509-1582; 030-46
0304.3.8 Analysis of lubricants and fuels
L509-1582; 030-50
030.4.4 Drive group 030-56
030.4.4.1 Checking diesel engine oil level
L509-1582; 030-56
0304.4.2 Diesel engine: changing diesel engine oil
L509-1582; 030-58
030.4.4.3 Diesel engine: changing oil filter
1509-1582; 030-60
0304.4.4 Diesel engine: checking V-belt
1509-1582; 030-62
0304.45 Diesel engine: changing V-belt
1509-1582; 030-64
0304.46 Diesel engine: checking valve clearance
L509-1582; 030-65
030.4.4.7 Draining condensate and sediment from the fuel tank
1509-1582; 030-69
0304.4.8 Draining off condensate from fuel pre-filter
L509-1582; 030-70
0304.49 Changing fuel pre-filter element
1509-1582; 030-71
030.4.4.10 Changing fuel fine filter element
L509-1582; 030-73
030.4.4.11 Cleaning service cover and dust discharge valve of
air filter system
L509-1582; 030-74
copyright © Liebher-Werk Bischofshofen GmbH 2021
12 LIEBHERR 1509-1582
LBH/M2234436/13/211-20211019_122128/en
LBH/M2234436/13/211-20211019_122129/en
LBH/M2234436/13/211-20211019_122129/en
Service manual
Contents
030.4.4.12 Checking air filter vacuum switch function
L509-1582; 030-75
030.4.4.13 Cleaning or changing main element of air filter
system
1509-1582; 030-77
030.4.4.14 Changing safety element of air filter system
L509-1582; 030-79
030.4.4.15 Checking that diesel engine intake and exhaust
system is in good condition and not loose or leaking
L509-1582; 030-80
030.4.4.16 Cleaning or changing diesel particulate filter
1509-1582; 030-83
0304.5 Cooling system 030-89
030.4.5.1 Checking coolant level in cooling system
1509-1582; 030-89
030.4.5.2 Coolant: checking anti-freeze and corrosion protec-
tion agent concentration
1509-1582; 030-91
030.4.5.3 Cleaning cooling system
L509-1582; 030-98
030.45.4 Cooling system: changing coolant
1509-1582; 030-99
030.46 Working hydraulics 030-102
030.4.6.1 Cleaning and lubricating the pilot control unit
1509-1582; 030-102
0304.7 Hydraulic components 030-102
030.4.7.1 Checking oil level in hydraulic tank
L509-1582; 030-102
030.4.7.2 Draining off condensate and sediment from hydraulic
tank
1509-1582; 030-104
030.4.7.3 Hydraulic tank: changing filter cartridge in return-
suction filter
1509-1582; 030-106
030.4.7.4 Changing the hydraulic tank breather filter
L 509-1582; 030-107
030.4.7.5 Hydraulic tank: changing oil
L509-1582; 030-107
030.4.8 Steering system 030-110
030.4.8.1 Test steering
L 509-1582; 030-110
030.4.8.2 Steering cylinder: lubricating bearing
1509-1582; 030-110
030.4.9 Brake system 030-111
copyright ® Liebherr-Werk Bischofshofen GmbH 2021
1509-1582 LIEBHERR 13
Contents
L509-1582; 030-75
030.4.4.13 Cleaning or changing main element of air filter
system
1509-1582; 030-77
030.4.4.14 Changing safety element of air filter system
L509-1582; 030-79
030.4.4.15 Checking that diesel engine intake and exhaust
system is in good condition and not loose or leaking
L509-1582; 030-80
030.4.4.16 Cleaning or changing diesel particulate filter
1509-1582; 030-83
0304.5 Cooling system 030-89
030.4.5.1 Checking coolant level in cooling system
1509-1582; 030-89
030.4.5.2 Coolant: checking anti-freeze and corrosion protec-
tion agent concentration
1509-1582; 030-91
030.4.5.3 Cleaning cooling system
L509-1582; 030-98
030.45.4 Cooling system: changing coolant
1509-1582; 030-99
030.46 Working hydraulics 030-102
030.4.6.1 Cleaning and lubricating the pilot control unit
1509-1582; 030-102
0304.7 Hydraulic components 030-102
030.4.7.1 Checking oil level in hydraulic tank
L509-1582; 030-102
030.4.7.2 Draining off condensate and sediment from hydraulic
tank
1509-1582; 030-104
030.4.7.3 Hydraulic tank: changing filter cartridge in return-
suction filter
1509-1582; 030-106
030.4.7.4 Changing the hydraulic tank breather filter
L 509-1582; 030-107
030.4.7.5 Hydraulic tank: changing oil
L509-1582; 030-107
030.4.8 Steering system 030-110
030.4.8.1 Test steering
L 509-1582; 030-110
030.4.8.2 Steering cylinder: lubricating bearing
1509-1582; 030-110
030.4.9 Brake system 030-111
copyright ® Liebherr-Werk Bischofshofen GmbH 2021
1509-1582 LIEBHERR 13
Contents
Service manual
030.4.10
030.4.11
030.4.12
030.4.13
030.4.9.1 Testing service brake and parking brake
L509-1582; 030-111
0304.9.2 Checking the oil level in the brake system
0304.9.2 Checking the oil level in the brake system
1509-1582; 030-112
0304.93 Checking gap and wear on service brake linings
0304.93 Checking gap and wear on service brake linings
L509-1582; 030-114
0304.94 Checking service brake discs for wear
0304.94 Checking service brake discs for wear
L509-1582; 030-115
Electrical system 030-117
030.4.10.1 Checking function of lighting and horn
Electrical system 030-117
030.4.10.1 Checking function of lighting and horn
1509-1582; 030-117
0304.10.2 Checking battery fluid levels and terminals
0304.10.2 Checking battery fluid levels and terminals
L509-1582; 030-118
030.4.10.3 Use the control lever to change the travel direction
030.4.10.3 Use the control lever to change the travel direction
switch rocker and cap.
L509-1582; 030-120
Gearbox 030-123
0304.11.1 Transmission: checking oil level
Gearbox 030-123
0304.11.1 Transmission: checking oil level
L509-1582; 030-123
030.4.11.2 Transmission: changing oil
030.4.11.2 Transmission: changing oil
L509-1582; 030-124
Axles and drive shafts 030-125
0304.12.1 Checking the axle oil levels
Axles and drive shafts 030-125
0304.12.1 Checking the axle oil levels
L509-1582; 030-125
030.4.12.2 Changing the axle oil
030.4.12.2 Changing the axle oil
L509-1582; 030-127
030.4.12.3 Lubricating rear axle kingpin bearings
030.4.12.3 Lubricating rear axle kingpin bearings
L509-1582; 030-130
030.4.12.4 Checking fitting of rear axle kingpin bearings and
030.4.12.4 Checking fitting of rear axle kingpin bearings and
steering rod taper connections
L509-1582; 030-130
0304.12.5 Checking tightening torque of front axle fastening
0304.12.5 Checking tightening torque of front axle fastening
bolts
1509-1582; 030-131
0304.12.86 Checking and lubricating drive shaft
0304.12.86 Checking and lubricating drive shaft
1509-1582; 030-132
030.4.12.7 Tyres: checking tyre pressure
030.4.12.7 Tyres: checking tyre pressure
1509-1582; 030-133
030.4.12.8 Checking wheel tightness
030.4.12.8 Checking wheel tightness
L509-1582; 030-133
Steel parts of the basic machine 030-134
030.4.13.1 Lubricating articulated bearing
Steel parts of the basic machine 030-134
030.4.13.1 Lubricating articulated bearing
1509-1582; 030-134
0304.13.2 Lubricating articulation stops
0304.13.2 Lubricating articulation stops
L509-1582; 030-135
14
copyright © Liebher-Werk Bischofshofen GmbH 2021
L509-1582
LBH/M2234436/13/211-20211019_122128/en
LBH/M2234436/13/211-20211019_122129/en
LBH/M2234436/13/211-20211019_122129/en
Service manual
Contents
030.4.13.3 Engine bonnet: lubricating moving parts with pene-
trating oil
1509-1582; 030-135
030.4.13.4 Service hatches: cleaning and maintaining seals
1509-1582; 030-136
0304.14 Working attachment 030-137
030.4.14.1 Lubricating the lift arms and working attachment
L509-1582; 030-137
030.4.14.2 Checking lift arm bucket bearing bushings
1509-1582; 030-138
030.4.14.3 Checking the lift arm bucket stops
L509-1582; 030-138
030.4.14.4 Quick coupler: checking function
1509-1582; 030-139
030.4.14.5 Cleaning LIKUFIX hydraulic coupling
L 509-1582; 030-140
0304.15 Operator’s cab, heating and air conditioning 030-140
030.4.15.1 Cleaning operator’s cab air filter
L509-1582; 030-140
030.4.15.2 Changing operator’s cab air filter
L509-1582; 030-141
030.4.15.3 Safety belt: checking condition and function
1509-1582; 030-141
030.4.15.4 Windscreen washer system: testing
L509-1582; 030-142
030.4.15.5 Windscreen washer system: filling windscreen
washer fluid
1509-1582; 030-142
030.4.15.6 Operator’s cab: lubricating locking mechanism and
cylinder with penetrating oil
1509-1582; 030-143
030.4.15.7 Operator’s cab: cleaning and maintaining seals
L509-1582; 030-144
030.4.15.8 Air conditioning: checking V-belt
1509-1582; 030-145
030.4.15.9 Air conditioning: changing V-belt
L 509-1582; 030-147
030.4.15.10 Checking the indicator bead in the air conditioning
dryer-collector unit
L509-1582; 030-149
030.4.15.11 Heating and air conditioning unit: Testing function
L509-1582; 030-150
030.4.16 Lubrication system 030-151
trating oil
1509-1582; 030-135
030.4.13.4 Service hatches: cleaning and maintaining seals
1509-1582; 030-136
0304.14 Working attachment 030-137
030.4.14.1 Lubricating the lift arms and working attachment
L509-1582; 030-137
030.4.14.2 Checking lift arm bucket bearing bushings
1509-1582; 030-138
030.4.14.3 Checking the lift arm bucket stops
L509-1582; 030-138
030.4.14.4 Quick coupler: checking function
1509-1582; 030-139
030.4.14.5 Cleaning LIKUFIX hydraulic coupling
L 509-1582; 030-140
0304.15 Operator’s cab, heating and air conditioning 030-140
030.4.15.1 Cleaning operator’s cab air filter
L509-1582; 030-140
030.4.15.2 Changing operator’s cab air filter
L509-1582; 030-141
030.4.15.3 Safety belt: checking condition and function
1509-1582; 030-141
030.4.15.4 Windscreen washer system: testing
L509-1582; 030-142
030.4.15.5 Windscreen washer system: filling windscreen
washer fluid
1509-1582; 030-142
030.4.15.6 Operator’s cab: lubricating locking mechanism and
cylinder with penetrating oil
1509-1582; 030-143
030.4.15.7 Operator’s cab: cleaning and maintaining seals
L509-1582; 030-144
030.4.15.8 Air conditioning: checking V-belt
1509-1582; 030-145
030.4.15.9 Air conditioning: changing V-belt
L 509-1582; 030-147
030.4.15.10 Checking the indicator bead in the air conditioning
dryer-collector unit
L509-1582; 030-149
030.4.15.11 Heating and air conditioning unit: Testing function
L509-1582; 030-150
030.4.16 Lubrication system 030-151
L509-1682
copyright ® Liebherr-Werk Bischofshofen GmbH 2021
LIEBHERR 15
Contents
Contents
Service manual
030.6
030.4.16.1 Central lubrication system: checking level in grease
reservoir
1509-1582; 030-151
030.4.16.2 Central lubrication system: checking pipes, hoses
and lubrication points for leaks and damage.
L509-1582; 030-152
030.4.16.3 Central lubrication system: checking lubrication of
bearings
1509-1582; 030-153
030.5 Testing and adjustment checklist
1509-1582; 030-154
Testing and adjustment tasks 030-159
030.6.1 Safety precautions
1509-1582; 030-159
030.6.2 Overall machine 030-159
030.6.2.1 Preparing for adjustment procedures
1509-1582; 030-159
0306.2.2 Hydraulic oil and coolant: operating temperature
L509-1582; 030-161
030.6.3 Drive group 030-162
030.6.3.1 Pedals: calibration
1509-1582; 030-162
0306.3.2 Diesel engine speed
L509-1582; 030-163
030.6.3.3 Reading the diesel engine service files
1509-1582; 030-164
030.6.3.4 Performing a service regeneration on diesel particu-
late filter
1509-1582; 030-166
030.6.3.5 Diesel engine: changing engine control unit (ECU)
1509-1582; 030-167
030.6.4 Cooling system 030-177
030.6.4.1 Fan motor: fan speed proportional solenoid
L509-1582; 030-177
030.6.5 Working hydraulics 030-180
030.6.5.1 Control valve block: secondary pressure relief valves
1509-1582; 030-180
030.6.5.2 Control valve block: primary pressure relief valve
L509-1582; 030-182
0306.5.3 Control block: reduction of tilt-out speed (option)
1509-1582; 030-184
030.6.5.4 Stabilisation module (option), safety valve
L509-1582; 030-185
reservoir
1509-1582; 030-151
030.4.16.2 Central lubrication system: checking pipes, hoses
and lubrication points for leaks and damage.
L509-1582; 030-152
030.4.16.3 Central lubrication system: checking lubrication of
bearings
1509-1582; 030-153
030.5 Testing and adjustment checklist
1509-1582; 030-154
Testing and adjustment tasks 030-159
030.6.1 Safety precautions
1509-1582; 030-159
030.6.2 Overall machine 030-159
030.6.2.1 Preparing for adjustment procedures
1509-1582; 030-159
0306.2.2 Hydraulic oil and coolant: operating temperature
L509-1582; 030-161
030.6.3 Drive group 030-162
030.6.3.1 Pedals: calibration
1509-1582; 030-162
0306.3.2 Diesel engine speed
L509-1582; 030-163
030.6.3.3 Reading the diesel engine service files
1509-1582; 030-164
030.6.3.4 Performing a service regeneration on diesel particu-
late filter
1509-1582; 030-166
030.6.3.5 Diesel engine: changing engine control unit (ECU)
1509-1582; 030-167
030.6.4 Cooling system 030-177
030.6.4.1 Fan motor: fan speed proportional solenoid
L509-1582; 030-177
030.6.5 Working hydraulics 030-180
030.6.5.1 Control valve block: secondary pressure relief valves
1509-1582; 030-180
030.6.5.2 Control valve block: primary pressure relief valve
L509-1582; 030-182
0306.5.3 Control block: reduction of tilt-out speed (option)
1509-1582; 030-184
030.6.5.4 Stabilisation module (option), safety valve
L509-1582; 030-185
16
copyright © Liebher-Werk Bischofshofen GmbH 2021
LIEBHERR L509-1582
LBH/M2234436/13/211-20211019_122128/en
LBH/M2234436/13/211-20211019_122129/en
LBH/M2234436/13/211-20211019_122129/en
Service manual
Contents
030.6.6
030.6.7
030.6.8
030.6.9
030.6.5.5 Ride control hydro accumulator (option): nitrogen
filling
1509-1582; 030-187
Hydraulic components 030-189
030.6.6.1 Checking the hydraulic lines for damage
Hydraulic components 030-189
030.6.6.1 Checking the hydraulic lines for damage
1509-1582; 030-189
Travel hydraulics 030-194
030.6.7.1 Travel pump high pressure sensor B102: Deviation
Travel hydraulics 030-194
030.6.7.1 Travel pump high pressure sensor B102: Deviation
1509-1582; 030-194
030.6.7.2 Travel pump replenishing pressure relief valve
030.6.7.2 Travel pump replenishing pressure relief valve
1509-1582; 030-195
030.6.7.3 Travel pump: high pressure relief valves
030.6.7.3 Travel pump: high pressure relief valves
L509-1582; 030-197
030.6.7.4 Travel pump: pressure cut-off
030.6.7.4 Travel pump: pressure cut-off
1509-1582; 030-200
030.6.7.5 Travel pump: manual block curve calibration (up to
software version (Master4) 013, from software
version (Master4) 017 or from serial number 60030)
L509-1582; 030-202
software version (Master4) 013, from software
version (Master4) 017 or from serial number 60030)
L509-1582; 030-202
030.6.7.6 Travel pump: manual block curve calibration (from
software version (Master4) 014 to 016)
L509-1582; 030-203
software version (Master4) 014 to 016)
L509-1582; 030-203
030.6.7.7 Travel pump: automatic block curve calibration (from
software version (Master4) 020 or from serial number
software version (Master4) 020 or from serial number
60030)
L509-1582; 030-206
030.6.7.8 Travel motor: manual calibration (maximum swivel
030.6.7.8 Travel motor: manual calibration (maximum swivel
angle)
1509-1582; 030-206
030.6.7.9 = Travel motor: manual calibration (minimum swivel
030.6.7.9 = Travel motor: manual calibration (minimum swivel
angle)
1509-1582; 030-208
Brake system 030-210
030.6.8.1 Inching brake pedal: basic setting
Brake system 030-210
030.6.8.1 Inching brake pedal: basic setting
1509-1582; 030-210
030.6.8.2 Angle sensor for inching function: checking basic
030.6.8.2 Angle sensor for inching function: checking basic
setting
1509-1582; 030-211
030.6.8.3 Service brake: brake pressure in 1st brake circuit
030.6.8.3 Service brake: brake pressure in 1st brake circuit
L509-1582; 030-212
Electrical system 030-214
Electrical system 030-214
030.6.9.1 Central control unit (Master4) Creating a Servicefile
L509-1582/0-60029; 030-214
L509-1582/0-60029; 030-214
030.6.9.2 Central control unit (Master5): creating service file
L509-1582/60030-; 030-217
L509-1582/60030-; 030-217
L509-1682
copyright ® Liebherr-Werk Bischofshofen GmbH 2021
LIEBHERR 17
Contents Service manual
030.6.9.3 Updating the central controller software
L509-1582/0-60029; 030-218
0306.9.4 Central control unit (Master5): software update
L509-1582/60030~; 030-220
0306.9.5 Setting the IP addresses of the central control unit
(Master4)
L509-1582; 030-224
030.6.9.6 Resetting the central control unit (Master4)
L509-1582/0-60029; 030-226
0306.9.7 Central control unit (Master5): resetting to factory
settings
L509-1582/60030~; 030-228
030.6.9.8 Central control unit (Master5): connecting Sculi diag-
nostic software
L509-1582/60030-; 030-229
030.6.9.9 Central control unit (Master5): connecting LiFT func-
tion
L509-1582/60030-; 030-233
030.6.9.10 Addressing CAN module and checking system infor-
mation
1509-1582; 030-234
030.6.10 Gearbox 030-236
030.6.10.1 Gearbox: external servo pressure reducing valve
L 509-1582; 030-236
0306.10.2 External servo pressure hydro accumulator nitrogen
filling
1509-1582; 030-238
030.6.11 Axles and drive shafts 030-241
030.6.11.1 Tyres: setting radius
1509-1582; 030-241
030.6.12 Options 030-242
030.6.12.1 LiDAT: connecting to LIDAT module
L509-1582; 030-242
030.6.12.2 LiDAT: software update for LIDAT module
1509-1582; 030-244
030.6.12.3 LiDAT: creating report and snapshot
L509-1582; 030-246
040 Drive group 040-1
040.1 Engine 040-2
040.1.1 Diesel engine overview
L509-1582; 040-2
040.1.2 Electrical components of diesel engine
1509-1582; 040-10
040.1.3 Fuel system 040-11
copyright © Liebher-Werk Bischofshofen GmbH 2021
18 LIEBHERR 1509-1582
Contents Service manual
030.6.9.3 Updating the central controller software
L509-1582/0-60029; 030-218
0306.9.4 Central control unit (Master5): software update
L509-1582/60030~; 030-220
0306.9.5 Setting the IP addresses of the central control unit
(Master4)
L509-1582; 030-224
030.6.9.6 Resetting the central control unit (Master4)
L509-1582/0-60029; 030-226
0306.9.7 Central control unit (Master5): resetting to factory
settings
L509-1582/60030~; 030-228
030.6.9.8 Central control unit (Master5): connecting Sculi diag-
nostic software
L509-1582/60030-; 030-229
030.6.9.9 Central control unit (Master5): connecting LiFT func-
tion
L509-1582/60030-; 030-233
030.6.9.10 Addressing CAN module and checking system infor-
mation
1509-1582; 030-234
030.6.10 Gearbox 030-236
030.6.10.1 Gearbox: external servo pressure reducing valve
L 509-1582; 030-236
0306.10.2 External servo pressure hydro accumulator nitrogen
filling
1509-1582; 030-238
030.6.11 Axles and drive shafts 030-241
030.6.11.1 Tyres: setting radius
1509-1582; 030-241
030.6.12 Options 030-242
030.6.12.1 LiDAT: connecting to LIDAT module
L509-1582; 030-242
030.6.12.2 LiDAT: software update for LIDAT module
1509-1582; 030-244
030.6.12.3 LiDAT: creating report and snapshot
L509-1582; 030-246
040 Drive group 040-1
040.1 Engine 040-2
040.1.1 Diesel engine overview
L509-1582; 040-2
040.1.2 Electrical components of diesel engine
1509-1582; 040-10
040.1.3 Fuel system 040-11
copyright © Liebher-Werk Bischofshofen GmbH 2021
18 LIEBHERR 1509-1582
LBH/M2234436/13/211-20211019_122128/en
LBH/M2234436/13/211-20211019_122129/en
LBH/M2234436/13/211-20211019_122129/en
Service manual
Contents
040.1.3.1 Overview of fuel system
L509-1582; 040-12
040.1.3.2 Fuel level sensor
L 509-1582; 040-14
040.1.3.3 Fuel pre-filter
L509-1582; 040-16
040.1.3.4 Fuel fine filter
L 509-1582; 040-17
040.14 Air filter system 040-17
040.1.4.1 Air filter
L 509-1582; 040-18
040.1.4.2 Vacuum switch for air filter
L509-1582; 040-19
040.1.5 Exhaust system 040-19
040.1.5.1 Overview of diesel particulate filter
L 509-1582; 040-20
050 Cooling system 050-1
050.1 Overview of cooling system
1509-1582; 050-2
050.2 Cooling system hydraulics 050-3
050.2.1 Overview of cooling system hydraulics
L509-1582; 050-3
050.2.2 Fan pump
L509-1582; 050-6
050.2.3 Fan motor
L509-1582; 050-7
050.3 Cooling system electronics 050-9
050.3.1 General overview of electronic control system
L509-1582; 050-9
050.3.2 Hydraulic oil temperature sensor
L509-1582; 050-12
050.4 Cooler 050-14
050.4.1 Cooler unit
L509-1582; 050-14
050.5 Reversible fan drive 050-15
050.5.1 Overview of reversible fan drive
L509-1582; 050-15
050.5.2 Fan reversal valve block
L509-1582; 050-18
copyright ® Liebherr-Werk Bischofshofen GmbH 2021
L509-1582 LIEBHERR 19
Contents Service manual
L509-1582; 040-12
040.1.3.2 Fuel level sensor
L 509-1582; 040-14
040.1.3.3 Fuel pre-filter
L509-1582; 040-16
040.1.3.4 Fuel fine filter
L 509-1582; 040-17
040.14 Air filter system 040-17
040.1.4.1 Air filter
L 509-1582; 040-18
040.1.4.2 Vacuum switch for air filter
L509-1582; 040-19
040.1.5 Exhaust system 040-19
040.1.5.1 Overview of diesel particulate filter
L 509-1582; 040-20
050 Cooling system 050-1
050.1 Overview of cooling system
1509-1582; 050-2
050.2 Cooling system hydraulics 050-3
050.2.1 Overview of cooling system hydraulics
L509-1582; 050-3
050.2.2 Fan pump
L509-1582; 050-6
050.2.3 Fan motor
L509-1582; 050-7
050.3 Cooling system electronics 050-9
050.3.1 General overview of electronic control system
L509-1582; 050-9
050.3.2 Hydraulic oil temperature sensor
L509-1582; 050-12
050.4 Cooler 050-14
050.4.1 Cooler unit
L509-1582; 050-14
050.5 Reversible fan drive 050-15
050.5.1 Overview of reversible fan drive
L509-1582; 050-15
050.5.2 Fan reversal valve block
L509-1582; 050-18
copyright ® Liebherr-Werk Bischofshofen GmbH 2021
L509-1582 LIEBHERR 19
Contents Service manual
060 Working hydraulics 060-1
0680.1 Overview of working hydraulics
L509-1582; 060-3
060.2 Working pump
L509-1582/0-61222; 060-9
060.3 Working pump
L509-1582/61223-; 060-12
060.4 Control block
L509-1582; 060-15
060.5 Pilot control 060-24
060.5.1 Overview of pilot control unit
L509-1582; 060-24
060.5.2 Pilot control unit
L 509-1582; 060-28
060.5.3 Pilot pressure for solenoid valve
L509-1582; 060-30
060.6 Ride control 060-32
060.6.1 Overview of ride control system
L509-1582; 060-32
060.6.2 Stabilisation module
L509-1582; 060-36
060.7 Regulated flow rate 060-41
060.7.1 Regulated flow rate: total overview
L 509-1582; 060-41
060.7.2 Valve block for regulated flow rate
L509-1582; 060-43
080.8 Pipe break protection 060-45
060.8.1 Pipe break protection: overview
L509-1582; 060-45
060.8.2 Valve block for pipe break protection
1509-1582; 060-47
060.8.3 Ride control release solenoid valve
L509-1582; 060-48
060.9 High flow 060-50
060.9.1 High Flow: total overview
1509-1582; 060-50
060.9.2 High Flow pump
L509-1582; 060-53
060.9.3 Solenoid valve for High Flow
L 509-1582; 060-54
0680.1 Overview of working hydraulics
L509-1582; 060-3
060.2 Working pump
L509-1582/0-61222; 060-9
060.3 Working pump
L509-1582/61223-; 060-12
060.4 Control block
L509-1582; 060-15
060.5 Pilot control 060-24
060.5.1 Overview of pilot control unit
L509-1582; 060-24
060.5.2 Pilot control unit
L 509-1582; 060-28
060.5.3 Pilot pressure for solenoid valve
L509-1582; 060-30
060.6 Ride control 060-32
060.6.1 Overview of ride control system
L509-1582; 060-32
060.6.2 Stabilisation module
L509-1582; 060-36
060.7 Regulated flow rate 060-41
060.7.1 Regulated flow rate: total overview
L 509-1582; 060-41
060.7.2 Valve block for regulated flow rate
L509-1582; 060-43
080.8 Pipe break protection 060-45
060.8.1 Pipe break protection: overview
L509-1582; 060-45
060.8.2 Valve block for pipe break protection
1509-1582; 060-47
060.8.3 Ride control release solenoid valve
L509-1582; 060-48
060.9 High flow 060-50
060.9.1 High Flow: total overview
1509-1582; 060-50
060.9.2 High Flow pump
L509-1582; 060-53
060.9.3 Solenoid valve for High Flow
L 509-1582; 060-54
copyright © Liebher-Werk Bischofshofen GmbH 2021
20 LIEBHERR L509-1582
LBH/M2234436/13/211-20211019_122128/en
LBH/M2234436/13/211-20211019_122129/en
LBH/M2234436/13/211-20211019_122129/en
Service manual
Contents
070 Travel hydraulics 070-1
070.1 Overview of travel hydraulics
1509-1582; 070-2
070.2 Travel pump
L509-1582; 070-9
070.3 Travel motors 070-25
070.3.1 Travel motor
L509-1582; 070-25
080 Hydraulic components 080-1
080.1 Hydraulic system: overview
L509-1582; 080-2
080.2 Hydraulic tank 080-5
0802.1 Overview of the hydraulic tank
L509-1582; 080-5
080.2.2 Return suction filter
L509-1582; 080-7
0802.3 Breather filter
L509-1582; 080-13
090 Steering system 090-1
090.1 Steering system overview
L509-1582; 090-2
090.2 Servostat
L509-1582; 090-6
100 Brake system 100-1
100.1 Overview of brake system
1509-1582; 100-2
100.2 Service brake 100-7
100.2.1 Inch/brake unit
L509-1582; 100-7
100.2.2 Inching function angle sensor
L509-1582; 100-13
100.2.3 Brake light pressure switch
L509-1582; 100-15
100.24 Drum brake
L509-1582; 100-16
100.3 Parking brake 100-21
100.3.1 Valve block for parking brake and differential lockout
L509-1582; 100-21
100.3.2 Orifice bypass solenoid valve
L509-1582; 100-23
copyright ® Liebherr-Werk Bischofshofen GmbH 2021
1509-1582 LIEBHERR 21
Contents Service manual
070.1 Overview of travel hydraulics
1509-1582; 070-2
070.2 Travel pump
L509-1582; 070-9
070.3 Travel motors 070-25
070.3.1 Travel motor
L509-1582; 070-25
080 Hydraulic components 080-1
080.1 Hydraulic system: overview
L509-1582; 080-2
080.2 Hydraulic tank 080-5
0802.1 Overview of the hydraulic tank
L509-1582; 080-5
080.2.2 Return suction filter
L509-1582; 080-7
0802.3 Breather filter
L509-1582; 080-13
090 Steering system 090-1
090.1 Steering system overview
L509-1582; 090-2
090.2 Servostat
L509-1582; 090-6
100 Brake system 100-1
100.1 Overview of brake system
1509-1582; 100-2
100.2 Service brake 100-7
100.2.1 Inch/brake unit
L509-1582; 100-7
100.2.2 Inching function angle sensor
L509-1582; 100-13
100.2.3 Brake light pressure switch
L509-1582; 100-15
100.24 Drum brake
L509-1582; 100-16
100.3 Parking brake 100-21
100.3.1 Valve block for parking brake and differential lockout
L509-1582; 100-21
100.3.2 Orifice bypass solenoid valve
L509-1582; 100-23
copyright ® Liebherr-Werk Bischofshofen GmbH 2021
1509-1582 LIEBHERR 21
Contents Service manual
110 Electrical system 110-1
110.1 Overview of electrical system
L509-1582; 110-2
110.2 Lighting
L509-1582; 110-5
110.3 Circuit diagrams
L509-1582; 110-7
110.4 Electronic control unit 110-9
110.4.1 General overview of electronic control system
L509-1582/0-60029; 110-9
110.4.2 General overview of electronic control system
L509-1582/60030-; 110-11
110.4.3 Central control unit (Master4)
1 509-1582/0-60029; 110-12
110.44 Central control unit (Master5 Mini)
L509-1582/60030-; 110-17
110.4.5 Modules 110-19
110.4.5.1 Compact module: overview
L509-1582; 110-19
110.4.5.2 Compact module
L509-1582; 110-21
110.5 Electrical components of the driver’s cab 110-27
110.5.1 Fuse boards
L 509-1582; 110-27
110.5.2 Door contact switch
L509-1582; 110-29
110.6 Electrical components in the rear section 110-30
110.6.1 Battery installation
L509-1582; 110-30
120 Gearbox 120-1
120.1 Overview of the transmission
L509-1582; 120-2
120.2 Transmission hydraulics 120-7
120.2.1 Overview of transmission hydraulics
L509-1582; 120-7
120.2.2 Gear shifting
L509-1582; 120-12
120.2.3 Valve block for external servo pressure
1509-1582; 120-14
120.2.4 Travel motor bypass solenoid valve
1509-1582; 120-16
120.3 Transmission electronics 120-18
110.1 Overview of electrical system
L509-1582; 110-2
110.2 Lighting
L509-1582; 110-5
110.3 Circuit diagrams
L509-1582; 110-7
110.4 Electronic control unit 110-9
110.4.1 General overview of electronic control system
L509-1582/0-60029; 110-9
110.4.2 General overview of electronic control system
L509-1582/60030-; 110-11
110.4.3 Central control unit (Master4)
1 509-1582/0-60029; 110-12
110.44 Central control unit (Master5 Mini)
L509-1582/60030-; 110-17
110.4.5 Modules 110-19
110.4.5.1 Compact module: overview
L509-1582; 110-19
110.4.5.2 Compact module
L509-1582; 110-21
110.5 Electrical components of the driver’s cab 110-27
110.5.1 Fuse boards
L 509-1582; 110-27
110.5.2 Door contact switch
L509-1582; 110-29
110.6 Electrical components in the rear section 110-30
110.6.1 Battery installation
L509-1582; 110-30
120 Gearbox 120-1
120.1 Overview of the transmission
L509-1582; 120-2
120.2 Transmission hydraulics 120-7
120.2.1 Overview of transmission hydraulics
L509-1582; 120-7
120.2.2 Gear shifting
L509-1582; 120-12
120.2.3 Valve block for external servo pressure
1509-1582; 120-14
120.2.4 Travel motor bypass solenoid valve
1509-1582; 120-16
120.3 Transmission electronics 120-18
copyright © Liebher-Werk Bischofshofen GmbH 2021
22 LIEBHERR L509-1582
LBH/M2234436/13/211-20211019_122128/en
Service manual Contents
Service manual Contents
120.3.1 Gearbox: electrical system
L509-1582; 120-18
120.3.2 Output speed sensor
L509-1582; 120-20
120.3.3 Hall sensor for gear indicator
L509-1582; 120-21
130 Axles and drive shafts 130-1
130.1 Axles 130-2
130.1.1 Front axle
L509-1582; 130-2
130.1.2 Rear axle
L509-1582; 130-4
130.1.3 Engageable differential lockout 130-6
130.1.3.1 Overview of engageable differential lockout
1509-1582; 130-6
130.2 Cardan shafts 130-9
130.2.1 Drive shaft
L509-1582; 130-9
140 Steel parts of the basic machine 140-1
140.1 Vehicle frame 140-2
140.1.1 Articulation bearing
L509-1582; 140-2
140.1.2 Articulation lock
L509-1582; 140-3
150 Working attachment 150-1
150.1 Lift arms for Z kinematics 150-2
150.1.1 Lift arms for Z kinematics
L509-1582; 150-2
5 150.2 Quick coupler 150-4
§ 150.2.1 Quick coupler
ol L509-1582; 150-4
§ 160.2.2 Quick coupler hydraulics 150-5
5 150.2.2.1 Overview of quick coupler hydraulics
g 1509-1582; 150-6
§ 150.2.2.2 Opening solenoid valve for quick coupler
z 1509-1582; 150-8
120.3.2 Output speed sensor
L509-1582; 120-20
120.3.3 Hall sensor for gear indicator
L509-1582; 120-21
130 Axles and drive shafts 130-1
130.1 Axles 130-2
130.1.1 Front axle
L509-1582; 130-2
130.1.2 Rear axle
L509-1582; 130-4
130.1.3 Engageable differential lockout 130-6
130.1.3.1 Overview of engageable differential lockout
1509-1582; 130-6
130.2 Cardan shafts 130-9
130.2.1 Drive shaft
L509-1582; 130-9
140 Steel parts of the basic machine 140-1
140.1 Vehicle frame 140-2
140.1.1 Articulation bearing
L509-1582; 140-2
140.1.2 Articulation lock
L509-1582; 140-3
150 Working attachment 150-1
150.1 Lift arms for Z kinematics 150-2
150.1.1 Lift arms for Z kinematics
L509-1582; 150-2
5 150.2 Quick coupler 150-4
§ 150.2.1 Quick coupler
ol L509-1582; 150-4
§ 160.2.2 Quick coupler hydraulics 150-5
5 150.2.2.1 Overview of quick coupler hydraulics
g 1509-1582; 150-6
§ 150.2.2.2 Opening solenoid valve for quick coupler
z 1509-1582; 150-8
copyright ® Liebherr-Werk Bischofshofen GmbH 2021
L500-1582 LIEBHERR 23
Contents
Contents
Service manual
160 Operator’s cab, heating and air conditioning 160-1
160.1 Overview of operator’s cab, heating and air conditioning unit
1509-1582; 160-2
160.2 Display and control elements 160-4
160.2.1 Display
1509-1582; 160-4
160.2.2 Control lever
L 509-1582; 160-4
160.2.3 Accelerator pedal
1509-1582; 160-6
160.3 Heating, ventilation, air conditioning 160-8
160.3.1 Overview of heating, ventilation and air conditioning system
L 509-1582; 160-8
160.3.2 Heating and air conditioning unit 160-14
160.3.2.1 Heating and air conditioning unit
L509-1582; 160-14
160.3.2.2 Blower
1509-1582; 160-17
160.4 Air conditioning 160-18
160.4.1 Air conditioning (optional)
1509-1582; 160-18
160.42 Compressor magnetic coupling
1509-1582; 160-19
160.4.3 Air conditioning condenser
L 509-1582; 160-21
160.4.4 Dryer-collector unit
1509-1582; 160-21
160.4.5 Air conditioning pressure switch
L 509-1582; 160-23
170 Lubrication system 170-1
170.1 Liebherr automatic central lubrication system 170-2
170.1.1 Automatic central lubrication system: overview
1509-1582; 170-2
170.1.2 Central lubrication pump EP-1
L509-1582; 170-6
170.1.3 Progressive distributor MX-F
L 509-1582; 170-9
190 Options 190-1
190.1 LiDAT 190-2
160.1 Overview of operator’s cab, heating and air conditioning unit
1509-1582; 160-2
160.2 Display and control elements 160-4
160.2.1 Display
1509-1582; 160-4
160.2.2 Control lever
L 509-1582; 160-4
160.2.3 Accelerator pedal
1509-1582; 160-6
160.3 Heating, ventilation, air conditioning 160-8
160.3.1 Overview of heating, ventilation and air conditioning system
L 509-1582; 160-8
160.3.2 Heating and air conditioning unit 160-14
160.3.2.1 Heating and air conditioning unit
L509-1582; 160-14
160.3.2.2 Blower
1509-1582; 160-17
160.4 Air conditioning 160-18
160.4.1 Air conditioning (optional)
1509-1582; 160-18
160.42 Compressor magnetic coupling
1509-1582; 160-19
160.4.3 Air conditioning condenser
L 509-1582; 160-21
160.4.4 Dryer-collector unit
1509-1582; 160-21
160.4.5 Air conditioning pressure switch
L 509-1582; 160-23
170 Lubrication system 170-1
170.1 Liebherr automatic central lubrication system 170-2
170.1.1 Automatic central lubrication system: overview
1509-1582; 170-2
170.1.2 Central lubrication pump EP-1
L509-1582; 170-6
170.1.3 Progressive distributor MX-F
L 509-1582; 170-9
190 Options 190-1
190.1 LiDAT 190-2
190.1.1 Overview of LiDAT
L509-1582; 190-2
190.1.2 LiDAT on machine
L509-1582/0-50943; 190-4
190.1.3 LiDAT on machine
L509-1582/50944-; 190-5
190.1.4 LiDAT module (LiTU2)
L509-1582/0-50943; 190-7
190.1.5 LiDAT module (LiTU3)
L509-1582/50944-; 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
200.21 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 200-9
200.2.2 Replacing fuses 200-10
200.2.2.1 Fuses on the fuse board in the operator’s cab 200-10
200.2.2.2 Fuses in right of engine compartment 200-13
L509-1582; 190-2
190.1.2 LiDAT on machine
L509-1582/0-50943; 190-4
190.1.3 LiDAT on machine
L509-1582/50944-; 190-5
190.1.4 LiDAT module (LiTU2)
L509-1582/0-50943; 190-7
190.1.5 LiDAT module (LiTU3)
L509-1582/50944-; 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
200.21 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 200-9
200.2.2 Replacing fuses 200-10
200.2.2.1 Fuses on the fuse board in the operator’s cab 200-10
200.2.2.2 Fuses in right of engine compartment 200-13
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