Liebherr L 509 1778 Wheel Loader Service Manual – PDF DOWNLOAD
FILE DETAILS:
Liebherr L 509 1778 Wheel Loader Service Manual – PDF DOWNLOAD
Language : English
Pages : 782
Downloadable : Yes
File Type : PDF
Size: 162 MB
DESCRIPTION:
Liebherr L 509 1778 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 1778 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 telescopic cylinder 010-27
010.2.6 Special tools for compensating cylinder 010-28
010.2.7 Special tools for quick coupler locking hydraulic cylinder 010-29
010.2.8 Special tools for steering wheel 010-29
010.2.9 Special tools for steering cylinders 010-29
010.2.10 Special tools for the service brake 010-30
010.2.11 Special tools for the electrical system 010-30
010.2.12 Special tools for front axle 010-31
010.2.13 Special tools for rear axle 010-31
010.2.14 Special tools for air conditioning system 010-32
010.2.15 Special tools for cab glazing 010-33
010.2.16 Special tools for the central lubrication system (Liebherr) 010-34
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 telescopic cylinder 010-27
010.2.6 Special tools for compensating cylinder 010-28
010.2.7 Special tools for quick coupler locking hydraulic cylinder 010-29
010.2.8 Special tools for steering wheel 010-29
010.2.9 Special tools for steering cylinders 010-29
010.2.10 Special tools for the service brake 010-30
010.2.11 Special tools for the electrical system 010-30
010.2.12 Special tools for front axle 010-31
010.2.13 Special tools for rear axle 010-31
010.2.14 Special tools for air conditioning system 010-32
010.2.15 Special tools for cab glazing 010-33
010.2.16 Special tools for the central lubrication system (Liebherr) 010-34
Standards and regulations
010-35
010.3.1
Prestressing forces and tightening torques for bolts with metric
standard and fine threads as per DIN ISO 261 010-35
010.3.1.1 Range of application and purpose 010-35
010.3.1.2 Other applicable documents 010-35
010.3.1.1 Range of application and purpose 010-35
010.3.1.2 Other applicable documents 010-35
copyright © Liebher-Werk Bischofshofen GmbH 2021
L509-1778
LBH/M2261288/03/211-20211019_122138/en
LBH/M2261288/03/211-20211019_122138/en
LBH/M2261288/03/211-20211019_122138/en
Service manual Contents
010.3.1.3 Modifications and descriptions 010-36
010.3.1.4 Tightening torques 010-36
010.3.1.3 Modifications and descriptions 010-36
010.3.1.4 Tightening torques 010-36
010.3.2 Liebherr standards for assembly instructions and tightening torques010-42
010.4 Preservation guidelines 010-43
010.4.1 General information 010-43
010.4.2 Machine out of service for an unknown period of time 010-43
010.4.3 Putting the machine out of service 010-44
010.4.3.1 Out of service for up to 2 months 010-44
010.4 Preservation guidelines 010-43
010.4.1 General information 010-43
010.4.2 Machine out of service for an unknown period of time 010-43
010.4.3 Putting the machine out of service 010-44
010.4.3.1 Out of service for up to 2 months 010-44
010.4.3.2 Out of service for up to 12 months 010-45
010.4.3.3 Out of service for longer than 12 months 010-46
0104.4 Putting back into service 010-46
010.4.4.1 After being out of service for 2 months 010-46
010.4.4.1 After being out of service for 2 months 010-46
010.4.4.2 After being out of service for 12 months 010-47
0104.43 After being out of service for longer than 12 months 010-47
020 Technical data 020-1
020.1 Overall machine 020-4
020.1.1 Complete machine with loading bucket
L509-1778; 020-4
0201.2 Working attachment: light material bucket
L509-1778; 020-5
020.1.3 Working attachment: forklift
L509-1778; 020-7
020.14 Load curves
L509-1778; 020-8
020.1.4.1 Symbols on load curves 020-8
020.1.4.1 Bale clamp 020-8
020.1.4.1 Maximum load centre of gravity distance 020-9
020.1.4.1 Maximum permissible weight of the working attach-
ment 020-9
020.1.4.1 Maximum permissible bucket capacity for hydraulic
buckets 020-9
020.1.4.1 Maximum permissible bucket length for hydraulic
buckets 020-9
020.1.4.1 Maximum permissible bucket width for hydraulic
buckets 020-10
020.1.4.1 Telescopic crane arm 020-10
020.1.4.1 Crane arm in loaded condition 020-10
020.1 Overall machine 020-4
020.1.1 Complete machine with loading bucket
L509-1778; 020-4
0201.2 Working attachment: light material bucket
L509-1778; 020-5
020.1.3 Working attachment: forklift
L509-1778; 020-7
020.14 Load curves
L509-1778; 020-8
020.1.4.1 Symbols on load curves 020-8
020.1.4.1 Bale clamp 020-8
020.1.4.1 Maximum load centre of gravity distance 020-9
020.1.4.1 Maximum permissible weight of the working attach-
ment 020-9
020.1.4.1 Maximum permissible bucket capacity for hydraulic
buckets 020-9
020.1.4.1 Maximum permissible bucket length for hydraulic
buckets 020-9
020.1.4.1 Maximum permissible bucket width for hydraulic
buckets 020-10
020.1.4.1 Telescopic crane arm 020-10
020.1.4.1 Crane arm in loaded condition 020-10
020.1.4.1 Telescopic crane arm with increasing centre of
gravity 020-10
020.1.4.1 Pallet handling Liebherr FEM II 020-11
020.1.4.1 Maximum front end dimension for pallet fork 020-11
020.1.4.1 Pallet handling Liebherr FEM II 020-11
020.1.4.1 Maximum front end dimension for pallet fork 020-11
020.1.4.1 Pallet fork with increasing load centre of gravity 020-11
Drive group 020-20
020.2.1 Diesel engine
020.2.1 Diesel engine
1509-1778; 020-20
020.2.2 Fuel tank
020.2.2 Fuel tank
L509-1778; 020-21
020.2.3 Fuel level sensor
020.2.3 Fuel level sensor
L509-1778; 020-21
Cooling system 020-22
020.3.1 Fan pump
Cooling system 020-22
020.3.1 Fan pump
L509-1778; 020-22
020.3.2 Fan motor
020.3.2 Fan motor
1509-1778; 020-22
020.3.3 Hydraulic oil temperature sensor B8
020.3.3 Hydraulic oil temperature sensor B8
L509-1778; 020-22
Working hydraulics 020-23
020.4.1 Working pump
Working hydraulics 020-23
020.4.1 Working pump
L509-1778/0-61328; 020-23
020.4.2 Working pump
020.4.2 Working pump
L509-1778/61329-; 020-23
020.4.3 Pilot control hydro accumulator
020.4.3 Pilot control hydro accumulator
1509-1778; 020-23
020.4.4 Stabilisation module
020.4.4 Stabilisation module
L509-1778; 020-23
020.4.5 Ride control hydro accumulator
020.4.5 Ride control hydro accumulator
1509-1778; 020-24
020.4.6 Lift cylinder
020.4.6 Lift cylinder
L509-1778; 020-24
020.4.7 Tilt cylinder
020.4.7 Tilt cylinder
1509-1778; 020-24
020.4.8 Telescopic cylinder
020.4.8 Telescopic cylinder
L509-1778; 020-25
020.49 Compensating cylinder
020.49 Compensating cylinder
1509-1778; 020-25
020.4.10 Working pump
020.4.10 Working pump
L509-1778; 020-25
Travel hydraulics 020-26
Travel hydraulics 020-26
020.5.1 Travel pump
L509-1778; 020-26
L509-1778; 020-26
copyright © Liebher-Werk Bischofshofen GmbH 2021
LIEBHERR L509-1778
LBH/M2261288/03/211-20211019_122138/en
LBH/M2261288/03/211-20211019_122138/en
LBH/M2261288/03/211-20211019_122138/en
Service manual
Contents
020.5.2 Pressure sensor for high pressure of travel pump B102
L509-1778; 020-26
0205.3 Travel motor
L509-1778; 020-26
020.6 Hydraulic components 020-28
020.6.1 Return suction filter
L509-1778; 020-28
0206.2 Breather filter with filler strainer
L509-1778; 020-28
020.7 Steering system 020-29
020.7.1 Servostat
L509-1778; 020-29
020.7.2 Steering cylinder
L509-1778; 020-29
020.8 Brake system 020-30
020.8.1 Drum brake
L509-1778; 020-30
020.8.2 Inch/brake unit
L509-1778; 020-30
020.8.3 Brake light pressure switch B12
L509-1778; 020-30
020.9 Electrical system 020-31
020.9.1 Central control unit (Master5-Mini)
L509-1778; 020-31
020.9.2 Compact module
L509-1778; 020-31
020.9.3 Battery
L509-1778; 020-31
0209.4 Voltage transformer
L509-1778; 020-32
020.10 Gearbox 020-33
L509-1778; 020-26
0205.3 Travel motor
L509-1778; 020-26
020.6 Hydraulic components 020-28
020.6.1 Return suction filter
L509-1778; 020-28
0206.2 Breather filter with filler strainer
L509-1778; 020-28
020.7 Steering system 020-29
020.7.1 Servostat
L509-1778; 020-29
020.7.2 Steering cylinder
L509-1778; 020-29
020.8 Brake system 020-30
020.8.1 Drum brake
L509-1778; 020-30
020.8.2 Inch/brake unit
L509-1778; 020-30
020.8.3 Brake light pressure switch B12
L509-1778; 020-30
020.9 Electrical system 020-31
020.9.1 Central control unit (Master5-Mini)
L509-1778; 020-31
020.9.2 Compact module
L509-1778; 020-31
020.9.3 Battery
L509-1778; 020-31
0209.4 Voltage transformer
L509-1778; 020-32
020.10 Gearbox 020-33
020.10.1 Transmission
L509-1778; 020-33
020.10.2 Output B101 speed sensor
L509-1778; 020-33
020.10.3 Hydro accumulator for external servo pressure and service brake
L509-1778; 020-33
020.11 Axles and drive shafts 020-34
020.11.1 Front axle with engageable differential lockout
L509-1778; 020-34
020.11.2 Rear axle when front axle has engageable differential lockout
L509-1778; 020-34
copyright ® Liebherr-Werk Bischofshofen GmbH 2021
L509-1778 LIEBHERR 9
Contents
L509-1778; 020-33
020.10.2 Output B101 speed sensor
L509-1778; 020-33
020.10.3 Hydro accumulator for external servo pressure and service brake
L509-1778; 020-33
020.11 Axles and drive shafts 020-34
020.11.1 Front axle with engageable differential lockout
L509-1778; 020-34
020.11.2 Rear axle when front axle has engageable differential lockout
L509-1778; 020-34
copyright ® Liebherr-Werk Bischofshofen GmbH 2021
L509-1778 LIEBHERR 9
Contents
Service manual
020.11.3 Drive shaft
L509-1778; 020-34
020.11.4 Tyres
L509-1778; 020-34
020.11.4.2 Special tyres 020-35
020.12 Working attachment 020-37
020.12.1 Locking cylinder
1509-1778; 020-37
020.13 Operator’s cab, heating and air conditioning 020-38
020.13.1 Dryer
L509-1778; 020-38
020.13.2 Pressure switches
L509-1778; 020-38
020.14 Lubrication system 020-39
020.14.1 Central lubrication pump EP1
L509-1778; 020-39
020.14.2 Progressive distributor
L509-1778; 020-39
020.14.2.1 MX-F 020-39
020.1422 MX-F 25 020-39
020.14.23 MXF 45 020-39
020.1424 MX-F75 020-40
020.14.2.5 MX-F105 020-40
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
L509-1778; 030-15
030.22 Recommended operating fluids
1509-1778; 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
020.11.4 Tyres
L509-1778; 020-34
020.11.4.2 Special tyres 020-35
020.12 Working attachment 020-37
020.12.1 Locking cylinder
1509-1778; 020-37
020.13 Operator’s cab, heating and air conditioning 020-38
020.13.1 Dryer
L509-1778; 020-38
020.13.2 Pressure switches
L509-1778; 020-38
020.14 Lubrication system 020-39
020.14.1 Central lubrication pump EP1
L509-1778; 020-39
020.14.2 Progressive distributor
L509-1778; 020-39
020.14.2.1 MX-F 020-39
020.1422 MX-F 25 020-39
020.14.23 MXF 45 020-39
020.1424 MX-F75 020-40
020.14.2.5 MX-F105 020-40
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
L509-1778; 030-15
030.22 Recommended operating fluids
1509-1778; 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
10
copyright © Liebher-Werk Bischofshofen GmbH 2021
L509-1778
LBH/M2261288/03/211-20211019_122138/en
LBH/M2261288/03/211-20211019_122138/en
LBH/M2261288/03/211-20211019_122138/en
Service manual Contents
030.3.3 Converting hydraulic system from mineral oils to biodegradable
hydraulic fluids 030-17
030.34 Diesel fuels
030.34 Diesel fuels
L509-1778; 030-17
030.3.4.1 Minimum quality requirement 030-17
030.3.4.2 Operating temperatures of diesel fuels 030-17
030.34.3 Minimum quality requirement 030-18
030.3.5 Engine oils
030.3.5 Engine oils
L509-1778; 030-18
030.3.5.1 Liebherr recommendation 030-18
030.3.5.3 Minimum quality requirement 030-18
030.36 Refrigerant
030.36 Refrigerant
L509-1778; 030-19
030.3.7 Coolant
030.3.7 Coolant
L509-1778; 030-19
030.3.7.1 Requirements for the water used 030-19
030.3.7.2 Antifreeze and corrosion inhibitor 030-19
030.3.7.3 Minimum quality requirement 030-19
030.3.8 Hydraulic oil
030.3.8 Hydraulic oil
L509-1778; 030-20
030.3.8.1 Liebherr recommendation 030-20
030.3.8.2 Minimum quality requirement 030-20
030.3.8.3 Oil analysis 030-20
030.3.8.4 Oil change 030-21
030.3.9 Transmission
030.3.9 Transmission
L509-1778; 030-21
030.3.9.1 Liebherr recommendation 030-21
030.3.9.2 Minimum quality requirement 030-21
030.3.10 Axle oil
030.3.10 Axle oil
L509-1778; 030-21
030.3.10.1 Liebherr recommendation 030-21
030.3.10.2 Minimum quality requirement 030-22
030.3.11 Brake oil
030.3.11 Brake oil
L509-1778; 030-22
030.3.11.1 Liebherr recommendation 030-22
030.3.12 Lubrication grease
030.3.12 Lubrication grease
L509-1778; 030-22
030.3.12.1 Liebherr recommendation 030-22
030.3.12.2 Minimum quality requirement 030-22
copyright ® Liebherr-Werk Bischofshofen GmbH 2021
L500-1778 LIEBHERR 1″
Contents
Contents
Service manual
030.4
030.3.13 Lubrication grease for sliding surface on telescopic lift arms
L509-1778; 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
L509-1778; 030-23
030.3.14.1 Liebherr recommendation 030-23
030.3.14.2 Minimum quality requirement 030-23
030.3.15 Refrigerant oil for air conditioning compressor
L509-1778; 030-24
030.3.15.1 Liebherr recommendation 030-24
Maintenance tasks 030-25
030.4.1 Safety precautions
1509-1778; 030-25
030.4.2 Preparatory tasks for maintenance 030-25
030.4.2.1 Maintenance positions
1509-1778; 030-26
030.4.2.2 Opening service hatches
L509-1778; 030-27
030.423 Turning off battery main switch
1509-1778; 030-28
030.4.3 Overall machine 030-29
030.4.3.1 Checking machine is in proper condition
L509-1778; 030-29
0304.3.2 Removing loose parts, dirt, ice and snow from
machine
1509-1778; 030-31
0304.3.3 Cleaning machine
L509-1778; 030-31
030.4.3.4 Replacing VCI capsules
1509-1778; 030-34
0304.3.5 Operating fluid analysis: General specifications
1509-1778; 030-37
030.4.3.6 Operating fluid analysis: filling out sample information
form
L509-1778; 030-40
030.4.3.7 Fuel and operating fluid analysis: scope of analysis
1509-1778; 030-46
030.4.3.8 Analysis of lubricants and fuels
L509-1778; 030-50
030.4.4 Drive group 030-57
030.4.4.1 Checking diesel engine oil level
L509-1778; 030-57
030.3.13.1 Liebherr recommendation 030-23
030.3.13.2 Minimum quality requirement 030-23
030.3.14 Windscreen washer fluid
L509-1778; 030-23
030.3.14.1 Liebherr recommendation 030-23
030.3.14.2 Minimum quality requirement 030-23
030.3.15 Refrigerant oil for air conditioning compressor
L509-1778; 030-24
030.3.15.1 Liebherr recommendation 030-24
Maintenance tasks 030-25
030.4.1 Safety precautions
1509-1778; 030-25
030.4.2 Preparatory tasks for maintenance 030-25
030.4.2.1 Maintenance positions
1509-1778; 030-26
030.4.2.2 Opening service hatches
L509-1778; 030-27
030.423 Turning off battery main switch
1509-1778; 030-28
030.4.3 Overall machine 030-29
030.4.3.1 Checking machine is in proper condition
L509-1778; 030-29
0304.3.2 Removing loose parts, dirt, ice and snow from
machine
1509-1778; 030-31
0304.3.3 Cleaning machine
L509-1778; 030-31
030.4.3.4 Replacing VCI capsules
1509-1778; 030-34
0304.3.5 Operating fluid analysis: General specifications
1509-1778; 030-37
030.4.3.6 Operating fluid analysis: filling out sample information
form
L509-1778; 030-40
030.4.3.7 Fuel and operating fluid analysis: scope of analysis
1509-1778; 030-46
030.4.3.8 Analysis of lubricants and fuels
L509-1778; 030-50
030.4.4 Drive group 030-57
030.4.4.1 Checking diesel engine oil level
L509-1778; 030-57
12
copyright © Liebher-Werk Bischofshofen GmbH 2021
L509-1778
LBH/M2261288/03/211-20211019_122138/en
LBH/M2261288/03/211-20211019_122138/en
LBH/M2261288/03/211-20211019_122138/en
Service manual
Contents
030.4.5
030.4.6
030.4.4.2 Diesel engine: changing diesel engine oil
L509-1778; 030-58
030.4.4.3 Diesel engine: changing oil filter
030.4.4.3 Diesel engine: changing oil filter
1509-1778; 030-60
030.4.4.4 Diesel engine: checking V-belt
030.4.4.4 Diesel engine: checking V-belt
L509-1778; 030-62
030.44.5 Diesel engine: changing V-belt
030.44.5 Diesel engine: changing V-belt
1509-1778; 030-64
030.4.4.6 Diesel engine: checking valve clearance
030.4.4.6 Diesel engine: checking valve clearance
L509-1778; 030-65
030.4.4.7 Fuel tank: draining condensate and sediment
030.4.4.7 Fuel tank: draining condensate and sediment
1509-1778; 030-69
030.4.4.8 Draining off condensate from the fuel pre-filter
030.4.4.8 Draining off condensate from the fuel pre-filter
L509-1778; 030-70
030.4.4.9 Changing fuel pre-filter element
030.4.4.9 Changing fuel pre-filter element
1509-1778; 030-71
030.4.4.10 Changing fuel fine filter element
030.4.4.10 Changing fuel fine filter element
L509-1778; 030-73
030.4.4.11 Cleaning the service cover and dust discharge valve
030.4.4.11 Cleaning the service cover and dust discharge valve
of the air filter system
L509-1778; 030-74
030.4.4.12 Checking air filter vacuum switch function
030.4.4.12 Checking air filter vacuum switch function
1509-1778; 030-75
030.4.4.13 Cleaning or changing main element of air filter
030.4.4.13 Cleaning or changing main element of air filter
system
L509-1778; 030-77
030.4.4.14 Changing safety element of air filter system
030.4.4.14 Changing safety element of air filter system
1509-1778; 030-79
030.4.4.15 Checking that diesel engine intake and exhaust
030.4.4.15 Checking that diesel engine intake and exhaust
system is in good condition and not loose or leaking
1509-1778; 030-80
030.4.4.16 Cleaning or changing diesel particulate filter
030.4.4.16 Cleaning or changing diesel particulate filter
1509-1778; 030-83
Cooling system 030-89
030.4.5.1 Cooling system: checking coolant level
Cooling system 030-89
030.4.5.1 Cooling system: checking coolant level
L509-1778; 030-89
030.4.5.2 Coolant: checking anti-freeze and corrosion protec-
030.4.5.2 Coolant: checking anti-freeze and corrosion protec-
tion agent concentration
1509-1778; 030-91
030.4.5.3 Cleaning the cooling system
030.4.5.3 Cleaning the cooling system
L509-1778; 030-98
030.45.4 Cooling system: changing coolant
030.45.4 Cooling system: changing coolant
1509-1778; 030-99
Hydraulic components 030-102
Hydraulic components 030-102
L508-1778
copyright ® Liebherr-Werk Bischofshofen GmbH 2021
LIEBHERR 13
Contents
Contents
Service manual
030.4.7
030.4.8
030.4.9
030.4.10
030.4.11
030.4.6.1 Checking oil level in hydraulic tank
L509-1778; 030-102
0304.6.2 Draining off condensate and sediment from hydraulic
0304.6.2 Draining off condensate and sediment from hydraulic
tank
L509-1778; 030-104
0304.6.3 Hydraulic tank: changing filter cartridge in return-
0304.6.3 Hydraulic tank: changing filter cartridge in return-
suction filter
L509-1778; 030-105
0304.6.4 Changing the hydraulic tank breather filter
0304.6.4 Changing the hydraulic tank breather filter
L509-1778; 030-106
0304.6.5 Hydraulic tank: changing oil
0304.6.5 Hydraulic tank: changing oil
L509-1778; 030-107
Steering system 030-109
030.4.7.1 Test steering
Steering system 030-109
030.4.7.1 Test steering
L509-1778; 030-109
030.4.7.2 Lubricating steering cylinder bearing
030.4.7.2 Lubricating steering cylinder bearing
L509-1778; 030-109
Brake system 030-110
030.4.8.1 Testing service brake and parking brake
Brake system 030-110
030.4.8.1 Testing service brake and parking brake
L509-1778; 030-110
030.4.8.2 Checking oil level in brake system
030.4.8.2 Checking oil level in brake system
L509-1778; 030-111
030.4.8.3 Checking gap and wear on service brake linings
030.4.8.3 Checking gap and wear on service brake linings
L509-1778; 030-113
0304.8.4 Service brake: checking brake plates for wear
0304.8.4 Service brake: checking brake plates for wear
L509-1778; 030-114
Electrical system 030-116
030.4.9.1 Lighting and horn: checking function
Electrical system 030-116
030.4.9.1 Lighting and horn: checking function
L509-1778; 030-116
030.4.9.2 Checking battery fluid levels and terminals
030.4.9.2 Checking battery fluid levels and terminals
L509-1778; 030-117
030.4.9.3 Control lever: changing rocker of travel direction
030.4.9.3 Control lever: changing rocker of travel direction
switch
L509-1778; 030-119
Gearbox 030-120
030.4.10.1 Transmission: checking oil level
Gearbox 030-120
030.4.10.1 Transmission: checking oil level
L509-1778; 030-120
030.4.10.2 Transmission: changing oil
030.4.10.2 Transmission: changing oil
L509-1778; 030-121
Axles and drive shafts 030-123
030.4.11.1 Axle: checking oil levels
Axles and drive shafts 030-123
030.4.11.1 Axle: checking oil levels
L509-1778; 030-123
0304.11.2 Changing axle oil
0304.11.2 Changing axle oil
L509-1778; 030-124
14
copyright © Liebher-Werk Bischofshofen GmbH 2021
LIEBHERR L509-1778
LBH/M2261288/03/211-20211019_122138/en
LBH/M2261288/03/211-20211019_122138/en
LBH/M2261288/03/211-20211019_122138/en
Service manual
Contents
030.4.12
030.4.13
030.4.14
030.4.11.3 Lubricating rear axle kingpin bearings
L509-1778; 030-127
030.4.11.4 Checking fitting of rear axle kingpin bearings and
030.4.11.4 Checking fitting of rear axle kingpin bearings and
steering rod taper connections
L509-1778; 030-127
030.4.11.5 Checking tightening torque of front axle fastening
030.4.11.5 Checking tightening torque of front axle fastening
bolts
L509-1778; 030-128
030.4.11.6 Checking and lubricating drive shaft
030.4.11.6 Checking and lubricating drive shaft
L509-1778; 030-129
030.4.11.7 Tyres: checking tyre pressure
030.4.11.7 Tyres: checking tyre pressure
L509-1778; 030-130
030.4.11.8 Checking wheel tightness
030.4.11.8 Checking wheel tightness
L509-1778; 030-130
Steel parts of the basic machine 030-131
030.4.12.1 Lubricating the articulated bearing
Steel parts of the basic machine 030-131
030.4.12.1 Lubricating the articulated bearing
1509-1778; 030-131
030.4.12.2 Lubricating the articulation stops
030.4.12.2 Lubricating the articulation stops
L509-1778; 030-132
030.4.12.3 Engine bonnet: lubricating moving parts with pene-
030.4.12.3 Engine bonnet: lubricating moving parts with pene-
trating oil
1509-1778; 030-132
030.4.12.4 Service hatches: cleaning and maintaining seals
030.4.12.4 Service hatches: cleaning and maintaining seals
L509-1778; 030-133
Working attachment 030-134
030.4.13.1 Quick coupler: checking function
Working attachment 030-134
030.4.13.1 Quick coupler: checking function
L509-1778; 030-134
030.4.13.2 Lubricating telescopic lift arms and working attach-
030.4.13.2 Lubricating telescopic lift arms and working attach-
ment
L509-1778; 030-134
030.4.13.3 Telescopic lift arms: checking front slide surfaces for
030.4.13.3 Telescopic lift arms: checking front slide surfaces for
corrosion and lubricating
L509-1778; 030-135
030.4.13.4 Telescopic lift arms: checking rear slide surfaces for
030.4.13.4 Telescopic lift arms: checking rear slide surfaces for
corrosion and lubricating
L509-1778; 030-137
030.4.13.5 Telescopic lift arms: checking slide elements for wear
030.4.13.5 Telescopic lift arms: checking slide elements for wear
L509-1778; 030-139
030.4.13.6 Telescopic lift arms: checking slide elements for
030.4.13.6 Telescopic lift arms: checking slide elements for
proper seating
L509-1778; 030-139
030.4.13.7 Telescopic lift arms: changing slide elements
030.4.13.7 Telescopic lift arms: changing slide elements
L509-1778; 030-141
Operator’s cab, heating and air conditioning 030-146
030.4.14.1 Cleaning operator’s cab air filter
Operator’s cab, heating and air conditioning 030-146
030.4.14.1 Cleaning operator’s cab air filter
1509-1778; 030-146
L508-1778
copyright ® Liebherr-Werk Bischofshofen GmbH 2021
LIEBHERR 15
Contents Service manual
030.4.14.2 Changing operator’s cab air filter
L509-1778; 030-147
030.4.14.3 Safety belt: checking condition and function
L509-1778; 030-147
030.4.144 Windscreen washer system: testing
L509-1778; 030-148
030.4.14.5 Windscreen washer system: filling windscreen
washer fluid
L509-1778; 030-148
030.4.14.6 Operator’s cab: lubricating locking mechanism and
cylinder with penetrating oil
L509-1778; 030-149
030.4.14.7 Cleaning and maintaining the seals of the operator’s
cab
L509-1778; 030-150
030.4.14.8 Air conditioning: checking V-belt
L509-1778; 030-151
030.4.14.9 Air conditioning: changing V-belt
L509-1778; 030-153
030.4.14.10 Checking the indicator bead in the air conditioning
dryer-collector unit
L509-1778; 030-155
030.4.14.11 Heating and air conditioning unit: Testing function
L509-1778; 030-156
030.4.15 Lubrication system 030-157
030.4.15.1 Checking the level in the grease reservoir of the
central lubrication system
L509-1778; 030-157
030.4.15.2 Central lubrication system: checking pipes, hoses
and lubrication points for leaks and damage.
L509-1778; 030-158
030.4.16.3 Central lubrication system: checking lubrication of
bearings
L509-1778; 030-159
030.5 Testing and adjustment checklist
L509-1778; 030-160
030.6 Testing and adjustment tasks 030-166
030.6.1 Safety precautions
L509-1778; 030-166
030.6.2 Overall machine 030-166
030.6.2.1 Preparing for adjustment procedures
L509-1778; 030-166
030.6.2.2 Hydraulic oil and coolant: operating temperature
L509-1778; 030-168
030.6.3 Drive group 030-169
copyright © Liebher-Werk Bischofshofen GmbH 2021
16 LIEBHERR 1509-1778
Contents Service manual
030.4.14.2 Changing operator’s cab air filter
L509-1778; 030-147
030.4.14.3 Safety belt: checking condition and function
L509-1778; 030-147
030.4.144 Windscreen washer system: testing
L509-1778; 030-148
030.4.14.5 Windscreen washer system: filling windscreen
washer fluid
L509-1778; 030-148
030.4.14.6 Operator’s cab: lubricating locking mechanism and
cylinder with penetrating oil
L509-1778; 030-149
030.4.14.7 Cleaning and maintaining the seals of the operator’s
cab
L509-1778; 030-150
030.4.14.8 Air conditioning: checking V-belt
L509-1778; 030-151
030.4.14.9 Air conditioning: changing V-belt
L509-1778; 030-153
030.4.14.10 Checking the indicator bead in the air conditioning
dryer-collector unit
L509-1778; 030-155
030.4.14.11 Heating and air conditioning unit: Testing function
L509-1778; 030-156
030.4.15 Lubrication system 030-157
030.4.15.1 Checking the level in the grease reservoir of the
central lubrication system
L509-1778; 030-157
030.4.15.2 Central lubrication system: checking pipes, hoses
and lubrication points for leaks and damage.
L509-1778; 030-158
030.4.16.3 Central lubrication system: checking lubrication of
bearings
L509-1778; 030-159
030.5 Testing and adjustment checklist
L509-1778; 030-160
030.6 Testing and adjustment tasks 030-166
030.6.1 Safety precautions
L509-1778; 030-166
030.6.2 Overall machine 030-166
030.6.2.1 Preparing for adjustment procedures
L509-1778; 030-166
030.6.2.2 Hydraulic oil and coolant: operating temperature
L509-1778; 030-168
030.6.3 Drive group 030-169
copyright © Liebher-Werk Bischofshofen GmbH 2021
16 LIEBHERR 1509-1778
LBH/M2261288/03/211-20211019_122138/en
LBH/M2261288/03/211-20211019_122138/en
LBH/M2261288/03/211-20211019_122138/en
Service manual
Contents
030.6.4
030.6.5
030.6.6
030.6.7
030.6.3.1 Pedals: calibration
L509-1778; 030-169
030.6.3.2 Diesel engine speed
030.6.3.2 Diesel engine speed
1509-1778; 030-170
030.6.3.3 Reading the diesel engine service files
030.6.3.3 Reading the diesel engine service files
L509-1778; 030-171
030.6.3.4 Performing a service regeneration on diesel particu-
030.6.3.4 Performing a service regeneration on diesel particu-
late filter
1509-1778; 030-173
030.6.3.5 Diesel engine: changing engine control unit (ECU)
030.6.3.5 Diesel engine: changing engine control unit (ECU)
L 509-1778; 030-174
Cooling system 030-184
030.6.4.1 Fan motor: fan speed proportional solenoid
Cooling system 030-184
030.6.4.1 Fan motor: fan speed proportional solenoid
L 509-1778; 030-184
Working hydraulics 030-186
030.6.5.1 Calibrating working hydraulics angle sensors
Working hydraulics 030-186
030.6.5.1 Calibrating working hydraulics angle sensors
1509-1778; 030-186
030.6.5.2 Calibrating proportional solenoids in control valve
030.6.5.2 Calibrating proportional solenoids in control valve
block
L 509-1778; 030-189
030.6.5.3 Pressure sensors for lift cylinders and compensating
030.6.5.3 Pressure sensors for lift cylinders and compensating
cylinders B90, B91, B92, B93
L 509-1778; 030-180
030.6.5.4 Control valve block: secondary pressure relief valves
030.6.5.4 Control valve block: secondary pressure relief valves
1509-1778; 030-193
030.6.5.5 Control valve block: primary pressure relief valve
030.6.5.5 Control valve block: primary pressure relief valve
L509-1778; 030-195
030.6.5.6 Stabilisation module (option), safety valve
030.6.5.6 Stabilisation module (option), safety valve
1509-1778; 030-197
030.6.5.7 Ride control hydro accumulator (option): nitrogen
030.6.5.7 Ride control hydro accumulator (option): nitrogen
filling
1509-1778; 030-198
Hydraulic components 030-200
030.6.6.1 Checking the hydraulic lines for damage
Hydraulic components 030-200
030.6.6.1 Checking the hydraulic lines for damage
L509-1778; 030-200
Travel hydraulics 030-205
030.6.7.1 Travel pump high pressure sensor B102: Deviation
Travel hydraulics 030-205
030.6.7.1 Travel pump high pressure sensor B102: Deviation
L509-1778; 030-205
030.6.7.2 Travel pump replenishing pressure relief valve
030.6.7.2 Travel pump replenishing pressure relief valve
L509-1778; 030-206
030.6.7.3 Travel pump: high pressure relief valves
030.6.7.3 Travel pump: high pressure relief valves
L 509-1778; 030-208
030.6.7.4 Travel pump: pressure cut-off
030.6.7.4 Travel pump: pressure cut-off
1509-1778; 030-211
L508-1778
copyright ® Liebherr-Werk Bischofshofen GmbH 2021
LIEBHERR 17
Contents Service manual
030.6.7.5 Travel pump: manual block curve calibration
L509-1778; 030-212
0306.7.6 Travel pump: automatic block curve calibration
L509-1778; 030-214
0306.7.7 Travel motor: manual calibration (maximum swivel
angle)
L509-1778; 030-215
030.6.7.8 =Travel motor: manual calibration (minimum swivel
angle)
L509-1778; 030-217
030.6.8 Brake system 030-218
030.6.8.1 Inching brake pedal: basic setting
L509-1778; 030-218
030.6.8.2 Angle sensor for inching function: checking basic
setting
L509-1778; 030-220
030.6.8.3 Service brake: brake pressure in 1st brake circuit
L509-1778; 030-221
030.6.9 Electrical system 030-222
030.6.9.1 Central control unit (Master5): creating service file
L509-1778; 030-222
0306.9.2 Central control unit (Master5): software update
L509-1778; 030-223
030.6.9.3 Central control unit (Master5): resetting to factory
settings
L509-1778; 030-227
0306.9.4 Central control unit (Master5): connecting Sculi diag-
nostic software
L509-1778; 030-228
030.6.9.5 Central control unit (Master5): connecting LiF T func-
tion
L509-1778; 030-232
030.6.9.6 Addressing CAN module and checking system infor-
mation
L509-1778; 030-233
030.6.10 Gearbox 030-235
0306.10.1 Gearbox: external servo pressure reducing valve
L509-1778; 030-235
030.6.10.2 External servo pressure hydro accumulator nitrogen
filling
L509-1778; 030-237
030.6.11 Axles and drive shafts 030-240
030.6.11.1 Tyres: setting radius
L509-1778; 030-240
030.6.12 Operator’s cab, heating and air conditioning 030-241
copyright © Liebher-Werk Bischofshofen GmbH 2021
18 LIEBHERR 508-1778
Contents Service manual
030.6.7.5 Travel pump: manual block curve calibration
L509-1778; 030-212
0306.7.6 Travel pump: automatic block curve calibration
L509-1778; 030-214
0306.7.7 Travel motor: manual calibration (maximum swivel
angle)
L509-1778; 030-215
030.6.7.8 =Travel motor: manual calibration (minimum swivel
angle)
L509-1778; 030-217
030.6.8 Brake system 030-218
030.6.8.1 Inching brake pedal: basic setting
L509-1778; 030-218
030.6.8.2 Angle sensor for inching function: checking basic
setting
L509-1778; 030-220
030.6.8.3 Service brake: brake pressure in 1st brake circuit
L509-1778; 030-221
030.6.9 Electrical system 030-222
030.6.9.1 Central control unit (Master5): creating service file
L509-1778; 030-222
0306.9.2 Central control unit (Master5): software update
L509-1778; 030-223
030.6.9.3 Central control unit (Master5): resetting to factory
settings
L509-1778; 030-227
0306.9.4 Central control unit (Master5): connecting Sculi diag-
nostic software
L509-1778; 030-228
030.6.9.5 Central control unit (Master5): connecting LiF T func-
tion
L509-1778; 030-232
030.6.9.6 Addressing CAN module and checking system infor-
mation
L509-1778; 030-233
030.6.10 Gearbox 030-235
0306.10.1 Gearbox: external servo pressure reducing valve
L509-1778; 030-235
030.6.10.2 External servo pressure hydro accumulator nitrogen
filling
L509-1778; 030-237
030.6.11 Axles and drive shafts 030-240
030.6.11.1 Tyres: setting radius
L509-1778; 030-240
030.6.12 Operator’s cab, heating and air conditioning 030-241
copyright © Liebher-Werk Bischofshofen GmbH 2021
18 LIEBHERR 508-1778
LBH/M2261288/03/211-20211019_122138/en
Service manual
Service manual
Contents
030.6.12.1 Checking pressure and temperature conditions of air
conditioning unit
L509-1778; 030-241
030.6.13 Options 030-242
030.6.13.1 LiDAT: connecting to LIDAT module
1509-1778; 030-242
030.6.13.2 LiDAT: software update for LiDAT module
L509-1778; 030-244
030.6.13.3 LiDAT: creating report and snapshot
1509-1778; 030-246
040 Drive group 040-1
040.1 Engine 040-2
040.1.1 Diesel engine overview
L509-1778; 040-2
040.1.2 Electrical components of diesel engine
L509-1778; 040-10
040.1.3 Fuel system 040-11
040.1.3.1 Overview of fuel system
L509-1778; 040-12
040.1.3.2 Fuel level sensor
1509-1778; 040-14
040.1.3.3 Fuel pre-filter
L509-1778; 040-16
040.1.3.4 Fuel fine filter
1509-1778; 040-17
0401.4 Air filter system 040-17
040.1.4.1 Air filter
L509-1778; 040-18
040.1.4.2 Vacuum switch for air filter
L509-1778; 040-19
040.1.5 Exhaust system 040-19
§ 040.1.5.1 Overview of diesel particulate filter
g 1509-1778; 040-20
o
§ 050 Cooling system 050-1
§ 050.1 Overview of cooling system
g L509-1778; 050-2
§ 050.2 Cooling system hydraulics 050-3
ES
3 0502.1 Overview of cooling system hydraulics
L509-1778; 050-3
050.2.2 Fan pump
L509-1778; 050-6
copyright ® Liebherr-Werk Bischofshofen GmbH 2021
1509-1778 LIEBHERR 19
Contents Service manual
050.2.3 Fan motor
L509-1778; 050-7
050.3 Cooling system electronics 050-9
050.3.1 General overview of electronic control system
L509-1778; 050-9
050.3.2 Hydraulic oil temperature sensor
L509-1778; 050-12
050.4 Cooler 050-14
050.4.1 Cooler unit
L509-1778; 050-14
050.5 Reversible fan drive 050-15
050.5.1 Overview of reversible fan drive
L509-1778; 050-15
050.5.2 Fan reversal valve block
1509-1778; 050-18
060 Working hydraulics 060-1
060.1 Overview of working hydraulics
L509-1778/0-65271; 060-3
060.2 Overview of working hydraulics
L509-1778/65272-; 060-7
060.3 Working pump
L509-1778/0-61328; 060-11
060.4 Working pump
L509-1778/61329-; 060-14
080.5 Control block
L509-1778; 060-17
060.6 Pilot control 060-24
060.6.1 Pilot pressure for solenoid valve
L509-1778; 060-24
060.7 Ride control 060-26
060.7.1 Overview of ride control system
1509-1778; 060-26
060.7.2 Stabilisation module
L509-1778; 060-29
060.8 Electronics of the working hydraulics 060-34
060.8.1 Overview of electrical controls the working hydraulics
L509-1778; 060-34
060.8.2 Working hydraulics angle sensors
1509-1778; 060-37
060.9 Regulated flow rate 060-39
060.9.1 Regulated flow rate: total overview
L509-1778; 060-39
copyright © Liebher-Werk Bischofshofen GmbH 2021
20 LIEBHERR L509-1778
030.6.13 Options 030-242
030.6.13.1 LiDAT: connecting to LIDAT module
1509-1778; 030-242
030.6.13.2 LiDAT: software update for LiDAT module
L509-1778; 030-244
030.6.13.3 LiDAT: creating report and snapshot
1509-1778; 030-246
040 Drive group 040-1
040.1 Engine 040-2
040.1.1 Diesel engine overview
L509-1778; 040-2
040.1.2 Electrical components of diesel engine
L509-1778; 040-10
040.1.3 Fuel system 040-11
040.1.3.1 Overview of fuel system
L509-1778; 040-12
040.1.3.2 Fuel level sensor
1509-1778; 040-14
040.1.3.3 Fuel pre-filter
L509-1778; 040-16
040.1.3.4 Fuel fine filter
1509-1778; 040-17
0401.4 Air filter system 040-17
040.1.4.1 Air filter
L509-1778; 040-18
040.1.4.2 Vacuum switch for air filter
L509-1778; 040-19
040.1.5 Exhaust system 040-19
§ 040.1.5.1 Overview of diesel particulate filter
g 1509-1778; 040-20
o
§ 050 Cooling system 050-1
§ 050.1 Overview of cooling system
g L509-1778; 050-2
§ 050.2 Cooling system hydraulics 050-3
ES
3 0502.1 Overview of cooling system hydraulics
L509-1778; 050-3
050.2.2 Fan pump
L509-1778; 050-6
copyright ® Liebherr-Werk Bischofshofen GmbH 2021
1509-1778 LIEBHERR 19
Contents Service manual
050.2.3 Fan motor
L509-1778; 050-7
050.3 Cooling system electronics 050-9
050.3.1 General overview of electronic control system
L509-1778; 050-9
050.3.2 Hydraulic oil temperature sensor
L509-1778; 050-12
050.4 Cooler 050-14
050.4.1 Cooler unit
L509-1778; 050-14
050.5 Reversible fan drive 050-15
050.5.1 Overview of reversible fan drive
L509-1778; 050-15
050.5.2 Fan reversal valve block
1509-1778; 050-18
060 Working hydraulics 060-1
060.1 Overview of working hydraulics
L509-1778/0-65271; 060-3
060.2 Overview of working hydraulics
L509-1778/65272-; 060-7
060.3 Working pump
L509-1778/0-61328; 060-11
060.4 Working pump
L509-1778/61329-; 060-14
080.5 Control block
L509-1778; 060-17
060.6 Pilot control 060-24
060.6.1 Pilot pressure for solenoid valve
L509-1778; 060-24
060.7 Ride control 060-26
060.7.1 Overview of ride control system
1509-1778; 060-26
060.7.2 Stabilisation module
L509-1778; 060-29
060.8 Electronics of the working hydraulics 060-34
060.8.1 Overview of electrical controls the working hydraulics
L509-1778; 060-34
060.8.2 Working hydraulics angle sensors
1509-1778; 060-37
060.9 Regulated flow rate 060-39
060.9.1 Regulated flow rate: total overview
L509-1778; 060-39
copyright © Liebher-Werk Bischofshofen GmbH 2021
20 LIEBHERR L509-1778
LBH/M2261288/03/211-20211019_122138/en
Service manual Contents
Service manual Contents
060.9.2 Valve block for regulated flow rate
L509-1778; 060-41
060.10 Pipe break protection 060-43
060.10.1 Pipe break protection: overview
L509-1778/0-65922; 060-43
060.10.2 Pipe break protection: overview
L509-1778/65923-; 060-46
060.11 High flow 060-50
060.11.1 High Flow: total overview
L509-1778; 060-50
060.11.2 High Flow pump
L509-1778; 060-53
060.11.3 Solenoid valve for High Flow
L509-1778; 060-54
070 Travel hydraulics 070-1
070.1 Overview of travel hydraulics
L509-1778; 070-2
070.2 Travel pump
L509-1778; 070-9
070.3 Travel motors 070-25
070.3.1 Travel motor
L509-1778; 070-25
080 Hydraulic components 080-1
080.1 Hydraulic system: overview
L509-1778/0-65271; 080-2
080.2 Hydraulic system: overview
L509-1778/65272-; 080-5
080.3 Hydraulic tank 080-8
080.3.1 Overview of hydraulic tank
L509-1778; 080-8
2 080.3.2 Return suction filter
8 L509-1778; 080-10
g 080.3.3 Breather filter
g L509-1778; 080-16
§
2 090 Steering system 090-1
g 090.1 Steering system overview
3 L509-1778; 090-2
090.2 Servostat
L509-1778; 090-4
060.10 Pipe break protection 060-43
060.10.1 Pipe break protection: overview
L509-1778/0-65922; 060-43
060.10.2 Pipe break protection: overview
L509-1778/65923-; 060-46
060.11 High flow 060-50
060.11.1 High Flow: total overview
L509-1778; 060-50
060.11.2 High Flow pump
L509-1778; 060-53
060.11.3 Solenoid valve for High Flow
L509-1778; 060-54
070 Travel hydraulics 070-1
070.1 Overview of travel hydraulics
L509-1778; 070-2
070.2 Travel pump
L509-1778; 070-9
070.3 Travel motors 070-25
070.3.1 Travel motor
L509-1778; 070-25
080 Hydraulic components 080-1
080.1 Hydraulic system: overview
L509-1778/0-65271; 080-2
080.2 Hydraulic system: overview
L509-1778/65272-; 080-5
080.3 Hydraulic tank 080-8
080.3.1 Overview of hydraulic tank
L509-1778; 080-8
2 080.3.2 Return suction filter
8 L509-1778; 080-10
g 080.3.3 Breather filter
g L509-1778; 080-16
§
2 090 Steering system 090-1
g 090.1 Steering system overview
3 L509-1778; 090-2
090.2 Servostat
L509-1778; 090-4
copyright ® Liebherr-Werk Bischofshofen GmbH 2021
L500-1778 LIEBHERR 2
Contents
Contents
Service manual
100 Brake system 100-1
100.1 Overview of brake system
L509-1778; 100-2
100.2 Service brake 100-7
100.2.1 Inch/brake unit
L 509-1778; 100-7
100.2.2 Inching function angle sensor
L509-1778; 100-13
100.2.3 Brake light pressure switch
1509-1778; 100-15
100.2.4 Drum brake
L509-1778; 100-16
100.3 Parking brake 100-21
100.3.1 Valve block for parking brake and differential lockout
L 509-1778; 100-21
100.3.2 Orifice bypass solenoid valve
1509-1778; 100-23
110 Electrical system 110-1
110.1 Overview of electrical system
L509-1778; 110-2
110.2 Circuit diagrams
L509-1778; 110-6
110.3 Electronic control unit 110-8
110.3.1 General overview of electronic control system
1509-1778; 110-8
110.3.2 Central control unit (Master5 Mini)
L 509-1778; 110-10
110.3.3 Modules 110-12
110.3.3.1 Compact module: overview
L509-1778; 110-12
110.3.3.2 Compact module
L509-1778; 110-14
110.4 Electrical components of the driver’s cab 110-20
110.4.1 Fuse boards
L509-1778; 110-20
110.4.2 Door contact switch
L509-1778; 110-22
110.5 Electrical components in the rear section 110-23
110.5.1 Battery installation
L509-1778; 110-23
copyright © Liebher-Werk Bischofshofen GmbH 2021
22 LIEBHERR L509-1778
100.1 Overview of brake system
L509-1778; 100-2
100.2 Service brake 100-7
100.2.1 Inch/brake unit
L 509-1778; 100-7
100.2.2 Inching function angle sensor
L509-1778; 100-13
100.2.3 Brake light pressure switch
1509-1778; 100-15
100.2.4 Drum brake
L509-1778; 100-16
100.3 Parking brake 100-21
100.3.1 Valve block for parking brake and differential lockout
L 509-1778; 100-21
100.3.2 Orifice bypass solenoid valve
1509-1778; 100-23
110 Electrical system 110-1
110.1 Overview of electrical system
L509-1778; 110-2
110.2 Circuit diagrams
L509-1778; 110-6
110.3 Electronic control unit 110-8
110.3.1 General overview of electronic control system
1509-1778; 110-8
110.3.2 Central control unit (Master5 Mini)
L 509-1778; 110-10
110.3.3 Modules 110-12
110.3.3.1 Compact module: overview
L509-1778; 110-12
110.3.3.2 Compact module
L509-1778; 110-14
110.4 Electrical components of the driver’s cab 110-20
110.4.1 Fuse boards
L509-1778; 110-20
110.4.2 Door contact switch
L509-1778; 110-22
110.5 Electrical components in the rear section 110-23
110.5.1 Battery installation
L509-1778; 110-23
copyright © Liebher-Werk Bischofshofen GmbH 2021
22 LIEBHERR L509-1778
LBH/M2261288/03/211-20211019_122138/en
Service manual
Service manual
Contents
120 Gearbox 120-1
120.1 Overview of the transmission
L509-1778; 120-2
120.2 Transmission hydraulics 120-7
120.2.1 Overview of transmission hydraulics
L509-1778; 120-7
120.2.2 Gear shifting
L509-1778; 120-12
120.2.3 Valve block for external servo pressure
L509-1778; 120-14
120.2.4 Travel motor bypass solenoid valve
L509-1778; 120-16
120.3 Transmission electronics 120-18
120.3.1 Gearbox: electrical system
L509-1778; 120-18
120.3.2 Output speed sensor
L509-1778; 120-20
120.3.3 Hall sensor for gear indicator
L509-1778; 120-21
130 Axles and drive shafts 130-1
130.1 Axles 130-2
130.1.1 Front axle
L509-1778; 130-2
130.1.2 Rear axle
L509-1778; 130-4
130.1.3 Engageable differential lockout 130-6
130.1.3.1 Overview of engageable differential lockout
L509-1778; 130-6
130.2 Cardan shafts 130-9
130.2.1 Drive shaft
L509-1778; 130-9
8
g 140 Steel parts of the basic machine 140-1
£ 140.1 Vehicle frame 140-2
q§
8 140.1.1 Articulation bearing
8 L509-1778; 140-2
§ 140.1.2 Articulation lock
z L509-1778; 140-3
150 Working attachment 150-1
150.1 Lift arms for Z kinematics 150-2
copyright ® Liebherr-Werk Bischofshofen GmbH 2021
1509-1778 LIEBHERR 23
Contents Service manual
120.1 Overview of the transmission
L509-1778; 120-2
120.2 Transmission hydraulics 120-7
120.2.1 Overview of transmission hydraulics
L509-1778; 120-7
120.2.2 Gear shifting
L509-1778; 120-12
120.2.3 Valve block for external servo pressure
L509-1778; 120-14
120.2.4 Travel motor bypass solenoid valve
L509-1778; 120-16
120.3 Transmission electronics 120-18
120.3.1 Gearbox: electrical system
L509-1778; 120-18
120.3.2 Output speed sensor
L509-1778; 120-20
120.3.3 Hall sensor for gear indicator
L509-1778; 120-21
130 Axles and drive shafts 130-1
130.1 Axles 130-2
130.1.1 Front axle
L509-1778; 130-2
130.1.2 Rear axle
L509-1778; 130-4
130.1.3 Engageable differential lockout 130-6
130.1.3.1 Overview of engageable differential lockout
L509-1778; 130-6
130.2 Cardan shafts 130-9
130.2.1 Drive shaft
L509-1778; 130-9
8
g 140 Steel parts of the basic machine 140-1
£ 140.1 Vehicle frame 140-2
q§
8 140.1.1 Articulation bearing
8 L509-1778; 140-2
§ 140.1.2 Articulation lock
z L509-1778; 140-3
150 Working attachment 150-1
150.1 Lift arms for Z kinematics 150-2
copyright ® Liebherr-Werk Bischofshofen GmbH 2021
1509-1778 LIEBHERR 23
Contents Service manual
160.1.1 Liftarms
L509-1778; 150-2
150.2 Quick coupler 150-4
150.2.1 Quick coupler
L509-1778; 150-4
1560.2.2 Quick coupler hydraulics 150-5
150.2.2.1 Overview of quick coupler hydraulics
L509-1778/0-65271; 150-5
160.2.2.2 Overview of quick coupler hydraulics
L509-1778/65272-; 150-7
150.2.2.3 Valve block for quick coupler
L509-1778/0-65271; 150-9
160.2.2.4 Valve block for quick coupler
L509-1778/65272-; 150-10
160 Operator’s cab, heating and air conditioning 160-1
160.1 Overview of operator’s cab, heating and air conditioning unit
L509-1778; 160-2
160.2 Display and control elements 160-4
160.2.1 Control lever
1509-1778; 160-4
160.2.2 Accelerator pedal
L509-1778; 160-6
160.3 Heating, ventilation, air conditioning 160-8
160.3.1 Overview of heating, ventilation and air conditioning system
1509-1778; 160-8
160.3.2 Heating and air conditioning unit 160-14
160.3.2.1 Heating and air conditioning unit
L509-1778; 160-14
160.3.2.2 Blower
L509-1778; 160-17
160.4 Air conditioning 160-18
160.4.1 Air conditioning (optional)
1509-1778; 160-18
160.4.2 Compressor magnetic coupling
L509-1778; 160-19
160.4.3 Air conditioning condenser
1509-1778; 160-21
150.2 Quick coupler 150-4
150.2.1 Quick coupler
L509-1778; 150-4
1560.2.2 Quick coupler hydraulics 150-5
150.2.2.1 Overview of quick coupler hydraulics
L509-1778/0-65271; 150-5
160.2.2.2 Overview of quick coupler hydraulics
L509-1778/65272-; 150-7
150.2.2.3 Valve block for quick coupler
L509-1778/0-65271; 150-9
160.2.2.4 Valve block for quick coupler
L509-1778/65272-; 150-10
160 Operator’s cab, heating and air conditioning 160-1
160.1 Overview of operator’s cab, heating and air conditioning unit
L509-1778; 160-2
160.2 Display and control elements 160-4
160.2.1 Control lever
1509-1778; 160-4
160.2.2 Accelerator pedal
L509-1778; 160-6
160.3 Heating, ventilation, air conditioning 160-8
160.3.1 Overview of heating, ventilation and air conditioning system
1509-1778; 160-8
160.3.2 Heating and air conditioning unit 160-14
160.3.2.1 Heating and air conditioning unit
L509-1778; 160-14
160.3.2.2 Blower
L509-1778; 160-17
160.4 Air conditioning 160-18
160.4.1 Air conditioning (optional)
1509-1778; 160-18
160.4.2 Compressor magnetic coupling
L509-1778; 160-19
160.4.3 Air conditioning condenser
1509-1778; 160-21
160.4.4 Dryer-collector unit
1509-1778; 160-21
1509-1778; 160-21
160.4.5 Air conditioning pressure switch
L509-1778; 160-23
L509-1778; 160-23
Contents
170 Lubrication system 170-1
170.1 Liebherr automatic central lubrication system 170-2
170.1.1 Automatic central lubrication system: overview
L509-1778; 170-2
170.1.2 Central lubrication pump EP-1
L509-1778; 170-6
170.1.3 Progressive distributor MX-F
L509-1778; 170-9
190 Options 190-1
190.1 LiDAT 190-2
190.1.1 Overview of LiDAT
L509-1778; 190-2
190.1.2 LiDAT on machine
L509-1778; 190-4
190.1.3 LiDAT module (LiTU3)
L509-1778; 190-5
200 Diagnosis 200-1
200.1 Malfunctions 200-2
200.1.1 Warming symbols 200-2
200.1.2 Service code indicator in the display 200-3
200.2 Troubleshooting 200-5
170.1 Liebherr automatic central lubrication system 170-2
170.1.1 Automatic central lubrication system: overview
L509-1778; 170-2
170.1.2 Central lubrication pump EP-1
L509-1778; 170-6
170.1.3 Progressive distributor MX-F
L509-1778; 170-9
190 Options 190-1
190.1 LiDAT 190-2
190.1.1 Overview of LiDAT
L509-1778; 190-2
190.1.2 LiDAT on machine
L509-1778; 190-4
190.1.3 LiDAT module (LiTU3)
L509-1778; 190-5
200 Diagnosis 200-1
200.1 Malfunctions 200-2
200.1.1 Warming symbols 200-2
200.1.2 Service code indicator in the display 200-3
200.2 Troubleshooting 200-5
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