Liebherr Wheel loaders L 506-1816 Service manual – PDF DOWNLOAD
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FILE DETAILS:
Liebherr Wheel loaders L 506-1816 Service manual – PDF DOWNLOAD
Language : English
Pages :602
Downloadable : Yes
File Type : PDF
Size:83.2 MB
DESCRIPTION:
Liebherr Wheel loaders L 506-1816 Service manual – PDF DOWNLOAD
- 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:
- 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”.
To ensure safe operation:
- Consult with the worksite manager about safety regulations at the place of use.
- Adhere to safety regulations at the place of use.
- Follow traffic regulations.
- Adhere to valid guidelines provided by insurers (for example, employers’ professional liability insurance companies, accident insurance, etc.).
- Avoid working methods that can endanger safety.
- Follow all intervals specified for recurrent checks and inspections as outlined in this operator’s manual.
1.2. Intended Use of Wheel Loader
The wheel loader is used to pick up, move, and dump the following materials:
- Soil
- Stones
- Broken rocks
- Bulk materials
This applies to a standard machine under normal operating conditions. Special applications are described in a separate options operator’s manual.
To ensure the intended use:
- Adhere to the operator’s manual.
- Follow maintenance intervals.
- Carry out inspection and maintenance tasks.
- Follow the specifications in the technical data.
- When using the machine on public roads, ensure it complies with applicable national regulations.
- Only lift loads with intended working attachments (fork prongs, crane boom), which must be properly fitted and functioning.
- Ensure that machines used underground (for mining and tunnel construction) are fitted with systems to reduce exhaust emissions (such as diesel particulate filters).
- Adhere to the requirements of each individual country for underground operation.
- For special uses, use special working attachments and, if necessary, special safety equipment.
- Exclusively mount and use special working attachments with approval and as per the stipulations of the manufacturer of the basic machine.
TABLE OF CONTENTS:
Liebherr Wheel loaders L 506-1816 Service manual – PDF DOWNLOAD
Introduction 010-1
010.1 Safety instructions 010-4
010.1.1 Information on these instructions 010-4
010.1.1.1 Representation of warning messages 010-4
010.1.1.2 Graphic symbols in these instructions 010-4
010.1.2 Intended use 010-5
010.1.2.1 Laws, rules, guidelines and safety regulations 010-5
010.1.2.2 Intended use 010-5
010.1.2.3 Foreseeable misuse 010-6
010.1.2.4 Operating conditions 010-6
010.1.2.5 Disposal 010-7
010.1.3 Description of staff 010-7
010.1.3.1 Personal protective equipment 010-7
010.1.3.2 Requirements for staff 010-8
010.1.3.3 Operating company 010-8
010.1.3.4 Operator 010-9
010.1.3.5 Maintenance staff 010-9
010.1.3.6 Refrigeration technician 010-10
010.1.3.7 Slinger 010-11
010.1.3.8 Spotter 010-12
010.1.4 Protective devices on the machine 010-12
010.1.4.1 Operator’s cab 010-12
010.1.4.2 Roll over protective structure (ROPS) 010-13 0
010.1.4.3 Falling object protective structures (FOPS) 010-13
010.1.5 Emergency equipment on the machine 010-13 52
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
010.2 Special tools for maintenance and repair work 010-23
010.2.1 Special tools, general 010-23
010.2.2 Special tools for diesel engine 010-24
010.2.3 Special tools for lift cylinders 010-26
010.2.4 Special tools for tilt cylinders 010-26
010.2.5 Special tools for quick coupler locking hydraulic cylinder 010-27
010.2.6 Special tools for steering wheel 010-27
010.2.7 Special tools for steering cylinders 010-27
010.2.8 Special tools for the electrical system 010-28
010.2.9 Special tools for axles 010-28
010.2.10 Special tools for air conditioning system 010-28
010.2.11 Special tools for cab glazing 010-29
010.2.12 Special tools for the central lubrication system 010-29
010.3 Standards and regulations 010-31 C:
010.3.1 Prestressing forces and tightening torques for bolts with metric :;::,: standard and fine threads as per DIN ISO 261 010-31 “‘ 0
010.3.1.1 Range of application and purpose
010.3.1.2 Other applicable documents 010-31
010.3.1.3 Modifications and descriptions 010-32 “”…”
010.3.1.4 Tightening torques 010-32 ~ ID
010.3.2 Liebherr standards for assembly instructions and tightening torques010-38
010.4 Preservation guidelines 010-39
010.4.1 General information 010-39
010.4.2 Machine out of service for an unknown period of time 010-39
010.4.3 Putting the machine out of service 010-40
010.4.3.1 Out of service for up to 2 months 010-40
010.4.3.2 Out of service for up to 12 months 010-41
010.4.3.3 Out of service for longer than 12 months 010-42
010.4.4 Putting back into service 010-42
010.4.4.1 After being out of service for 2 months 010-42
010.4.4.2 After being out of service for 12 months 010-43
010.4.4.3 After being out of service for longer than 12 months 010-43
020 Technical data 020-1
020.1 Overall machine 020-4
020.1.1 Complete machine with loading bucket
L506-1816; 020-4
020.1.2 Working attachment: 4 in 1 bucket
L506-1816; 020-5
020.1.3 Working attachment: forklift
L506-1816; 020-7
020.2 Drive group 020-9
020.2.1 Diesel engine
L506-1816; 020-9
020.2.2 Fuel tank
L506-1816; 020-10
020.2.3 Air filter vacuum switch
L506-1816; 020-10
020.2.4 Clutch
L506-1816; 020-10
020.3 Cooling system 020-12
020.3.1 Water cooler C:
4 Working hydraulics 020-13
020.4.1 Working pump
L506-1816; 020-13
52 020.4.2 Control block
L506-1816; 020-13
L506-1816; 020-14
020.4.4 Ride control hydro accumulator
020.4.5 Lift cylinder
L506-1816; 020-14
020.4.6 Tilt cylinder
L506-1816; 020-14
020.5 Travel hydraulics 020-16
020.5.1 Travel pump
L506-1816; 020-16
020.5.2 Travel motor
L506-1816; 020-16
020.6 Hydraulic components 020-18
020.6.1 Temperature switch for hydraulic oil B8
L506-1816; 020-18
020.6.2 Return suction filter
L506-1816; 020-18
020.6.3 Breather filter with filler strainer
L506-1816; 020-18
020.7 Steering system 020-19
020.7.1 Servostat
L506-1816; 020-19
020.7.2 Steering cylinder
L506-1816; 020-19
020.8 Brake system 020-20
020.8.1 Drum brake
L506-1816; 020-20
020.8.2 Inch/brake unit
L506-1816; 020-20
020.8.3 Brake light pressure switch B12
L506-1816; 020-20
020.9 Electrical system 020-21
020.9.1 Central control unit (HY-TTC-32S)
L506-1816; 020-21
020.9.2 Battery
L506-1816; 020-21 C:
L506-1816; 020-23
020.11.3 Drive shaft
L506-1816; 020-23
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020.12 Steel parts of the basic machine
020.12.1 Ballast weight
L506-1816;
020.13 Working attachment
020.13.1 Lift arms for Z kinematics
L506-1816;
020.13.2 Quick coupler locking hydraulic cylinder
L506-1816;
020.14 Operator’s cab, heating and air conditioning
020.14.1 Heating, air conditioning
L506-1816; 020-27
020.14.2.1 Air conditioning 020-27
020.14.3.1 Air conditioning compressor 020-27
020.14.4.1 Dryer 020-28
020.14. 5. 1 Air conditioning pressure switch 020-28
020.14.6 Anti-icing thermostat
L506-1816;
020.15 Lubrication system
020.15.1 Central lubrication pump EP1
020.15.2 Progressive distributor
030 Maintenance 030-1
L506-1816
030.1 Maintenance and inspection schedule
030.2 Filling quantities and lubrication chart
030.2.1 Lubricant filling quantity
L506-1816;
030.2.2 Fuel and operating fluid filling quantity
L506-1816;
030.3 Lubricants and fuels
030.3.1 General information on lubricants and fuels
Contents Service manual
030.3.1.3 Technical data sheets 030-14
030.3.1.4 Specific Liebherr standards 030-14
030.3.2 General information on changing lubricants and fuels 030-14
030.3.3 Converting hydraulic system from mineral oils to biodegradable
hydraulic fluids 030-15
030.3.4 Diesel fuels
L506-1816; 030-15
030.3.4.1 Minimum quality requirement 030-15
030.3.4.2 Operating temperatures of diesel fuels 030-15
030.3.4.3 Minimum quality requirement 030-16
030.3.5 Engine oils
L506-1816; 030-16
030.3.5.1 Liebherr recommendation 030-16
030.3.5.3 Minimum quality requirement 030-16
030.3.6 Refrigerant
L506-1816; 030-17
030.3.7 Coolant
L506-1816; 030-17
030.3.7.1 Requirements for the water used 030-17
030.3.7.2 Antifreeze and corrosion inhibitor 030-17
030.3.7.3 Minimum quality requirement 030-17
030.3.8 Hydraulic oil
L506-1816; 030-18
030.3.8.1 Liebherr recommendation 030-18
030.3.8.2 Minimum quality requirement 030-18
030.3.8.3 Oil analysis 030-18
030.3.8.4 Oil change 030-19
030.3.9 Transmission
030.3.11.1 Liebherr recommendation 030-20
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L506-1816
030.3.12 Lubrication grease
L506-1816;
030.3.12.1 Liebherr recommendation
030.3.12.2 Minimum quality requirement
030.4 Maintenance tasks
030.4.1 Safety precautions
030.4.2 Preparatory tasks for maintenance
Maintenance positions
Opening the service hatches
Turning off battery main switch
030.4.3 Overall machine
Checking machine is in proper condition
Removing loose parts, dirt, ice and snow from
machine
Cleaning machine
Replacing VCI capsules
Operating fluid analysis: General specifications
030.4.3.6 Operating fluid analysis: filling out sample information
030.4.3.7 Fuel and operating fluid analysis: scope of analysis
030.4.3.8 Analysis of lubricants and fuels
030.4.4 Drive group
030.4.4.1 Checking diesel engine oil level
030.4.4.2 Diesel engine: changing diesel engine oil
030.4.4.3 Diesel engine: changing oil filter
030.4.4.4 Diesel engine: checking V-belt
030.4.4.5 Diesel engine: changing V-belt
Contents Service manual
030.4.4.6 Diesel engine: checking valve clearance
L506-1816; 030-61
030.4.4.7 Draining condensate and sediment from fuel tank
L506-1816; 030-66
030.4.4.8 Draining off condensate from the fuel pre-filter
L506-1816; 030-66
030.4.4.9 Changing fuel pre-filter element
L506-1816; 030-67
030.4.4.10 Changing fuel fine filter element
L506-1816; 030-69
030.4.4.11 Cleaning service cover and dust discharge valve of
air filter system
L506-1816; 030-70
030.4.4.12 Checking air filter vacuum switch function
L506-1816; 030-71
030.4.4.13 Cleaning or changing the main element of the air
filter system
L506-1816; 030-72
030.4.4.14 Changing the safety element of the air filter system
L506-1816; 030-75
030.4.4.15 Checking that diesel engine intake and exhaust
system is in good condition and not loose or leaking
L506-1816; 030-76
030.4.4.16 Diesel particulate filter: cleaning or changing filter
module
L506-1816; 030-79
030.4.5 Cooling system 030-85
030.4.5.1 Checking coolant level in cooling system
L506-1816; 030-85
030.4.5.2 Coolant: checking anti-freeze and corrosion protection
agent concentration
L506-1816; 030-87
030.4.5.2 Checking corrosion inhibitor concentration
L506-1816; 030-87
030.4.5.3 Cleaning the cooling system C:
030.4.6.2 Draining off condensate and sediment from hydraulic ~ ID
tank …J
L506-1816; 030-99
030.4.6.3 Changing hydraulic tank return suction filter cartridge
L506-1816; 030-101
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12 IIIBHIRR L506-1816
Service manual Contents
030.4.6.4 Changing hydraulic tank breather filter
L506-1816; 030-102
030.4.6.5 Hydraulic tank: changing oil
L506-1816; 030-103
030.4.7 Steering system 030-106
030.4.7.1 Test steering
L506-1816; 030-106
030.4.7.2 Steering cylinder: lubricating bearing
L506-1816; 030-106
030.4.8 Brake system 030-107
030.4.8.1 Testing service brake and parking brake
L506-1816; 030-107
030.4.8.2 Checking oil level in brake system
L506-1816; 030-108
030.4.8.3 Checking gap and wear on service brake linings
L506-1816; 030-109
030.4.9 Electrical system 030-111
030.4.9.1 Checking function of lighting and horn
L506-1816; 030-111
030.4.9.2 Checking battery fluid levels and terminals
L506-1816; 030-112
030.4.9.3 Use the control lever to change the travel direction
switch rocker and cap.
L506-1816; 030-114
030.4.10 Gearbox 030-117
030.4.10.1 Transmission: checking oil level
L506-1816; 030-117
030.4.10.2 Changing transmission oil
L506-1816; 030-117
030.4.11 Axles and drive shafts 030-119
030.4.11.1 Checking axle oil levels
L506-1816; 030-119
030.4.11.6 Checking wheel tightness
L506-1816; 030-126
030.4.12 Steel parts of the basic machine 030-126
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L506-1816 IIIBHIRR 13
Contents Service manual
030.4.12.1 Lubricating articulated bearing
L506-1816; 030-126
030.4.12.2 Lubricating articulation stops
L506-1816; 030-127
030.4.12.3 Engine bonnet: lubricating moving parts with penetrating
oil
L506-1816; 030-128
030.4.12.4 Service hatches: cleaning and maintaining seals
L506-1816; 030-128
030.4.13 Working attachment 030-129
030.4.13.1 Lubricating the lift arms and working attachment
L506-1816; 030-129
030.4.13.2 Checking lift arm bucket bearing bushings
L506-1816; 030-130
030.4.13.3 Checking lift arm bucket stops
L506-1816; 030-131
030.4.13.4 Quick coupler: checking function
L506-1816; 030-132
030.4.14 Operator’s cab, heating and air conditioning 030-133
030.4.14.1 Cleaning operator’s cab air filter
L506-1816; 030-133
030.4.14.2 Changing operator’s cab air filter
L506-1816; 030-133
030.4.14.3 Safety belt: checking condition and function
L506-1816; 030-134
030.4.14.4 Windscreen washer system: testing
L506-1816; 030-135
030.4.14.5 Windscreen washer system: filling windscreen
washer fluid
L506-1816; 030-135
030.4.14.6 Operator’s cab: lubricating locking mechanism and
cylinder with penetrating oil
Service manual Contents
L506-1816
030.4.15.1 Central lubrication system: checking level in grease
reservoir
L506-1816;
030.4.15.2 Central lubrication system: checking pipes, hoses
and lubrication points for leaks and damage.
030-144
L506-1816; 030-145
030.4.15.3 Central lubrication system: checking lubrication of
bearings
L506-1816; 030-146
030.5 Testing and adjustment checklist
L506-1816;
030.6 Testing and adjustment tasks
030.6.1 Safety precautions
L506-1816;
030.6.2 Overall machine
030.6.2.1 Preparing for adjustment procedures
L506-1816; 030-151
030.6.2.2 Hydraulic oil and coolant: operating temperature
L506-1816; 030-152
030.6.3 Drive group
030.6.3.1 Diesel engine speed
Reading the diesel engine service files
Performing a service regeneration on diesel particulate
filter
L506-1816; 030-156
Diesel engine: changing engine control unit (ECU)
L506-1816; 030-157
030.6.4 Working hydraulics 030-167
Control block: pressure relief valves
L506-1816;
Stabilisation module (option), safety valve
L506-1816;
Ride control hydro accumulator (option): nitrogen
filling
L506-1816;
Hydraulic components
030.6.5.1 Checking the hydraulic lines for damage
L506-1816;
Travel hydraulics
030.6.6.1 Travel pump replenishing pressure relief valve
L506-1816;
Contents Service manual
030.6.6.2 Blocked condition
L506-1816; 030-181
030.6.6.3 Travel pump: control valve
L506-1816; 030-183
030.6.6.4 Travel pump: pump power
L506-1816; 030-184
030.6.6.5 Travel pump: high pressure relief valves
L506-1816; 030-185
030.6.6.6 Travel pump: pressure cut-off
L506-1816; 030-188
030.6.6.7 Travel motor: regulation range
L506-1816; 030-189
030.6.6.8 Diesel engine: Performance
L506-1816; 030-191
030.6.7 Brake system 030-191
030.6.7.1 Inch/brake unit: pedal
L506-1816; 030-191
030.6.7.2 Inch/brake unit: inch valve
L506-1816; 030-192
030.6.8 Operator’s cab, heating and air conditioning 030-193
030.6.8.1 Setting the service hours in the display
L506-1816; 030-193
040 Drive group 040-1
040.1 Engine 040-2
040.1.1 Diesel engine overview
L506-1816; 040-2
040.1.2 Electrical components of diesel engine
L506-1816; 040-10
040.1.3 Fuel system 040-11
040.1.3.1 Overview of fuel system
L506-1816; 040-12
040.1.3.2 Fuel level sensor C:
Service manual
L506-1816
040.1.4.3 Vacuum switch for air filter
L506-1816;
040.1.5 Exhaust system
040.1.5.1
050 Cooling system
Overview of diesel particulate filter
L506-1816;
050.1 Overview of cooling system
L506-1816;
050.2 Cooler
050.2.1 Water cooler
L506-1816;
050.2.2 Hydraulic oil cooler
L506-1816;
050.2.3 Fuel cooler
L506-1816;
060 Working hydraulics
060.1 Overview of working hydraulics
L506-1816;
060.2 Working pump
L506-1816;
060.3 Control block
L506-1816;
060.4 Ride control
060.4.1 Overview of ride control system
L506-1816;
060.4.2 Stabilization module
L506-1816;
060.5 3. Function with electrohydraulic pilot control
060.5.1 3rd function with electrohydraulic pilot control – overview
L506-1816;
060.5.2 Control block for 3rd function with electrohydraulic pilot control
L506-1816;
060.6 4. Function with comfort control
060.6.1 4. Function with comfort control – overview
L506-1816;
060.6.2 Solenoid valve for comfort control
L506-1816;
060. 7 Regulated flow rate
060.7.1 Regulated flow rate: total overview
Contents Service manual
060.7.2 Valve block for regulated flow rate
L506-1816; 060-38
060.8 Pipe break protection 060-40
060.8.1 Pipe break protection: overview
L506-1816; 060-40
060.8.2 Valve block for pipe break protection
L506-1816; 060-43
070 Travel hydraulics 070-1
070.1 Overview of travel hydraulics
L506-1816; 070-2
070.2 Travel pump
L506-1816; 070-5
070.3 Travel motors 070-20
070.3.1 Travel motor
L506-1816; 070-20
070.4 Electrical system of travel hydraulics 070-30
070.4.1 Travel drive: electric control unit
L506-1816; 070-30
080 Hydraulic components 080-1
080.1 Hydraulic system – overview
L506-1816; 080-2
080.2 Hydraulic tank 080-4
080.2.1 Overview of hydraulic tank
L506-1816; 080-4
080.2.2 Return suction filter
L506-1816; 080-6
080.2.3 Breather filter
L506-1816; 080-12
090 Steering system 090-1
100.1 Overview of the brake system ~ ID
L506-1816; 100-2 …J
100.2 Service brake and parking brake 100-5
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18 IIIBHIRR L506-1816
Service manual Contents
100.2.1 Drum brake
L506-1816; 100-5
100.3 Service brake 100-10
100.3.1 Inch/brake unit
L506-1816; 100-10
100.3.2 Brake light pressure switch
L506-1816; 100-14
100.4 Parking brake 100-16
100.4.1 Switch for parking brake B5
L506-1816; 100-16
110 Electrical system 110-1
110.1 Overview of electrical system
L506-1816; 110-2
110.2 Lighting
L506-1816; 110-5
110.3 Circuit diagrams
L506-1816; 110-7
110.4 Electronic control unit 110-9
110.4.1 General overview of electronic control system
L506-1816; 110-9
110.4.2 Central control unit (HY-TTC-32S)
L506-1816; 110-10
110.5 Electrical components of the driver’s cab 110-12
110.5.1 Fuse boards
L506-1816; 110-12
110.6 Electrical components in the rear section 110-14
110.6.1 Battery installation
L506-1816; 110-14
120 Gearbox 120-1
120.1 Overview of transmission
130.2.1 Drive shaft
140 Steel parts of the basic machine
140.1 Vehicle frame
140.1.1 Articulation bearing
140.1.2 Articulation lock
150 Working attachment
150.1 Lift arms for Z kinematics
150.1.1 Lift arms for Z kinematics
150.2 Quick coupler
150.2.1 Quick coupler
150.2.2 Quick coupler hydraulics
Overview of quick coupler hydraulics
Opening solenoid valve for quick coupler
160 Operator’s cab, heating and air conditioning
160.1 Overview of operator’s cab, heating and air conditioning unit
Display and control elements
160.2.1 Electrical components in the control panel
160.2.1.1 Starting switch
160.2.2 Display
160.2.3 Control lever
160.2.4 Accelerator pedal
Heating, ventilation, air conditioning
160.3.1 Overview of heating, ventilation and air conditioning system
160.3.2 Heating and air conditioning unit
160.3.2.1 Heating and air conditioning unit
Service manual
160.4 Air conditioning
Blower
160.4.1 Basic function of the air conditioning unit
160.4.2 Air conditioning compressor
160.4.3 Condenser
160.4.4 Dryer
160.4.5 Air conditioning pressure switch
170 Lubrication system
170.1 Liebherr automatic central lubrication system
170.1.1 Automatic central lubrication system: overview
170.1.2 Central lubrication pump EP-1
170.1.3 Progressive distributor MX-F
200 Diagnosis
200.1 Malfunctions
200.1.1 Warning symbols
200.1.2 Service codes: indication on display
200.1.3 Display service code table
200.2 Troubleshooting
200.2.1 Replacing fuses
Fuses on the fuse board in the cab
Fuses in the battery compartment
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S.M
