Liebherr L 546 1560 Wheel Loader Service Manual – PDF DOWNLOAD
FILE DETAILS:
Liebherr L 546 1560 Wheel Loader Service Manual – PDF DOWNLOAD
Language : English
Pages : 1058
Downloadable : Yes
File Type : PDF
Size: 226 MB
DESCRIPTION:
Liebherr L 546 1560 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:
- Consult with the worksite manager about safety regulations at the place of use.
- Adhere to safety regulations at the place of use.
- Follow traffic regulations.
- Adhere to valid guidelines provided by insurers (for example, employers’ professional liability insurance companies, accident insurance, etc.).
- Avoid working methods that can endanger safety.
- Follow all intervals specified for recurrent checks and inspections as outlined in this operator’s manual.
1.2. Intended Use of Wheel Loader
The wheel loader is used to pick up, move, and dump the following materials:
- Soil
- Stones
- Broken rocks
- Bulk materials
This applies to a standard machine under normal operating conditions. Special applications are described in a separate options operator’s manual.
To ensure the intended use:
- Adhere to the operator’s manual.
- Follow maintenance intervals.
- Carry out inspection and maintenance tasks.
- Follow the specifications in the technical data.
- When using the machine on public roads, ensure it complies with applicable national regulations.
- Only lift loads with intended working attachments (fork prongs, crane boom), which must be properly fitted and functioning.
- Ensure that machines used underground (for mining and tunnel construction) are fitted with systems to reduce exhaust emissions (such as diesel particulate filters).
- Adhere to the requirements of each individual country for underground operation.
- For special uses, use special working attachments and, if necessary, special safety equipment.
- Exclusively mount and use special working attachments with approval and as per the stipulations of the manufacturer of the basic machine.
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
Liebherr L 546 1560 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 warning messages 010-4
010.1.1.2 Graphic symbols in these instructions 010-4
010.1.2 Intended use 010-5
010.1.2.1 Laws, rules, guidelines and safety regulations 010-5
010.1.2.2 Intended use 010-5
010.1.2.3 Foreseeable misuse 010-6
010.1.2.4 Operating conditions 010-6
010.1.2.5 Disposal 010-7
010.1.3 Description of staff 010-7
010.1.3.1 Personal protective equipment 010-7
010.1.3.2 Requirements for staff 010-8
010.1.3.3 Operator 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 warning messages 010-4
010.1.1.2 Graphic symbols in these instructions 010-4
010.1.2 Intended use 010-5
010.1.2.1 Laws, rules, guidelines and safety regulations 010-5
010.1.2.2 Intended use 010-5
010.1.2.3 Foreseeable misuse 010-6
010.1.2.4 Operating conditions 010-6
010.1.2.5 Disposal 010-7
010.1.3 Description of staff 010-7
010.1.3.1 Personal protective equipment 010-7
010.1.3.2 Requirements for staff 010-8
010.1.3.3 Operator 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
010.1.7.1 Spare parts 010-21
010.1.7.2 Heavy parts 010-21
010.1.7.3 Regular checks 010-22
010.1.8 Modifications to the machine 010-22
010.1.8.1 Modifications, add-ons and retrofittings 010-22
010.1.8.1 Modifications, add-ons and retrofittings 010-22
010.2 Special tools for maintenance and repair work 010-23
010.21 Special tools, general 010-23
010.2.2 Special tools for the engine 010-25
010.2.3 Special tools for lift cylinders with Z kinematics 010-29
010.2.4 Special tools for tilt cylinders with Z kinematics 010-30
010.2.5 Special tools for lift cylinders with P kinematics 010-31
010.2.6 Special tools for tilt cylinders with P kinematics 010-31
010.2.7 Special tools for steering wheel 010-32
010.2.8 Special tools for steering cylinders 010-32
010.2.8 Special tools for the electrical system 010-33
010.2.10 Special tools for the air conditioning system 010-34
010.2.11 Special tools for cab glazing 010-36
010.2.12 Special tools for the central lubrication system (Liebherr) 010-36
010.3 Standards and regulations 010-37
010.21 Special tools, general 010-23
010.2.2 Special tools for the engine 010-25
010.2.3 Special tools for lift cylinders with Z kinematics 010-29
010.2.4 Special tools for tilt cylinders with Z kinematics 010-30
010.2.5 Special tools for lift cylinders with P kinematics 010-31
010.2.6 Special tools for tilt cylinders with P kinematics 010-31
010.2.7 Special tools for steering wheel 010-32
010.2.8 Special tools for steering cylinders 010-32
010.2.8 Special tools for the electrical system 010-33
010.2.10 Special tools for the air conditioning system 010-34
010.2.11 Special tools for cab glazing 010-36
010.2.12 Special tools for the central lubrication system (Liebherr) 010-36
010.3 Standards and regulations 010-37
010.3.1
010.3.2
Prestressing forces and tightening torques for bolts with metric
standard and fine threads as per DIN ISO 261
010-37
010.3.1.1 Range of application and purpose
010-37
010.3.1.2 Other applicable documents
010-37
010.3.1.3 Modifications and descriptions
010-38
010.3.1.4 Tightening torques
010-38
Liebherr standards for assembly instructions and tightening torques010-44
010.4 Preservation guidelines
0104.1 General information 010-45
0104.2 Machine out of service for an unknown period of time 010-45
0104.3 Putting the machine out of service 010-46
010.4.3.1 Out of service for up to 2 months 010-46
010.4.3.2 Out of service for up to 12 months 010-47
010.4.3.3 Out of service for longer than 12 months 010-48
010.44 Putting back into service 010-48
010.4.4.1 After being out of service for 2 months 010-48
010.4.4.2 After being out of service for 12 months 010-49
010.4.4.3 After being out of service for longer than 12 months 10-49
020 Technical data 020-1
020.1 Overall machine 020-5
020.1.1 Complete machine with bucket (Z kinematics)
1546-1560; 020-5
020.1.2 Complete machine with bucket (parallel kinematics)
L 546-1560; 020-6
020.1.3 Working attachment: light material bucket
1546-1560; 020-8
020.14 Working attachment: high dump bucket
L 546-1560; 020-10
020.1.5 Working attachment: forklift
1546-1560; 020-11
020.1.6 Working attachment: log grappler
L 546-1560; 020-13
020.2 Drive group 020-15
0202.1 Diesel engine
L 546-1560; 020-15
0202.2 Fuel tank
L546-1560; 020-16
020.2.2.1 Plastic version 020-16
020.2.2.2 Steel version (optional) 020-16
020.2.2.3 Diesel exhaust fluid tank 020-16
020.2.3 Fuel level sensor
L546-1560; 020-16
020.2.4 Fuel pre-filter
L 546-1560; 020-17
020.2.5 Fuel fine filter
1546-1560; 020-17
0104.2 Machine out of service for an unknown period of time 010-45
0104.3 Putting the machine out of service 010-46
010.4.3.1 Out of service for up to 2 months 010-46
010.4.3.2 Out of service for up to 12 months 010-47
010.4.3.3 Out of service for longer than 12 months 010-48
010.44 Putting back into service 010-48
010.4.4.1 After being out of service for 2 months 010-48
010.4.4.2 After being out of service for 12 months 010-49
010.4.4.3 After being out of service for longer than 12 months 10-49
020 Technical data 020-1
020.1 Overall machine 020-5
020.1.1 Complete machine with bucket (Z kinematics)
1546-1560; 020-5
020.1.2 Complete machine with bucket (parallel kinematics)
L 546-1560; 020-6
020.1.3 Working attachment: light material bucket
1546-1560; 020-8
020.14 Working attachment: high dump bucket
L 546-1560; 020-10
020.1.5 Working attachment: forklift
1546-1560; 020-11
020.1.6 Working attachment: log grappler
L 546-1560; 020-13
020.2 Drive group 020-15
0202.1 Diesel engine
L 546-1560; 020-15
0202.2 Fuel tank
L546-1560; 020-16
020.2.2.1 Plastic version 020-16
020.2.2.2 Steel version (optional) 020-16
020.2.2.3 Diesel exhaust fluid tank 020-16
020.2.3 Fuel level sensor
L546-1560; 020-16
020.2.4 Fuel pre-filter
L 546-1560; 020-17
020.2.5 Fuel fine filter
1546-1560; 020-17
020.2.6 Clutch
L 546-1560; 020-17
020.3 Cooling system 020-18
020.3.1 Fan pump
L 546-1560; 020-18
020.3.2 Fan motor
L 546-1560; 020-18
020.3.3 Hydraulic oil temperature sensor B8
1 546-1560; 020-18
020.4 Working hydraulics 020-19
020.4.1 Working pump
1546-1560; 020-19
020.4.2 Control valve block for Z kinematics
L 546-1560; 020-19
020.4.3 P kinematics control valve block
1546-1560; 020-19
020.4.4 Pilot control unit
L 546-1560; 020-20
020.4.5 Pilot control hydro accumulator
L 546-1560; 020-20
020.4.6 Stabilisation module
1546-1560; 020-20
020.4.7 Ride control hydro accumulator
1546-1560; 020-21
020.4.8 Z kinematics lift cylinder
L 546-1560; 020-21
020.4.9 Z kinematics tilt cylinder
1546-1560; 020-21
020.4.10 P kinematics lift cylinder
1 546-1560; 020-22
020.4.11 P kinematics tilt cylinder
1546-1560; 020-22
020.5 Travel hydraulics 020-23
020.5.1 Travel pump
L 546-1560; 020-23
020.5.2 Travel pump high pressure sensor B45
1546-1560; 020-23
020.5.3 Travel motor 1
L 546-1560; 020-23
020.5.4 Travel motor 2
1546-1560; 020-24
020.6 Hydraulic components 020-25
020.6.1 Return suction filter
L 546-1560; 020-25
L 546-1560; 020-17
020.3 Cooling system 020-18
020.3.1 Fan pump
L 546-1560; 020-18
020.3.2 Fan motor
L 546-1560; 020-18
020.3.3 Hydraulic oil temperature sensor B8
1 546-1560; 020-18
020.4 Working hydraulics 020-19
020.4.1 Working pump
1546-1560; 020-19
020.4.2 Control valve block for Z kinematics
L 546-1560; 020-19
020.4.3 P kinematics control valve block
1546-1560; 020-19
020.4.4 Pilot control unit
L 546-1560; 020-20
020.4.5 Pilot control hydro accumulator
L 546-1560; 020-20
020.4.6 Stabilisation module
1546-1560; 020-20
020.4.7 Ride control hydro accumulator
1546-1560; 020-21
020.4.8 Z kinematics lift cylinder
L 546-1560; 020-21
020.4.9 Z kinematics tilt cylinder
1546-1560; 020-21
020.4.10 P kinematics lift cylinder
1 546-1560; 020-22
020.4.11 P kinematics tilt cylinder
1546-1560; 020-22
020.5 Travel hydraulics 020-23
020.5.1 Travel pump
L 546-1560; 020-23
020.5.2 Travel pump high pressure sensor B45
1546-1560; 020-23
020.5.3 Travel motor 1
L 546-1560; 020-23
020.5.4 Travel motor 2
1546-1560; 020-24
020.6 Hydraulic components 020-25
020.6.1 Return suction filter
L 546-1560; 020-25
0206.2 Breather filter
L 546-1560; 020-25
020.7 Steering system 020-26
020.71 Servostat
L 546-1560; 020-26
020.7.2 Steering cylinder
L 546-1560; 020-26
020.7.3 Steering damper hydro accumulator
L 546-1560; 020-26
020.7.4 Emergency steering pump
1546-1560; 020-26
020.7.5 Emergency steering pressure switch B3
L546-1560; 020-27
020.7.6 Emergency steering check pressure switch B3a
L 546-1560; 020-27
020.7.7 Joystick steering control valve block
L546-1560/0-53763; 020-27
020.7.8 Joystick steering control valve block
L546-1560/53764-; 020-28
020.8 Brake system 020-29
020.8.1 Brake pump
1546-1560; 020-29
020.8.2 Compact brake valve
1546-1560; 020-29
0208.3 Service brake hydro accumulator
L 546-1560; 020-29
020.8.4 Brake light pressure switch B12
L546-1560; 020-29
0208.5 Brake accumulator pressure sensor B19
L 546-1560; 020-29
020.8.6 Parking brake hydro accumulator
L546-1560; 020-30
020.9 Electrical system 020-31
020.9.1 Central control unit (Master 4)
L 546-1560; 020-31
0209.2 Compact module
1546-1560; 020-31
0209.3 Battery
L546-1560/0-48346; 020-31
020.9.4 Battery
L546-1560/48347-; 020-32
020.9.5 Voltage transformer
1546-1560; 020-32
020.10 Gearbox 020-33
L 546-1560; 020-25
020.7 Steering system 020-26
020.71 Servostat
L 546-1560; 020-26
020.7.2 Steering cylinder
L 546-1560; 020-26
020.7.3 Steering damper hydro accumulator
L 546-1560; 020-26
020.7.4 Emergency steering pump
1546-1560; 020-26
020.7.5 Emergency steering pressure switch B3
L546-1560; 020-27
020.7.6 Emergency steering check pressure switch B3a
L 546-1560; 020-27
020.7.7 Joystick steering control valve block
L546-1560/0-53763; 020-27
020.7.8 Joystick steering control valve block
L546-1560/53764-; 020-28
020.8 Brake system 020-29
020.8.1 Brake pump
1546-1560; 020-29
020.8.2 Compact brake valve
1546-1560; 020-29
0208.3 Service brake hydro accumulator
L 546-1560; 020-29
020.8.4 Brake light pressure switch B12
L546-1560; 020-29
0208.5 Brake accumulator pressure sensor B19
L 546-1560; 020-29
020.8.6 Parking brake hydro accumulator
L546-1560; 020-30
020.9 Electrical system 020-31
020.9.1 Central control unit (Master 4)
L 546-1560; 020-31
0209.2 Compact module
1546-1560; 020-31
0209.3 Battery
L546-1560/0-48346; 020-31
020.9.4 Battery
L546-1560/48347-; 020-32
020.9.5 Voltage transformer
1546-1560; 020-32
020.10 Gearbox 020-33
020.10.1 Transmission
L 546-1560; 020-33
020.10.2 Gear shifting proportional solenoid valve Y60
1546-1560; 020-33
020.10.3 Output B1 speed sensor
L 546-1560; 020-33
020.10.4 Travel motor 2 speed sensor B2
1546-1560; 020-33
020.11 Axles and drive shafts 020-34
020.11.1 Front axle
1546-1560; 020-34
020.11.2 Rear axle
L 546-1560; 020-34
020.11.3 Cardan shaft
L 546-1560; 020-34
020.11.4 Tyres
1546-1560; 020-34
020.11.4.1 Tyres for machines with Z kinematics 020-35
020.11.4.2 Tyres for machines with parallel kinematics 020-36
020.11.4.3 Special tyres 020-36
020.12 Working attachment 020-38
020.12.1 Quick coupler locking hydraulic cylinder
L546-1560/0-45466; 020-38
020.12.2 Quick coupler locking hydraulic cylinder
L546-1560/45467-; 020-38
020.13 Operator’s cab, heating and air conditioning 020-39
020.13.1.1 Air conditioning compressor 020-39
020.13.2 Dryer
L 546-1560; 020-39
020.13.3 Pressure switches
1546-1560; 020-39
020.13.4 Anti-icing temperature sensor
1546-1560; 020-39
020.14 Lubrication system 020-41
020.14.1 Central lubrication system (Liebherr)
L 546-1560; 020-41
020.14.1.1 Central lubrication pump 020-41
020.14.2 Progressive distributor
1546-1560; 020-41
020.14.21 MXF 020-41
020.14.22 MX-F 25 020-41
020.14.2.3 MX-F 45 020-42
020.14.24 MX-F75 020-42
020.1425 MX-F105 020-42
030 Maintenance 030-1
030.1 Maintenance and inspection schedule 030-10
030.2 Filling quantities and lubrication chart 030-15
030.21 Recommended lubricants
L 546-1560; 030-15
0302.2 Recommended operating fluids
L 546-1560; 030-16
030.3 Lubricants and fuels 030-17
030.3.1 General information on lubricants and fuels 030-17
030.3.1.1 General questions 030-17
030.3.1.2 Safety data sheets 030-17
030.3.1.3 Technical data sheets 030-17
030.3.1.4 Specific Liebherr standards 030-17
030.3.2 General information on changing lubricants and fuels 030-17
030.3.3 Converting hydraulic system from mineral oils to biodegradable
hydraulic fluids 030-18
030.3.4 Diesel fuels
L 546-1560; 030-18
030.34.1 Minimum quality requirement 030-18
030.34.2 Minimum quality requirement 030-18
030.3.5 Diesel exhaust fluid
L 546-1560; 030-19
030.3.5.1 Liebherr recommendation 030-19
030.3.5.2 Minimum quality requirement 030-19
030.3.6 Engine oils
L 546-1560; 030-19
030.3.6.1 Liebherr recommendation 030-19
030.36.3 Minimum quality requirement 030-19
030.3.7 Refrigerant
1546-1560; 030-20
030.3.8 Coolant
L546-1560; 030-20
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 030-21
020.10.2 Gear shifting proportional solenoid valve Y60
1546-1560; 020-33
020.10.3 Output B1 speed sensor
L 546-1560; 020-33
020.10.4 Travel motor 2 speed sensor B2
1546-1560; 020-33
020.11 Axles and drive shafts 020-34
020.11.1 Front axle
1546-1560; 020-34
020.11.2 Rear axle
L 546-1560; 020-34
020.11.3 Cardan shaft
L 546-1560; 020-34
020.11.4 Tyres
1546-1560; 020-34
020.11.4.1 Tyres for machines with Z kinematics 020-35
020.11.4.2 Tyres for machines with parallel kinematics 020-36
020.11.4.3 Special tyres 020-36
020.12 Working attachment 020-38
020.12.1 Quick coupler locking hydraulic cylinder
L546-1560/0-45466; 020-38
020.12.2 Quick coupler locking hydraulic cylinder
L546-1560/45467-; 020-38
020.13 Operator’s cab, heating and air conditioning 020-39
020.13.1.1 Air conditioning compressor 020-39
020.13.2 Dryer
L 546-1560; 020-39
020.13.3 Pressure switches
1546-1560; 020-39
020.13.4 Anti-icing temperature sensor
1546-1560; 020-39
020.14 Lubrication system 020-41
020.14.1 Central lubrication system (Liebherr)
L 546-1560; 020-41
020.14.1.1 Central lubrication pump 020-41
020.14.2 Progressive distributor
1546-1560; 020-41
020.14.21 MXF 020-41
020.14.22 MX-F 25 020-41
020.14.2.3 MX-F 45 020-42
020.14.24 MX-F75 020-42
020.1425 MX-F105 020-42
030 Maintenance 030-1
030.1 Maintenance and inspection schedule 030-10
030.2 Filling quantities and lubrication chart 030-15
030.21 Recommended lubricants
L 546-1560; 030-15
0302.2 Recommended operating fluids
L 546-1560; 030-16
030.3 Lubricants and fuels 030-17
030.3.1 General information on lubricants and fuels 030-17
030.3.1.1 General questions 030-17
030.3.1.2 Safety data sheets 030-17
030.3.1.3 Technical data sheets 030-17
030.3.1.4 Specific Liebherr standards 030-17
030.3.2 General information on changing lubricants and fuels 030-17
030.3.3 Converting hydraulic system from mineral oils to biodegradable
hydraulic fluids 030-18
030.3.4 Diesel fuels
L 546-1560; 030-18
030.34.1 Minimum quality requirement 030-18
030.34.2 Minimum quality requirement 030-18
030.3.5 Diesel exhaust fluid
L 546-1560; 030-19
030.3.5.1 Liebherr recommendation 030-19
030.3.5.2 Minimum quality requirement 030-19
030.3.6 Engine oils
L 546-1560; 030-19
030.3.6.1 Liebherr recommendation 030-19
030.36.3 Minimum quality requirement 030-19
030.3.7 Refrigerant
1546-1560; 030-20
030.3.8 Coolant
L546-1560; 030-20
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 030-21
030.3.9 Hydraulic oil
L 546-1560; 030-21
030.3.9.1 Liebherr recommendation 030-21
030.3.9.2 Minimum quality requirement 030-21
030.3.9.3 Oil analysis 030-21
030.3.9.4 Oil change 030-22
030.3.10 Gear oil
L 546-1560; 030-22
030.3.10.1 Liebherr recommendation 030-22
030.3.10.2 Minimum quality requirement 030-22
030.3.11 Axle oil
L 546-1560; 030-23
030.3.11.1 Liebherr recommendation 030-23
030.3.11.2 Minimum quality requirement 030-23
030.3.12 Lubrication grease
L 546-1560; 030-23
030.3.12.1 Liebherr recommendation 030-23
030.3.12.2 Minimum quality requirement 030-23
Maintenance tasks 030-24
030.4.1 Safety precautions
L 546-1560; 030-24
030.4.2 Preparatory tasks for maintenance 030-24
0304.21 Maintenance positions
L546-1560; 030-25
030.4.2.2 Opening the service hatches
L546-1560; 030-26
030.4.2.3 Turning off the battery main switch
1546-1560; 030-28
030.4.3 Overall machine 030-29
030.4.3.1 Checking the machine is in the proper condition
1546-1560; 030-29
030.4.3.2 Removing loose parts, dirt, ice and snow from
machine
1546-1560; 030-30
0304.33 Cleaning the machine
1546-1560; 030-30
030.4.3.4 Replacing VCI capsules
L546-1560; 030-33
030.4.3.5 Oil analyses
L546-1560; 030-36
030.4.4 Drive group 030-42
030.3.9.1 Liebherr recommendation 030-21
030.3.9.2 Minimum quality requirement 030-21
030.3.9.3 Oil analysis 030-21
030.3.9.4 Oil change 030-22
030.3.10 Gear oil
L 546-1560; 030-22
030.3.10.1 Liebherr recommendation 030-22
030.3.10.2 Minimum quality requirement 030-22
030.3.11 Axle oil
L 546-1560; 030-23
030.3.11.1 Liebherr recommendation 030-23
030.3.11.2 Minimum quality requirement 030-23
030.3.12 Lubrication grease
L 546-1560; 030-23
030.3.12.1 Liebherr recommendation 030-23
030.3.12.2 Minimum quality requirement 030-23
Maintenance tasks 030-24
030.4.1 Safety precautions
L 546-1560; 030-24
030.4.2 Preparatory tasks for maintenance 030-24
0304.21 Maintenance positions
L546-1560; 030-25
030.4.2.2 Opening the service hatches
L546-1560; 030-26
030.4.2.3 Turning off the battery main switch
1546-1560; 030-28
030.4.3 Overall machine 030-29
030.4.3.1 Checking the machine is in the proper condition
1546-1560; 030-29
030.4.3.2 Removing loose parts, dirt, ice and snow from
machine
1546-1560; 030-30
0304.33 Cleaning the machine
1546-1560; 030-30
030.4.3.4 Replacing VCI capsules
L546-1560; 030-33
030.4.3.5 Oil analyses
L546-1560; 030-36
030.4.4 Drive group 030-42
030.4.4.1 Checking diesel engine oil level
L 546-1560; 030-42
030.4.4.2 Diesel engine: Changing the oil
030.4.4.2 Diesel engine: Changing the oil
1546-1560; 030-44
030.4.4.3 Changing the diesel engine oil filter
030.4.4.3 Changing the diesel engine oil filter
L 546-1560; 030-46
030.44.4 Checking the V-ribbed belt on the diesel engine
030.44.4 Checking the V-ribbed belt on the diesel engine
1546-1560; 030-47
030.4.4.5 Changing V-ribbed belt on diesel engine
030.4.4.5 Changing V-ribbed belt on diesel engine
L 546-1560; 030-48
030.4.4.6 Checking diesel engine valve clearance
030.4.4.6 Checking diesel engine valve clearance
1546-1560; 030-50
030.4.4.7 Engine: changing the oil separator filter insert
030.4.4.7 Engine: changing the oil separator filter insert
L 546-1560; 030-54
030.44.8 Diesel engine: Checking the crankcase bleeder
030.44.8 Diesel engine: Checking the crankcase bleeder
system
1546-1560; 030-54
030.4.4.9 Diesel engine: Checking the glow plugs
030.4.4.9 Diesel engine: Checking the glow plugs
1546-1560; 030-55
030.4.4.10 Draining condensate and sediment from the fuel tank
030.4.4.10 Draining condensate and sediment from the fuel tank
L 546-1560; 030-56
030.4.4.11 Draining off condensate from the fuel pre-filter
030.4.4.11 Draining off condensate from the fuel pre-filter
1546-1560; 030-57
030.4.4.12 Fuel pre-filter: Changing the filter element
030.4.4.12 Fuel pre-filter: Changing the filter element
1546-1560; 030-58
030.4.4.13 Changing the fuel fine filter element
030.4.4.13 Changing the fuel fine filter element
L 546-1560; 030-60
030.4.4.14 Exhaust system: changing filter cartridge of diesel
030.4.4.14 Exhaust system: changing filter cartridge of diesel
exhaust fluid pump
L 546-1560; 030-61
030.4.4.15 Air filter system: Cleaning the service cover and dust
030.4.4.15 Air filter system: Cleaning the service cover and dust
discharge valve
1546-1560; 030-62
030.4.4.16 Cleaning or changing main element of air filter
030.4.4.16 Cleaning or changing main element of air filter
system
1546-1560; 030-63
030.4.4.17 Air filter system: Changing the safety element
030.4.4.17 Air filter system: Changing the safety element
1546-1560; 030-66
030.4.4.18 Diesel engine: Checking that the intake and exhaust
030.4.4.18 Diesel engine: Checking that the intake and exhaust
system is in good condition and not loose or leaking
1546-1560; 030-67
030.4.4.19 Cleaning or changing the diesel particulate filter
030.4.4.19 Cleaning or changing the diesel particulate filter
L 546-1560; 030-69
Cooling system 030-73
030.4.5.1 Cooling system: Checking the coolant level
Cooling system 030-73
030.4.5.1 Cooling system: Checking the coolant level
L 546-1560; 030-73
L546-1560
030.4.5.2 Checking the concentration of anti-freeze and corro-
sion protection agent or corrosion inhibitor in the
coolant
1546-1560; 030-75
0304.53 Cleaning the cooling system
1546-1560; 030-82
030.4.5.4 Changing coolant in cooling system
1546-1560; 030-83
030.46 Hydraulic components 030-86
030.4.6.1 Hydraulic tank: Checking the oil level
1546-1560; 030-86
0304.6.2 Hydraulic tank: Checking and cleaning the magnetic
rod
1546-1560; 030-88
030.4.6.3 Hydraulic tank: Draining off condensate and sedi-
ment
1546-1560; 030-88
0304.6.4 Hydraulic tank: Changing the return suction filter
cartridge
1546-1560; 030-89
0304.6.5 Hydraulic tank: Change the breather filter
1546-1560; 030-90
0304.6.6 Hydraulic tank: analysing the oil
1546-1560; 030-91
0304.6.7 Hydraulic tank: changing the oil
1546-1560; 030-93
030.4.7 Steering system 030-96
030.4.7.1 Steering: Checking the function
1546-1560; 030-96
0304.7.2 Steering cylinders: Lubricating the bearings
1546-1560; 030-96
030.4.8 Brake system 030-97
030.4.8.1 Testing service brake and parking brake
1546-1560; 030-97
030.4.8.2 Checking service brake discs for wear
1546-1560; 030-99
030.4.8.3 Checking gap and wear on parking brake linings
1546-1560; 030-100
030.4.9 Electrical system 030-106
030.4.9.1 Checking function of the lighting and horn
1546-1560; 030-106
0304.9.2 Batteries: Checking the acid level and terminals
1546-1560; 030-107
030.4.5.2 Checking the concentration of anti-freeze and corro-
sion protection agent or corrosion inhibitor in the
coolant
1546-1560; 030-75
0304.53 Cleaning the cooling system
1546-1560; 030-82
030.4.5.4 Changing coolant in cooling system
1546-1560; 030-83
030.46 Hydraulic components 030-86
030.4.6.1 Hydraulic tank: Checking the oil level
1546-1560; 030-86
0304.6.2 Hydraulic tank: Checking and cleaning the magnetic
rod
1546-1560; 030-88
030.4.6.3 Hydraulic tank: Draining off condensate and sedi-
ment
1546-1560; 030-88
0304.6.4 Hydraulic tank: Changing the return suction filter
cartridge
1546-1560; 030-89
0304.6.5 Hydraulic tank: Change the breather filter
1546-1560; 030-90
0304.6.6 Hydraulic tank: analysing the oil
1546-1560; 030-91
0304.6.7 Hydraulic tank: changing the oil
1546-1560; 030-93
030.4.7 Steering system 030-96
030.4.7.1 Steering: Checking the function
1546-1560; 030-96
0304.7.2 Steering cylinders: Lubricating the bearings
1546-1560; 030-96
030.4.8 Brake system 030-97
030.4.8.1 Testing service brake and parking brake
1546-1560; 030-97
030.4.8.2 Checking service brake discs for wear
1546-1560; 030-99
030.4.8.3 Checking gap and wear on parking brake linings
1546-1560; 030-100
030.4.9 Electrical system 030-106
030.4.9.1 Checking function of the lighting and horn
1546-1560; 030-106
0304.9.2 Batteries: Checking the acid level and terminals
1546-1560; 030-107
030.4.9.3 Control lever: Change the travel direction switch
rocker and cap.
1546-1560; 030-109
Gearbox 030-112
030.4.10.1 Transmission: checking the oil level
Gearbox 030-112
030.4.10.1 Transmission: checking the oil level
1546-1560; 030-112
030.4.10.2 Changing the transmission oil
030.4.10.2 Changing the transmission oil
L 546-1560; 030-112
Axles and drive shafts 030-114
030.4.11.1 Checking the axle oil levels
Axles and drive shafts 030-114
030.4.11.1 Checking the axle oil levels
1546-1560; 030-114
030.4.11.2 Changing the axle oil
030.4.11.2 Changing the axle oil
L 546-1560; 030-115
030.4.11.3 Front axle: Checking the tightening torque of the
030.4.11.3 Front axle: Checking the tightening torque of the
fastening bolts
1546-1560; 030-117
030.4.11.4 Checking the drive shaft
030.4.11.4 Checking the drive shaft
L 546-1560; 030-118
030.4.11.5 Checking the tyre pressure
030.4.11.5 Checking the tyre pressure
1546-1560; 030-119
030.4.11.86 Checking the wheel tightness
030.4.11.86 Checking the wheel tightness
L 546-1560; 030-119
Steel parts of the basic machine 030-120
030.4.12.1 Lubricating the articulation bearing and the rear axle
Steel parts of the basic machine 030-120
030.4.12.1 Lubricating the articulation bearing and the rear axle
oscillating bearing
1546-15860; 030-120
030.4.12.2 Service hatches: Cleaning and maintaining the seals
030.4.12.2 Service hatches: Cleaning and maintaining the seals
L 546-1560; 030-121
Working attachment 030-121
030.4.13.1 Lubricating the lift arms and working attachment
Working attachment 030-121
030.4.13.1 Lubricating the lift arms and working attachment
1546-1560; 030-121
030.4.13.2 Checking the lift arm bucket bearing bushings
030.4.13.2 Checking the lift arm bucket bearing bushings
L 546-1560; 030-123
030.4.13.3 Checking lift arm bucket stops
030.4.13.3 Checking lift arm bucket stops
1546-1560; 030-124
030.4.13.4 Scoop: Check teeth or undercut blade for wear and
030.4.13.4 Scoop: Check teeth or undercut blade for wear and
replace if necessary
L 546-1560; 030-125
030.4.13.5 Lubricate and test the bearings on the quick coupler.
030.4.13.5 Lubricate and test the bearings on the quick coupler.
L 546-1560; 030-127
030.4.13.6 High dump bucket: bearing lubrication
030.4.13.6 High dump bucket: bearing lubrication
1546-1560; 030-128
Operator’s cab, heating and air conditioning 030-129
Operator’s cab, heating and air conditioning 030-129
L546-1560
030.4.14.1 Cab: Cleaning the fresh and recirculated air filters
1546-1560; 030-129
030.4.14.2 Cab: Changing the fresh and recirculated air filters
1546-1560; 030-131
030.4.14.3 Safety belt: checking condition and function
1546-1560; 030-133
030.4.14.4 Testing the windscreen washer system
1546-1560; 030-134
030.4.14.5 Windscreen washer system: Topping up windscreen
washer fluid
1546-1560; 030-134
030.4.14.6 Comfort safety door: lubricating rising hinge
1546-1560; 030-135
030.4.14.7 Lubricating the locking mechanism and cylinder of
the operator’s cab with penetrating oil
1546-1560; 030-135
030.4.14.8 Cab: Cleaning and maintaining the seals
1546-1560; 030-136
030.4.14.9 Checking the indicator bead in the air conditioning
dryer-collector unit
1546-1560; 030-137
030.4.14.10 Heating and air conditioning unit: Testing the function
1546-1560; 030-137
030.4.15 Lubrication system 030-139
030.4.15.1 Checking grease level in reservoir of central lubrica-
tion system
1546-1560; 030-139
030.4.15.2 Central lubrication system: Checking the pipes,
hoses and lubrication points for leaks and damage
1546-1560; 030-140
030.4.15.3 Central lubrication system: Checking the lubrication
of the bearings
1546-1560; 030-141
030.5 Testing and adjustment checklist
L546-1560; 030-142
030.6 Testing and adjustment tasks 030-148
030.6.1 Safety precautions
1546-1560; 030-148
030.6.2 Overall machine 030-148
030.6.2.1 Preparing for adjustment procedures
1546-1560; 030-148
030.6.2.2 Hydraulic oil and coolant: operating temperature
1546-1560; 030-150
030.6.2.3 Service management
1546-1560; 030-151
1546-1560; 030-129
030.4.14.2 Cab: Changing the fresh and recirculated air filters
1546-1560; 030-131
030.4.14.3 Safety belt: checking condition and function
1546-1560; 030-133
030.4.14.4 Testing the windscreen washer system
1546-1560; 030-134
030.4.14.5 Windscreen washer system: Topping up windscreen
washer fluid
1546-1560; 030-134
030.4.14.6 Comfort safety door: lubricating rising hinge
1546-1560; 030-135
030.4.14.7 Lubricating the locking mechanism and cylinder of
the operator’s cab with penetrating oil
1546-1560; 030-135
030.4.14.8 Cab: Cleaning and maintaining the seals
1546-1560; 030-136
030.4.14.9 Checking the indicator bead in the air conditioning
dryer-collector unit
1546-1560; 030-137
030.4.14.10 Heating and air conditioning unit: Testing the function
1546-1560; 030-137
030.4.15 Lubrication system 030-139
030.4.15.1 Checking grease level in reservoir of central lubrica-
tion system
1546-1560; 030-139
030.4.15.2 Central lubrication system: Checking the pipes,
hoses and lubrication points for leaks and damage
1546-1560; 030-140
030.4.15.3 Central lubrication system: Checking the lubrication
of the bearings
1546-1560; 030-141
030.5 Testing and adjustment checklist
L546-1560; 030-142
030.6 Testing and adjustment tasks 030-148
030.6.1 Safety precautions
1546-1560; 030-148
030.6.2 Overall machine 030-148
030.6.2.1 Preparing for adjustment procedures
1546-1560; 030-148
030.6.2.2 Hydraulic oil and coolant: operating temperature
1546-1560; 030-150
030.6.2.3 Service management
1546-1560; 030-151
Drive group 030-152
030.6.3.1 Pedals: calibration
030.6.3.1 Pedals: calibration
1546-1560; 030-152
030.6.3.2 Diesel engine speed
030.6.3.2 Diesel engine speed
L 546-1560; 030-153
030.6.3.3 Reading the diesel engine service files
030.6.3.3 Reading the diesel engine service files
L 546-1560; 030-153
Cooling system 030-156
030.6.4.1 Fan speed proportional solenoid valve
Cooling system 030-156
030.6.4.1 Fan speed proportional solenoid valve
L 546-1560; 030-156
Working hydraulics 030-158
030.6.5.1 Multi-lever control (optional): Calibration
Working hydraulics 030-158
030.6.5.1 Multi-lever control (optional): Calibration
1546-1560; 030-158
030.6.5.2 Working hydraulics angle sensors (option): calibra-
030.6.5.2 Working hydraulics angle sensors (option): calibra-
tion
1546-1560; 030-159
030.6.5.3 Proportional solenoids in the control valve block: cali-
030.6.5.3 Proportional solenoids in the control valve block: cali-
bration
L 546-1560; 030-163
030.6.5.4 Working pump: flow regulator (standby pressure)
030.6.5.4 Working pump: flow regulator (standby pressure)
1546-1560; 030-166
030.6.5.5 Working pump flow regulator (differential pressure)
030.6.5.5 Working pump flow regulator (differential pressure)
L 546-1560; 030-167
030.6.5.6 Z-bar kinematics control valve block: secondary pres-
030.6.5.6 Z-bar kinematics control valve block: secondary pres-
sure relief valves
1546-15860; 030-169
030.6.5.7 P-kinematics control valve block (option): secondary
030.6.5.7 P-kinematics control valve block (option): secondary
pressure relief valves
1546-1560; 030-172
030.6.5.8 Control valve block: working hydraulics LS pressure
030.6.5.8 Control valve block: working hydraulics LS pressure
cut-off
L 546-1560; 030-174
030.6.5.9 Stabilisation module cut-out function
030.6.5.9 Stabilisation module cut-out function
1546-1560; 030-175
030.6.5.10 Ride control hydro accumulator nitrogen filling
030.6.5.10 Ride control hydro accumulator nitrogen filling
L 546-1560; 030-177
Hydraulic components 030-178
030.6.6.1 Hydro accumulator: checking and topping up
Hydraulic components 030-178
030.6.6.1 Hydro accumulator: checking and topping up
nitrogen filling
1546-1560; 030-178
030.6.6.2 Checking the hydraulic lines for damage
030.6.6.2 Checking the hydraulic lines for damage
L 546-1560; 030-179
Travel hydraulics 030-184
030.6.7.1 Travel pump high pressure sensor B45: Deviation
Travel hydraulics 030-184
030.6.7.1 Travel pump high pressure sensor B45: Deviation
L546-1560; 030-184
L546-1560
030.6.7.2 Travel pump replenishing pressure relief valve
L546-1560; 030-185
0306.7.3 Travel pump: high pressure relief valves
0306.7.3 Travel pump: high pressure relief valves
1546-1560; 030-187
030.6.7.4 Travel pump: pressure cut-off
030.6.7.4 Travel pump: pressure cut-off
1546-1560; 030-190
030.6.7.5 Travel pump: manual block curve calibration (up to
030.6.7.5 Travel pump: manual block curve calibration (up to
software version 017)
1546-1560; 030-192
0306.7.6 Travel pump: automatic block curve calibration (from
0306.7.6 Travel pump: automatic block curve calibration (from
software version 018)
1546-1560; 030-194
030.6.7.7 Travel motor 1: start of regulation
030.6.7.7 Travel motor 1: start of regulation
1546-1560; 030-194
030.6.7.8 Travel motor 2 automatic calibration
030.6.7.8 Travel motor 2 automatic calibration
1546-1560; 030-196
030.6.7.9 Diesel engine: Performance
030.6.7.9 Diesel engine: Performance
1546-1560; 030-197
Steering system 030-198
030.6.8.1 Angle sensor for articulation angle (option): calibra-
Steering system 030-198
030.6.8.1 Angle sensor for articulation angle (option): calibra-
tion
1546-1560; 030-198
030.6.8.2 Control block for joystick steering (option): calibration
030.6.8.2 Control block for joystick steering (option): calibration
1546-1560; 030-199
030.6.8.3 Control valve block: Steering system LS pressure
030.6.8.3 Control valve block: Steering system LS pressure
cut-off
1546-1560; 030-201
030.6.8.4 Steering damper hydro accumulator nitrogen filling
030.6.8.4 Steering damper hydro accumulator nitrogen filling
L546-1560; 030-203
030.6.8.5 Control block for joystick steering: determining instal-
030.6.8.5 Control block for joystick steering: determining instal-
lation position of position sensors
1546-1560; 030-204
Brake system 030-205
030.6.9.1 Compact brake valve hydro accumulator charging
Brake system 030-205
030.6.9.1 Compact brake valve hydro accumulator charging
function
1546-1560; 030-205
030.6.9.2 Service brake pressure
030.6.9.2 Service brake pressure
1546-1560; 030-206
0306.9.3 Service brake hydro accumulator capacity
0306.9.3 Service brake hydro accumulator capacity
1546-1560; 030-208
030.6.9.4 Brake accumulator pressure sensor B19: deviation
030.6.9.4 Brake accumulator pressure sensor B19: deviation
1546-1560; 030-209
Electrical system 030-210
030.6.10.1 Central control unit (Master4) Creating a Servicefile
Electrical system 030-210
030.6.10.1 Central control unit (Master4) Creating a Servicefile
L 546-1560; 030-210
030.6.10.2 Updating the central controller software
L 546-1560; 030-214
030.6.10.3 Setting the IP addresses of the central control unit
030.6.10.3 Setting the IP addresses of the central control unit
(Master4)
1546-1560; 030-216
030.6.10.4 Resetting the central control unit (Master4)
030.6.10.4 Resetting the central control unit (Master4)
L 546-1560; 030-219
030.6.10.5 Testing the CAN line
030.6.10.5 Testing the CAN line
1546-1560; 030-220
030.6.10.6 Addressing the CAN module and checking the
system information
system information
1546-1560; 030-224
Gearbox 030-226
030.6.11.1 Proportional solenoid for clutch: calibration
Gearbox 030-226
030.6.11.1 Proportional solenoid for clutch: calibration
1546-1560; 030-226
030.6.11.2 Rapid draining phase: calibration
030.6.11.2 Rapid draining phase: calibration
1546-1560; 030-227
030.6.11.3 Transmission hydraulics: Hydraulic oil adjustment
030.6.11.3 Transmission hydraulics: Hydraulic oil adjustment
1546-1560; 030-229
Axles and drive shafts 030-229
030.6.12.1 Tyres: setting radius
Axles and drive shafts 030-229
030.6.12.1 Tyres: setting radius
L 546-1560; 030-229
Working attachment 030-230
Working attachment 030-230
030.6.13.1 Valve block for quick coupler (optional): Pressure
reducing valve
reducing valve
1546-15860; 030-230
030.6.13.2 Parameters for lift arm geometry
030.6.13.2 Parameters for lift arm geometry
L546-1560; 030-231
030.6.13.3 Working attachment: freedom of movement
030.6.13.3 Working attachment: freedom of movement
1546-1560; 030-233
Operator’s cab, heating and air conditioning 030-234
Operator’s cab, heating and air conditioning 030-234
030.6.14.1 Checking the pressure and temperature conditions of
the air conditioning unit
the air conditioning unit
L546-1560; 030-234
030.6.14.2 Calibrating the display (Display4)
030.6.14.2 Calibrating the display (Display4)
1546-1560; 030-235
030.6.14.3 Formatting the display and reinstalling the software
030.6.14.3 Formatting the display and reinstalling the software
(Display4)
L546-1560; 030-236
Options 030-238
030.6.15.1 Checking the LiDAT connection status
Options 030-238
030.6.15.1 Checking the LiDAT connection status
1546-1560; 030-238
030.6.15.2 LiDAT: activating data transmission manually
030.6.15.2 LiDAT: activating data transmission manually
L 546-1560; 030-240
L546-1560
copyright ® Liebherr-Werk Bischofshofen GmbH 2019
LIEBHERR 19
Contents
Contents
Service manual
040 Drive group 040-1
040.1 Engine 040-2
040.1.1 Diesel engine overview
L 546-1560; 040-2
040.1.2 Diesel engine: Electrical components
1546-1560; 040-6
040.1.3 Fuel system 040-16
040.1.3.1 Overview of the fuel system
1546-1560; 040-16
040.1.3.2 Fuel level sensor
L546-1560; 040-17
040.1.3.3 Fuel pre-filter
1546-1560; 040-19
040.1.3.4 Fuel fine filter
1546-1560; 040-20
040.1.4 Air filter system 040-21
040.1.4.1 Air filter
1546-1560; 040-21
040.1.5 Exhaust system 040-22
040.1.5.1 Overview of exhaust system
1546-1560; 040-22
040.1.5.2 Diesel particulate filter (DPF): General overview
1546-1560; 040-25
040.1.5.3 SCR system
1546-1560; 040-30
040.1.5.4 Sampling module
1.546-1560/0-45060; 040-34
040.1.5.5 Sampling module
L546-1560/45061-; 040-35
040.2 Clutch
1546-1560; 040-37
050 Cooling system 050-1
050.1 Overview of the cooling system
1546-1560; 050-2
050.2 Cooling system hydraulics 050-3
050.2.1 Overview of cooling system hydraulics
L 546-1560; 050-3
050.2.2 Fan pump
1546-1560; 050-7
050.2.3 Fan motor
1546-1560; 050-8
050.3 Cooling system electronics 050-12
040.1 Engine 040-2
040.1.1 Diesel engine overview
L 546-1560; 040-2
040.1.2 Diesel engine: Electrical components
1546-1560; 040-6
040.1.3 Fuel system 040-16
040.1.3.1 Overview of the fuel system
1546-1560; 040-16
040.1.3.2 Fuel level sensor
L546-1560; 040-17
040.1.3.3 Fuel pre-filter
1546-1560; 040-19
040.1.3.4 Fuel fine filter
1546-1560; 040-20
040.1.4 Air filter system 040-21
040.1.4.1 Air filter
1546-1560; 040-21
040.1.5 Exhaust system 040-22
040.1.5.1 Overview of exhaust system
1546-1560; 040-22
040.1.5.2 Diesel particulate filter (DPF): General overview
1546-1560; 040-25
040.1.5.3 SCR system
1546-1560; 040-30
040.1.5.4 Sampling module
1.546-1560/0-45060; 040-34
040.1.5.5 Sampling module
L546-1560/45061-; 040-35
040.2 Clutch
1546-1560; 040-37
050 Cooling system 050-1
050.1 Overview of the cooling system
1546-1560; 050-2
050.2 Cooling system hydraulics 050-3
050.2.1 Overview of cooling system hydraulics
L 546-1560; 050-3
050.2.2 Fan pump
1546-1560; 050-7
050.2.3 Fan motor
1546-1560; 050-8
050.3 Cooling system electronics 050-12
20
copyright ® Liebher-Werk Bischofshofen GmbH 2019
L546-1560
LBH/12204899/11/211-20180801_073732/en
LBH/M2204899/11/211-20190801_073732/en
LBH/M2204899/11/211-20190801_073732/en
Service manual
Contents
050.3.1 General overview of electronic control system
L546-1560; 050-12
050.3.2 Temperature sensor for coolant
L 546-1560; 050-15
050.3.3 Hydraulic oil temperature sensor
L546-1560; 050-17
050.34 Temperature sensor for charge air
L 546-1560; 050-18
050.4 Cooler 050-20
050.4.1 Cooler unit
L 546-1560; 050-20
050.5 Reversible fan drive 050-21
050.5.1 Overview of the reversible fan drive
L546-1560; 050-21
050.5.2 Fan reversal valve block
L 546-1560; 050-23
060 Working hydraulics 060-1
060.1 Overview of Z-bar kinematics working hydraulics
1546-1560; 060-2
060.2 Overview of the P kinematics working hydraulics
1546-1560; 060-10
060.3 Working pump
1546-1560; 060-14
060.4 Control valve block for Z-bar kinematics
L546-1560; 060-22
060.5 Control block for P kinematics
1546-1560; 060-31
060.6 Pilot control 060-37
060.6.1 Servo pressure solenoid valve
L546-1560; 060-37
060.7 Ride control 060-39
060.7.1 Overview of ride control system
L 546-1560; 060-39
060.7.2 Stabilisation module
L 546-1560; 060-42
060.8 Electronics of the working hydraulics 060-45
060.8.1 Overview of electrical controls the working hydraulics
L546-1560; 060-45
060.8.2 Working hydraulics angle sensors
L 546-1560; 060-48
060.9 Pipe break protection 060-51
copyright ® Liebherr-Werk Bischofshofen GmbH 2019
L546-1560 LIEBHERR 2
Contents Service manual
060.9.1 Pipe break protection: overview
L546-1560; 060-51
060.9.2 Valve block for pipe break protection
1546-1560; 060-53
060.9.3 Solenoid valve for release of the ride control
L 546-1560; 060-54
070 Travel hydraulics 070-1
070.1 Overview of travel hydraulics
L 546-1560; 070-2
070.2 Travel pump
1546-1560; 070-7
070.3 Travel motors 070-22
070.3.1 Overview of the travel motors
1546-1560; 070-22
070.3.2 Travel motor 1
1546-1560; 070-24
070.3.3 Travel motor 2
L546-1560; 070-32
080 Hydraulic components 080-1
080.1 Hydraulic system: overview
L546-1560; 080-2
080.2 Hydraulic tank 080-6
080.2.1 Overview of the hydraulic tank
L546-1560; 080-6
080.2.2 Return suction filter
1546-1560; 080-9
080.2.3 Breather filter
L 546-1560; 080-14
090 Steering system 090-1
090.1 Steering system overview
L546-1560; 090-3
090.2 Servostat
L 546-1560; 090-7
090.3 Emergency steering 090-10
090.3.1 Emergency steering overview
L546-1560; 090-10
090.3.2 Emergency steering pump
1546-1560; 090-12
090.3.3 Emergency steering electronics 090-13
050.3.2 Temperature sensor for coolant
L 546-1560; 050-15
050.3.3 Hydraulic oil temperature sensor
L546-1560; 050-17
050.34 Temperature sensor for charge air
L 546-1560; 050-18
050.4 Cooler 050-20
050.4.1 Cooler unit
L 546-1560; 050-20
050.5 Reversible fan drive 050-21
050.5.1 Overview of the reversible fan drive
L546-1560; 050-21
050.5.2 Fan reversal valve block
L 546-1560; 050-23
060 Working hydraulics 060-1
060.1 Overview of Z-bar kinematics working hydraulics
1546-1560; 060-2
060.2 Overview of the P kinematics working hydraulics
1546-1560; 060-10
060.3 Working pump
1546-1560; 060-14
060.4 Control valve block for Z-bar kinematics
L546-1560; 060-22
060.5 Control block for P kinematics
1546-1560; 060-31
060.6 Pilot control 060-37
060.6.1 Servo pressure solenoid valve
L546-1560; 060-37
060.7 Ride control 060-39
060.7.1 Overview of ride control system
L 546-1560; 060-39
060.7.2 Stabilisation module
L 546-1560; 060-42
060.8 Electronics of the working hydraulics 060-45
060.8.1 Overview of electrical controls the working hydraulics
L546-1560; 060-45
060.8.2 Working hydraulics angle sensors
L 546-1560; 060-48
060.9 Pipe break protection 060-51
copyright ® Liebherr-Werk Bischofshofen GmbH 2019
L546-1560 LIEBHERR 2
Contents Service manual
060.9.1 Pipe break protection: overview
L546-1560; 060-51
060.9.2 Valve block for pipe break protection
1546-1560; 060-53
060.9.3 Solenoid valve for release of the ride control
L 546-1560; 060-54
070 Travel hydraulics 070-1
070.1 Overview of travel hydraulics
L 546-1560; 070-2
070.2 Travel pump
1546-1560; 070-7
070.3 Travel motors 070-22
070.3.1 Overview of the travel motors
1546-1560; 070-22
070.3.2 Travel motor 1
1546-1560; 070-24
070.3.3 Travel motor 2
L546-1560; 070-32
080 Hydraulic components 080-1
080.1 Hydraulic system: overview
L546-1560; 080-2
080.2 Hydraulic tank 080-6
080.2.1 Overview of the hydraulic tank
L546-1560; 080-6
080.2.2 Return suction filter
1546-1560; 080-9
080.2.3 Breather filter
L 546-1560; 080-14
090 Steering system 090-1
090.1 Steering system overview
L546-1560; 090-3
090.2 Servostat
L 546-1560; 090-7
090.3 Emergency steering 090-10
090.3.1 Emergency steering overview
L546-1560; 090-10
090.3.2 Emergency steering pump
1546-1560; 090-12
090.3.3 Emergency steering electronics 090-13
090.3.3.1 Overview of electrical controls of emergency steering
system
1546-1560; 090-14
090.3.3.2 Emergency steering pressure switch
1546-1560; 090-18
090.3.3.3 Emergency steering check pressure switch
L 546-1560; 090-19
090.4 Joystick steering 090-21
0904.1 Overview of joystick steering
L546-1560/0-44504; 090-21
090.42 Overview of joystick steering
L546-1560/44505-53763; 090-25
0904.3 Overview of joystick steering
L546-1560/53764-; 090-30
0904.4 Joystick steering control valve block
L546-1560/0-44504; 090-34
0904.5 Joystick steering control valve block
L546-1560/44505-53763; 090-39
0904.6 Joystick steering control block
L546-1560/53764-; 090-44
090.4.7 Joystick steering electrical system 090-49
090.4.7.1 Electronic control unit for joystick steering: overview
1546-1560/0-53763; 090-49
090.4.7.2 Electronic control unit for joystick steering: overview
L546-1560/53764-; 090-56
090.5 2in1 steering 090-63
0905.1 Steering system overview
1546-1560; 090-63
090.5.2 Servostat for 2in1 steering
L546-1560; 090-65
100 Brake system 100-1
100.1 Overview of brake system
1546-1560; 100-2
100.2 Service brake and parking brake 100-7
100.2.1 Brake pump
L 546-1560; 100-7
100.2.2 Compact brake valve
1546-1560; 100-8
100.3 Parking brake 100-16
100.3.1 Parking brake
1546-1560; 100-16
1546-1560; 090-14
090.3.3.2 Emergency steering pressure switch
1546-1560; 090-18
090.3.3.3 Emergency steering check pressure switch
L 546-1560; 090-19
090.4 Joystick steering 090-21
0904.1 Overview of joystick steering
L546-1560/0-44504; 090-21
090.42 Overview of joystick steering
L546-1560/44505-53763; 090-25
0904.3 Overview of joystick steering
L546-1560/53764-; 090-30
0904.4 Joystick steering control valve block
L546-1560/0-44504; 090-34
0904.5 Joystick steering control valve block
L546-1560/44505-53763; 090-39
0904.6 Joystick steering control block
L546-1560/53764-; 090-44
090.4.7 Joystick steering electrical system 090-49
090.4.7.1 Electronic control unit for joystick steering: overview
1546-1560/0-53763; 090-49
090.4.7.2 Electronic control unit for joystick steering: overview
L546-1560/53764-; 090-56
090.5 2in1 steering 090-63
0905.1 Steering system overview
1546-1560; 090-63
090.5.2 Servostat for 2in1 steering
L546-1560; 090-65
100 Brake system 100-1
100.1 Overview of brake system
1546-1560; 100-2
100.2 Service brake and parking brake 100-7
100.2.1 Brake pump
L 546-1560; 100-7
100.2.2 Compact brake valve
1546-1560; 100-8
100.3 Parking brake 100-16
100.3.1 Parking brake
1546-1560; 100-16
L546-1560
110 Electrical system 110-1
110.1 Overview of the electrical system
1546-1560; 110-2
110.2 Lighting
1546-1560; 110-6
110.3 Circuit diagrams
L 546-1560; 110-8
110.4 Electronic control unit 110-10
110.4.1 General overview of the electronic control system
1546-1560; 110-10
110.42 Central control unit (Master4)
L 546-1560; 110-12
110.4.3 Modules 110-16
110.4.3.1 General overview of the compact modules
1546-1560; 110-16
110.4.3.2 Compact module
1546-1560; 110-18
110.5 Electrical components of the driver’s cab 110-24
110.5.1 Fuse and relay boards
L 546-1560; 110-24
110.5.2 Door contact switch
1546-1560; 110-28
110.6 Electrical components in the rear section 110-29
110.6.1 Battery installation
L 546-1560; 110-29
110.7 Rear area monitoring with camera 110-31
110.7.1 Overview of rear area monitoring with camera
1546-1560; 110-31
110.7.2 Camera
L 546-1560; 110-32
120 Gearbox 120-1
110.1 Overview of the electrical system
1546-1560; 110-2
110.2 Lighting
1546-1560; 110-6
110.3 Circuit diagrams
L 546-1560; 110-8
110.4 Electronic control unit 110-10
110.4.1 General overview of the electronic control system
1546-1560; 110-10
110.42 Central control unit (Master4)
L 546-1560; 110-12
110.4.3 Modules 110-16
110.4.3.1 General overview of the compact modules
1546-1560; 110-16
110.4.3.2 Compact module
1546-1560; 110-18
110.5 Electrical components of the driver’s cab 110-24
110.5.1 Fuse and relay boards
L 546-1560; 110-24
110.5.2 Door contact switch
1546-1560; 110-28
110.6 Electrical components in the rear section 110-29
110.6.1 Battery installation
L 546-1560; 110-29
110.7 Rear area monitoring with camera 110-31
110.7.1 Overview of rear area monitoring with camera
1546-1560; 110-31
110.7.2 Camera
L 546-1560; 110-32
120 Gearbox 120-1
Qverview of the transmission
Transmission hydraulics
120.2.1 Overview of transmission hydraulic
120.2.2 Gear shifting proportional solenoid valve
1546-1560; 120-9
Transmission electronics 120-11
120.3.1 General overview of electronic control system
Transmission electronics 120-11
120.3.1 General overview of electronic control system
L546-1560; 120-11
120.3.2 Output speed sensor and travel motor 2 speed sensor
L546-1560; 120-14
130 Axles and drive shafts 130-1
130.1 Axles 130-2
130.1.1 Front axle
L546-1560; 130-2
130.1.2 Rear axle
L546-1560; 130-3
130.2 Cardan shafts 130-5
130.2.1 Drive shaft
L546-1560; 130-5
140 Steel parts of the basic machine 140-1
140.1 Vehicle frame 140-2
140.1.1 Articulation bearing
L546-1560; 140-2
140.1.2 Articulation lock
L546-1560; 140-3
150 Working attachment 150-1
150.1 Lift arms for Z kinematics 150-2
160.1.1 Lift arms for Z kinematics
1546-1560; 150-2
150.2 Lift arms for P kinematics 150-4
160.2.1 Lift arms for parallel kinematics (P kinematics)
L546-1560; 150-4
150.3 Quick coupler 150-6
160.3.1 Quick coupler
L 546-1560; 150-6
160.3.2 Quick coupler hydraulics 150-7
160.3.2.1 Overview of quick coupler hydraulics
L546-1560/0-45466; 150-7
150.3.2.2 Overview of quick coupler hydraulics
L546-1560/45467-51128; 150-9
150.3.2.3 Overview of quick coupler hydraulics
L546-1560/51129-; 150-11
150.3.2.4 Valve block for quick coupler
L 546-1560; 150-13
160.3.3 Quick coupler electrics 150-15
1560.3.3.1 Quick coupler electric control unit
L 546-1560; 150-15
120.3.2 Output speed sensor and travel motor 2 speed sensor
L546-1560; 120-14
130 Axles and drive shafts 130-1
130.1 Axles 130-2
130.1.1 Front axle
L546-1560; 130-2
130.1.2 Rear axle
L546-1560; 130-3
130.2 Cardan shafts 130-5
130.2.1 Drive shaft
L546-1560; 130-5
140 Steel parts of the basic machine 140-1
140.1 Vehicle frame 140-2
140.1.1 Articulation bearing
L546-1560; 140-2
140.1.2 Articulation lock
L546-1560; 140-3
150 Working attachment 150-1
150.1 Lift arms for Z kinematics 150-2
160.1.1 Lift arms for Z kinematics
1546-1560; 150-2
150.2 Lift arms for P kinematics 150-4
160.2.1 Lift arms for parallel kinematics (P kinematics)
L546-1560; 150-4
150.3 Quick coupler 150-6
160.3.1 Quick coupler
L 546-1560; 150-6
160.3.2 Quick coupler hydraulics 150-7
160.3.2.1 Overview of quick coupler hydraulics
L546-1560/0-45466; 150-7
150.3.2.2 Overview of quick coupler hydraulics
L546-1560/45467-51128; 150-9
150.3.2.3 Overview of quick coupler hydraulics
L546-1560/51129-; 150-11
150.3.2.4 Valve block for quick coupler
L 546-1560; 150-13
160.3.3 Quick coupler electrics 150-15
1560.3.3.1 Quick coupler electric control unit
L 546-1560; 150-15
160 Operator’s cab, heating and air conditioning 160-1
160.1 Overview of the cab, heating and air conditioning unit
1546-1560; 160-3
160.2 Display and control elements 160-5
160.2.1 Electrical components in the control panel 160-5
160.2.1.1 Control unit
1546-1560; 160-5
160.2.2 Touch screen display
1546-1560; 160-7
160.2.3 Control lever
L 546-1560; 160-9
160.2.4 Accelerator pedal
L 546-1560; 160-11
160.3 Heating, ventilation, air conditioning 160-13
160.3.1 Overview of the heating, ventilation and air conditioning system
L 546-1560; 160-13
160.3.2 Heating and air conditioning unit 160-19
160.3.2.1 Heating and air conditioning unit
1546-1560; 160-20
160.3.2.2 Blower
1546-1560; 160-22
160.3.3 Heating/air conditioning electronics
1546-1560; 160-22
160.3.4 Pressure relief valve for heating circuit
L 546-1560; 160-24
160.4 Air conditioning 160-26
160.4.1 Basic function of the air conditioning unit
1546-1560; 160-26
160.4.2 Air conditioning compressor
L 546-1560; 160-27
160.4.3 Condenser
1546-1560; 160-28
160.4.4 Dryer
1546-1560; 160-29
160.4.5 Air conditioning pressure switch
1546-1560; 160-31
160.4.6 Evaporator
L 546-1560; 160-33
160.4.7 Anti-icing temperature sensors
1546-1560; 160-34
160.4.8 Automatic air conditioning 160-34
160.1 Overview of the cab, heating and air conditioning unit
1546-1560; 160-3
160.2 Display and control elements 160-5
160.2.1 Electrical components in the control panel 160-5
160.2.1.1 Control unit
1546-1560; 160-5
160.2.2 Touch screen display
1546-1560; 160-7
160.2.3 Control lever
L 546-1560; 160-9
160.2.4 Accelerator pedal
L 546-1560; 160-11
160.3 Heating, ventilation, air conditioning 160-13
160.3.1 Overview of the heating, ventilation and air conditioning system
L 546-1560; 160-13
160.3.2 Heating and air conditioning unit 160-19
160.3.2.1 Heating and air conditioning unit
1546-1560; 160-20
160.3.2.2 Blower
1546-1560; 160-22
160.3.3 Heating/air conditioning electronics
1546-1560; 160-22
160.3.4 Pressure relief valve for heating circuit
L 546-1560; 160-24
160.4 Air conditioning 160-26
160.4.1 Basic function of the air conditioning unit
1546-1560; 160-26
160.4.2 Air conditioning compressor
L 546-1560; 160-27
160.4.3 Condenser
1546-1560; 160-28
160.4.4 Dryer
1546-1560; 160-29
160.4.5 Air conditioning pressure switch
1546-1560; 160-31
160.4.6 Evaporator
L 546-1560; 160-33
160.4.7 Anti-icing temperature sensors
1546-1560; 160-34
160.4.8 Automatic air conditioning 160-34
160.4.8.1 Overview of the automatic air conditioning
1546-1560; 160-35
1546-1560; 160-35
160.4.8.2 Interior and outlet temperature sensors
L 546-1560; 160-36
160.4.8.3 Outside temperature sensor
1546-1560; 160-37
160.4.8.4 Sun sensor
L 546-1560; 160-38
170 Lubrication system 170-1
170.1 Liebherr automatic central lubrication system 170-2
170.1.1 Liebherr automatic central lubrication system: overview
L546-1560; 170-2
170.1.2 Liebherr central lubrication pump
L 546-1560; 170-8
170.1.3 Progressive distributor MX-F
1546-1560; 170-12
190 Options 190-1
190.1 LiDAT 190-2
190.1.1 Overview of LiDAT
1546-1560; 190-2
190.1.2 LiDAT on the machine
L 546-1560; 190-4
190.2 Weighing device (Liebherr)
1546-1560; 190-6
200 Diagnosis 200-1
200.1 Malfunctions 200-2
200.1.1 Warning symbols 200-2
200.1.2 SCR system warning symbols 200-3
200.1.3 Service code indicator in the display 200-3
200.2 Troubleshooting 200-6
200.2.1 Replacing fuses 200-6
200.2.1.1 Fuses on fuse board A4 in the operator’s cab 200-6
200.2.1.2 Fuses on fuse board A4b in the operator’s cab 200-9
200.2.1.3 Fuses in the right ballast weight 200-10
L 546-1560; 160-36
160.4.8.3 Outside temperature sensor
1546-1560; 160-37
160.4.8.4 Sun sensor
L 546-1560; 160-38
170 Lubrication system 170-1
170.1 Liebherr automatic central lubrication system 170-2
170.1.1 Liebherr automatic central lubrication system: overview
L546-1560; 170-2
170.1.2 Liebherr central lubrication pump
L 546-1560; 170-8
170.1.3 Progressive distributor MX-F
1546-1560; 170-12
190 Options 190-1
190.1 LiDAT 190-2
190.1.1 Overview of LiDAT
1546-1560; 190-2
190.1.2 LiDAT on the machine
L 546-1560; 190-4
190.2 Weighing device (Liebherr)
1546-1560; 190-6
200 Diagnosis 200-1
200.1 Malfunctions 200-2
200.1.1 Warning symbols 200-2
200.1.2 SCR system warning symbols 200-3
200.1.3 Service code indicator in the display 200-3
200.2 Troubleshooting 200-6
200.2.1 Replacing fuses 200-6
200.2.1.1 Fuses on fuse board A4 in the operator’s cab 200-6
200.2.1.2 Fuses on fuse board A4b in the operator’s cab 200-9
200.2.1.3 Fuses in the right ballast weight 200-10
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- This is not a physical manual but a digital manual – meaning no physical copy will be couriered to you. The manual can be yours in the next 2 mins as once you make the payment, you will be directed to the download page IMMEDIATELY.
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