Liebherr Wheel loaders L 509-1778 Service manual – PDF DOWNLOAD
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Liebherr Wheel loaders L 509-1778 Service manual – PDF DOWNLOAD
Language : English
Pages :752
Downloadable : Yes
File Type : PDF
Size:109 MB
DESCRIPTION:
Liebherr Wheel loaders L 509-1778 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.
TABLE OF CONTENTS:
Liebherr Wheel loaders L 509-1778 Service manual – PDF DOWNLOAD
Contents
010 Introduction 010-1
010.1 Safety instructions 010-4
010.1.1 Information on these instructions 010-4
010.1.1.1 Representation of warning messages 010-4
010.1.1.2 Graphic symbols in these instructions 010-4
010.1.2 Intended use 010-5
010.1.2.1 Laws, rules, guidelines and safety regulations 010-5
010.1.2.2 Intended use 010-5
010.1.2.3 Foreseeable misuse 010-6
010.1.2.4 Operating conditions 010-6
010.1.2.5 Disposal 010-7
010.1.3 Description of staff 010-7
010.1.3.1 Personal protective equipment 010-7
010.1.3.2 Requirements for staff 010-8
010.1.3.3 Operating company 010-8
010.1.3.4 Operator 010-9
010.1.3.5 Maintenance staff 010-9
010.1.3.6 Refrigeration technician 010-10
010.1.3.7 Slinger 010-11
010.1.3.8 Spotter 010-12
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 010-1
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
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 010-1
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 010-32
010.2.14 Special tools for air conditioning system 010-32
010.2.15 Special tools for cab glazing 010-34
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 010-32
010.2.14 Special tools for air conditioning system 010-32
010.2.15 Special tools for cab glazing 010-34
010.2.16 Special tools for the central lubrication system (Liebherr) 010-34
Standards and regulations
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/M2261288/02/211-20210128_103447/en
LBH/M2261288/02/211-20210128_103447/en
LBH/M2261288/02/211-20210128_103447/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
copyright ® Liebherr-Werk Bischofshofen GmbH 2021
L509-1778 LIEBHERR 7
Contents Service manual
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 fork with increasing load centre of gravity 020-11
020.2 Drive group 020-20
020.2.1 Diesel engine
1509-1778; 020-20
020.2.2 Fuel tank
L509-1778; 020-21
020.2.3 Fuel level sensor
L509-1778; 020-21
020.3 Cooling system 020-22
020.3.1 Fan pump
L509-1778; 020-22
020.3.2 Fan motor
L 509-1778; 020-22
020.3.3 Hydraulic oil temperature sensor B8
L509-1778; 020-22
020.4 Working hydraulics 020-23
020.4.1 Working pump
1509-1778; 020-23
020.4.2 Pilot control hydro accumulator
L509-1778; 020-23
020.4.3 Stabilisation module
1509-1778; 020-23
020.4.4 Ride control hydro accumulator
L509-1778; 020-23
020.4.5 Lift cylinder
L509-1778; 020-24
020.4.6 Tilt cylinder
L509-1778; 020-24
020.4.7 Telescopic cylinder
1509-1778; 020-24
020.4.8 Compensating cylinder
L509-1778; 020-25
020.4.9 Working pump
L509-1778; 020-25
020.5 Travel hydraulics 020-26
020.5.1 Travel pump
1509-1778; 020-26
020.5.2 Pressure sensor for high pressure of travel pump B102
L509-1778; 020-26
copyright © Liebher-Werk Bischofshofen GmbH 2021
8 LIEBHERR 1500-1778
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
copyright ® Liebherr-Werk Bischofshofen GmbH 2021
L509-1778 LIEBHERR 7
Contents Service manual
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 fork with increasing load centre of gravity 020-11
020.2 Drive group 020-20
020.2.1 Diesel engine
1509-1778; 020-20
020.2.2 Fuel tank
L509-1778; 020-21
020.2.3 Fuel level sensor
L509-1778; 020-21
020.3 Cooling system 020-22
020.3.1 Fan pump
L509-1778; 020-22
020.3.2 Fan motor
L 509-1778; 020-22
020.3.3 Hydraulic oil temperature sensor B8
L509-1778; 020-22
020.4 Working hydraulics 020-23
020.4.1 Working pump
1509-1778; 020-23
020.4.2 Pilot control hydro accumulator
L509-1778; 020-23
020.4.3 Stabilisation module
1509-1778; 020-23
020.4.4 Ride control hydro accumulator
L509-1778; 020-23
020.4.5 Lift cylinder
L509-1778; 020-24
020.4.6 Tilt cylinder
L509-1778; 020-24
020.4.7 Telescopic cylinder
1509-1778; 020-24
020.4.8 Compensating cylinder
L509-1778; 020-25
020.4.9 Working pump
L509-1778; 020-25
020.5 Travel hydraulics 020-26
020.5.1 Travel pump
1509-1778; 020-26
020.5.2 Pressure sensor for high pressure of travel pump B102
L509-1778; 020-26
copyright © Liebher-Werk Bischofshofen GmbH 2021
8 LIEBHERR 1500-1778
LBH/M2261288/02/211-20210128_103447/en
LBH/M2261288/02/211-20210128_103447/en
LBH/M2261288/02/211-20210128_103447/en
Service manual
Contents
020.5.3 Travel motor
L509-1778; 020-26
020.6 Hydraulic components 020-28
020.6.1 Return suction filter
L509-1778; 020-28
020.6.2 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
020.9.4 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
020.11.3 Drive shaft
L509-1778; 020-34
copyright ® Liebherr-Werk Bischofshofen GmbH 2021
L509-1778 LIEBHERR 9
Contents Service manual
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
L509-1778; 020-37
020.13 Operator’s cab, heating and air conditioning 020-38
020.13.1 Dryer
1509-1778; 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
1509-1778; 020-39
020.14.21 MXF 020-39
020.14.2.2 MX-F 25 020-39
020.14.2.3 MX-F 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
030.3.3 Converting hydraulic system from mineral oils to biodegradable
hydraulic fluids 030-17
copyright © Liebher-Werk Bischofshofen GmbH 2021
10 LIEBHERR 1509-1778
020.6 Hydraulic components 020-28
020.6.1 Return suction filter
L509-1778; 020-28
020.6.2 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
020.9.4 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
020.11.3 Drive shaft
L509-1778; 020-34
copyright ® Liebherr-Werk Bischofshofen GmbH 2021
L509-1778 LIEBHERR 9
Contents Service manual
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
L509-1778; 020-37
020.13 Operator’s cab, heating and air conditioning 020-38
020.13.1 Dryer
1509-1778; 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
1509-1778; 020-39
020.14.21 MXF 020-39
020.14.2.2 MX-F 25 020-39
020.14.2.3 MX-F 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
030.3.3 Converting hydraulic system from mineral oils to biodegradable
hydraulic fluids 030-17
copyright © Liebher-Werk Bischofshofen GmbH 2021
10 LIEBHERR 1509-1778
LBH/M2261288/02/211-20210128_103447/en
LBH/M2261288/02/211-20210128_103447/en
LBH/M2261288/02/211-20210128_103447/en
Service manual Contents
030.3.4 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
030.3.4.3 Minimum quality requirement 030-18
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
L509-1778; 030-19
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
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 Qil analysis 030-20
030.3.8.4 Qil change 030-21
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
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
L509-1778; 030-22
030.3.11.1 Liebherr recommendation 030-22
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
030.3.13 Lubrication grease for sliding surface on telescopic lift arms
L509-1778; 030-23
copyright ® Liebherr-Werk Bischofshofen GmbH 2021
1509-1778 LIEBHERR 1″
Contents
030.3.4 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
030.3.4.3 Minimum quality requirement 030-18
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
L509-1778; 030-19
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
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 Qil analysis 030-20
030.3.8.4 Qil change 030-21
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
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
L509-1778; 030-22
030.3.11.1 Liebherr recommendation 030-22
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
030.3.13 Lubrication grease for sliding surface on telescopic lift arms
L509-1778; 030-23
copyright ® Liebherr-Werk Bischofshofen GmbH 2021
1509-1778 LIEBHERR 1″
Contents
Service manual
030.4
030.3.13.1 Liebherr recommendation 030-23
030.3.13.2 Minimum quality requirement 030-23
030.3.14 Windscreen washer fluid
1509-1778; 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
1509-1778; 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
L509-1778; 030-26
030.4.2.2 Opening service hatches
1509-1778; 030-27
030.4.2.3 Turning off battery main switch
L509-1778; 030-28
030.4.3 Overall machine 030-29
030.4.3.1 Checking machine is in proper condition
L509-1778; 030-29
030.4.3.2 Removing loose parts, dirt, ice and snow from
machine
L509-1778; 030-31
030.4.33 Cleaning machine
1509-1778; 030-31
030.4.3.4 Replacing VCI capsules
L509-1778; 030-34
0304.35 Operating fluid analysis: General specifications
1509-1778; 030-37
0304.3.6 Operating fluid analysis: filling out sample information
form
1509-1778; 030-40
030.4.3.7 Fuel and operating fluid analysis: scope of analysis
L509-1778; 030-46
0304.3.8 Analysis of lubricants and fuels
1509-1778; 030-50
030.4.4 Drive group 030-57
030.4.4.1 Checking diesel engine oil level
L509-1778; 030-57
030.4.4.2 Diesel engine: changing diesel engine oil
L509-1778; 030-58
030.3.13.2 Minimum quality requirement 030-23
030.3.14 Windscreen washer fluid
1509-1778; 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
1509-1778; 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
L509-1778; 030-26
030.4.2.2 Opening service hatches
1509-1778; 030-27
030.4.2.3 Turning off battery main switch
L509-1778; 030-28
030.4.3 Overall machine 030-29
030.4.3.1 Checking machine is in proper condition
L509-1778; 030-29
030.4.3.2 Removing loose parts, dirt, ice and snow from
machine
L509-1778; 030-31
030.4.33 Cleaning machine
1509-1778; 030-31
030.4.3.4 Replacing VCI capsules
L509-1778; 030-34
0304.35 Operating fluid analysis: General specifications
1509-1778; 030-37
0304.3.6 Operating fluid analysis: filling out sample information
form
1509-1778; 030-40
030.4.3.7 Fuel and operating fluid analysis: scope of analysis
L509-1778; 030-46
0304.3.8 Analysis of lubricants and fuels
1509-1778; 030-50
030.4.4 Drive group 030-57
030.4.4.1 Checking diesel engine oil level
L509-1778; 030-57
030.4.4.2 Diesel engine: changing diesel engine oil
L509-1778; 030-58
12
copyright © Liebher-Werk Bischofshofen GmbH 2021
L509-1778
LBH/M2261288/02/211-20210128_103447/en
LBH/M2261288/02/211-20210128_103447/en
LBH/M2261288/02/211-20210128_103447/en
Service manual
Contents
030.4.5
030.4.6
030.4.4.3 Diesel engine: changing oil filter
L509-1778; 030-60
030.4.4.4 Diesel engine: checking V-belt
030.4.4.4 Diesel engine: checking V-belt
1509-1778; 030-62
030.4.4.5 Diesel engine: changing V-belt
030.4.4.5 Diesel engine: changing V-belt
L509-1778; 030-64
030.44.6 Diesel engine: checking valve clearance
030.44.6 Diesel engine: checking valve clearance
1509-1778; 030-65
030.4.4.7 Fuel tank: draining condensate and sediment
030.4.4.7 Fuel tank: draining condensate and sediment
L509-1778; 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
1509-1778; 030-70
030.4.4.9 Changing fuel pre-filter element
030.4.4.9 Changing fuel pre-filter element
L509-1778; 030-71
030.4.4.10 Changing fuel fine filter element
030.4.4.10 Changing fuel fine filter element
1509-1778; 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
1509-1778; 030-74
030.4.4.12 Checking air filter vacuum switch function
030.4.4.12 Checking air filter vacuum switch function
L509-1778; 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
1509-1778; 030-77
030.4.4.14 Changing safety element of air filter system
030.4.4.14 Changing safety element of air filter system
L509-1778; 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
L509-1778; 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
1509-1778; 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
1509-1778; 030-98
030.4.5.4 Cooling system: changing coolant
030.4.5.4 Cooling system: changing coolant
L509-1778; 030-99
Hydraulic components 030-102
030.4.6.1 Checking oil level in hydraulic tank
Hydraulic components 030-102
030.4.6.1 Checking oil level in hydraulic tank
030.4.6.2 Draining off condensate and sediment from hydraulic
tank
L509-1778; 030-104
0304.63 Hydraulic tank: changing filter cartridge in retumn-
0304.63 Hydraulic tank: changing filter cartridge in retumn-
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
030.4.6.5 Hydraulic tank: changing oil
030.4.6.5 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
1509-1778; 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
030.4.84 Service brake: checking brake plates for wear
030.4.84 Service brake: checking brake plates for wear
1509-1778; 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
1509-1778; 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
1509-1778; 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
030.4.11.2 Changing axle oil
030.4.11.2 Changing axle oil
1509-1778; 030-124
030.4.11.3 Lubricating rear axle kingpin bearings
030.4.11.3 Lubricating rear axle kingpin bearings
030.4.11.4 Checking fitting of rear axle kingpin bearings and
steering rod taper connections
1509-1778; 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
1509-1778; 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
1509-1778; 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
1509-1778; 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
L509-1778; 030-132
030.4.124 Service hatches: cleaning and maintaining seals
030.4.124 Service hatches: cleaning and maintaining seals
1509-1778; 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
1509-1778; 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
1509-1778; 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
1509-1778; 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
1509-1778; 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
1509-1778; 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
030.4.14.2 Changing operator’s cab air filter
030.4.14.2 Changing operator’s cab air filter
1509-1778; 030-147
L508-1778
copyright ® Liebherr-Werk Bischofshofen GmbH 2021
LIEBHERR 15
Contents Service manual
030.4.14.3 Safety belt: checking condition and function
L509-1778; 030-147
030.4.14.4 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
030.4.16.1 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
030.4.15.3 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 030-165
030.6.1 Safety precautions
1509-1778; 030-165
030.6.2 Overall machine 030-165
030.6.2.1 Preparing for adjustment procedures
L509-1778; 030-165
030.6.2.2 Hydraulic oil and coolant: operating temperature
L509-1778; 030-167
030.6.3 Drive group 030-168
030.6.3.1 Pedals: calibration
L509-1778; 030-168
copyright © Liebher-Werk Bischofshofen GmbH 2021
16 LIEBHERR 508-1778
Contents Service manual
030.4.14.3 Safety belt: checking condition and function
L509-1778; 030-147
030.4.14.4 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
030.4.16.1 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
030.4.15.3 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 030-165
030.6.1 Safety precautions
1509-1778; 030-165
030.6.2 Overall machine 030-165
030.6.2.1 Preparing for adjustment procedures
L509-1778; 030-165
030.6.2.2 Hydraulic oil and coolant: operating temperature
L509-1778; 030-167
030.6.3 Drive group 030-168
030.6.3.1 Pedals: calibration
L509-1778; 030-168
copyright © Liebher-Werk Bischofshofen GmbH 2021
16 LIEBHERR 508-1778
LBH/M2261288/02/211-20210128_103447/en
LBH/M2261288/02/211-20210128_103447/en
LBH/M2261288/02/211-20210128_103447/en
Service manual
Contents
030.6.4
030.6.5
030.6.6
030.6.7
030.6.3.2 Diesel engine speed
L509-1778; 030-169
030.6.3.3 Reading the diesel engine service files
030.6.3.3 Reading the diesel engine service files
L509-1778; 030-170
030.6.3.4 Performing a service regeneration on diesel particu-
030.6.3.4 Performing a service regeneration on diesel particu-
late filter
L509-1778; 030-172
030.6.3.5 Diesel engine: changing engine control unit (ECU)
030.6.3.5 Diesel engine: changing engine control unit (ECU)
L509-1778; 030-173
Cooling system 030-183
030.6.4.1 Fan motor: fan speed proportional solenoid
Cooling system 030-183
030.6.4.1 Fan motor: fan speed proportional solenoid
L509-1778; 030-183
Working hydraulics 030-185
030.6.5.1 Calibrating working hydraulics angle sensors
Working hydraulics 030-185
030.6.5.1 Calibrating working hydraulics angle sensors
L509-1778; 030-185
030.6.5.2 Calibrating proportional solenoids in control valve
030.6.5.2 Calibrating proportional solenoids in control valve
block
L509-1778; 030-188
030.6.5.3 Control valve block: secondary pressure relief valves
030.6.5.3 Control valve block: secondary pressure relief valves
1509-1778; 030-189
030.6.5.4 Control valve block: primary pressure relief valve
030.6.5.4 Control valve block: primary pressure relief valve
L509-1778; 030-191
030.6.5.5 Stabilisation module (option), safety valve
030.6.5.5 Stabilisation module (option), safety valve
L509-1778; 030-192
030.6.5.6 Ride control hydro accumulator (option): nitrogen
030.6.5.6 Ride control hydro accumulator (option): nitrogen
filling
L509-1778; 030-194
Hydraulic components 030-196
030.6.6.1 Checking the hydraulic lines for damage
Hydraulic components 030-196
030.6.6.1 Checking the hydraulic lines for damage
L509-1778; 030-196
Travel hydraulics 030-201
030.6.7.1 Travel pump high pressure sensor B102: Deviation
Travel hydraulics 030-201
030.6.7.1 Travel pump high pressure sensor B102: Deviation
L509-1778; 030-201
030.6.7.2 Travel pump replenishing pressure relief valve
030.6.7.2 Travel pump replenishing pressure relief valve
L509-1778; 030-202
030.6.7.3 Travel pump: high pressure relief valves
030.6.7.3 Travel pump: high pressure relief valves
L509-1778; 030-204
030.6.7.4 Travel pump: pressure cut-off
030.6.7.4 Travel pump: pressure cut-off
1509-1778; 030-207
030.6.7.5 Travel pump: manual block curve calibration
030.6.7.5 Travel pump: manual block curve calibration
L509-1778; 030-208
030.6.7.6 Travel pump: automatic block curve calibration
030.6.7.6 Travel pump: automatic block curve calibration
030.6.7.7 Travel motor: manual calibration (maximum swivel
angle)
L509-1778; 030-211
030.6.7.8 = Travel motor: manual calibration (minimum swivel
030.6.7.8 = Travel motor: manual calibration (minimum swivel
angle)
L509-1778; 030-213
Brake system 030-214
030.6.8.1 Inching brake pedal: basic setting
Brake system 030-214
030.6.8.1 Inching brake pedal: basic setting
L509-1778; 030-214
030.6.8.2 Angle sensor for inching function: checking basic
030.6.8.2 Angle sensor for inching function: checking basic
setting
L509-1778; 030-216
030.6.8.3 Service brake: brake pressure in 1st brake circuit
030.6.8.3 Service brake: brake pressure in 1st brake circuit
L509-1778; 030-217
Electrical system 030-218
030.6.9.1 Central control unit (Master5): creating service file
Electrical system 030-218
030.6.9.1 Central control unit (Master5): creating service file
L509-1778; 030-218
030.6.9.2 Central control unit (Master5): software update
030.6.9.2 Central control unit (Master5): software update
L509-1778; 030-219
030.6.9.3 Central control unit (Master5): resetting to factory
030.6.9.3 Central control unit (Master5): resetting to factory
settings
L509-1778; 030-223
0306.9.4 Central control unit (Master5): connecting Sculi diag-
0306.9.4 Central control unit (Master5): connecting Sculi diag-
nostic software
L509-1778; 030-224
030.6.9.5 Central control unit (Master5): connecting LiF T func-
030.6.9.5 Central control unit (Master5): connecting LiF T func-
tion
L509-1778; 030-228
030.6.9.6 Addressing CAN module and checking system infor-
030.6.9.6 Addressing CAN module and checking system infor-
mation
L509-1778; 030-229
Gearbox 030-231
0306.10.1 Gearbox: external servo pressure reducing valve
Gearbox 030-231
0306.10.1 Gearbox: external servo pressure reducing valve
L509-1778; 030-231
030.6.10.2 External servo pressure hydro accumulator nitrogen
030.6.10.2 External servo pressure hydro accumulator nitrogen
filling
L509-1778; 030-233
Axles and drive shafts 030-236
030.6.11.1 Tyres: setting radius
Axles and drive shafts 030-236
030.6.11.1 Tyres: setting radius
L509-1778; 030-236
Operator’s cab, heating and air conditioning 030-237
030.6.12.1 Checking pressure and temperature conditions of air
Operator’s cab, heating and air conditioning 030-237
030.6.12.1 Checking pressure and temperature conditions of air
conditioning unit
L509-1778; 030-237
Options 030-238
Options 030-238
18
copyright © Liebher-Werk Bischofshofen GmbH 2021
LIEBHERR L509-1778
LBH/M2261288/02/211-20210128_103447/en
Service manual
Service manual
Contents
LBH/M2261288/02/211-20210128_103447/en
030.6.13.1 LiDAT: connecting to LiDAT module
L509-1778; 030-238
030.6.13.2 LiDAT: software update for LIDAT module
1509-1778; 030-240
030.6.13.3 LiDAT: creating report and snapshot
L509-1778; 030-242
040 Drive group 040-1
040.1 Engine 040-2
040.1.1 Diesel engine overview
L509-1778; 040-2
0401.2 Electrical components of diesel engine
L509-1778; 040-10
040.1.3 Fuel system 040-11
040.1.3.1 Overview of fuel system
1509-1778; 040-12
040.1.3.2 Fuel level sensor
L509-1778; 040-14
040.1.3.3 Fuel pre-filter
1509-1778; 040-15
040.1.3.4 Fuel fine filter
L509-1778; 040-16
040.14 Air filter system 040-17
040.1.4.1 Air filter
L509-1778; 040-17
040.1.4.2 Vacuum switch for air filter
L509-1778; 040-18
0401.5 Exhaust system 040-18
040.1.5.1 Overview of diesel particulate filter
L509-1778; 040-19
050 Cooling system 050-1
050.1 Overview of cooling system
L509-1778; 050-2
050.2 Cooling system hydraulics 050-3
0502.1 Overview of cooling system hydraulics
L509-1778; 050-3
050.2.2 Fan pump
L509-1778; 050-6
050.2.3 Fan motor
L509-1778; 050-7
050.3 Cooling system electronics 050-9
copyright ® Liebherr-Werk Bischofshofen GmbH 2021
1509-1778 LIEBHERR 19
Contents Service manual
050.3.1 General overview of electronic control system
L509-1778; 050-9
050.3.2 Hydraulic oil temperature sensor
1509-1778; 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; 060-3
060.2 Working pump
L509-1778; 060-7
060.3 Control block
L509-1778; 060-10
060.4 Pilot control 060-17
060.4.1 Pilot pressure for solenoid valve
L509-1778; 060-17
060.5 Ride control 060-19
060.5.1 Overview of ride control system
L509-1778; 060-19
060.5.2 Stabilisation module
L 509-1778; 060-22
060.6 Electronics of the working hydraulics 060-27
060.6.1 Overview of electrical controls the working hydraulics
L509-1778; 060-27
060.6.2 Working hydraulics angle sensors
1509-1778; 060-30
060.7 Regulated flow rate 060-32
060.7.1 Regulated flow rate: total overview
L509-1778; 060-32
060.7.2 Valve block for regulated flow rate
L509-1778; 060-34
060.8 Pipe break protection 060-36
060.8.1 Pipe break protection: overview
1509-1778; 060-36
060.9 High flow 060-40
copyright © Liebher-Werk Bischofshofen GmbH 2021
20 LIEBHERR L509-1778
030.6.13.2 LiDAT: software update for LIDAT module
1509-1778; 030-240
030.6.13.3 LiDAT: creating report and snapshot
L509-1778; 030-242
040 Drive group 040-1
040.1 Engine 040-2
040.1.1 Diesel engine overview
L509-1778; 040-2
0401.2 Electrical components of diesel engine
L509-1778; 040-10
040.1.3 Fuel system 040-11
040.1.3.1 Overview of fuel system
1509-1778; 040-12
040.1.3.2 Fuel level sensor
L509-1778; 040-14
040.1.3.3 Fuel pre-filter
1509-1778; 040-15
040.1.3.4 Fuel fine filter
L509-1778; 040-16
040.14 Air filter system 040-17
040.1.4.1 Air filter
L509-1778; 040-17
040.1.4.2 Vacuum switch for air filter
L509-1778; 040-18
0401.5 Exhaust system 040-18
040.1.5.1 Overview of diesel particulate filter
L509-1778; 040-19
050 Cooling system 050-1
050.1 Overview of cooling system
L509-1778; 050-2
050.2 Cooling system hydraulics 050-3
0502.1 Overview of cooling system hydraulics
L509-1778; 050-3
050.2.2 Fan pump
L509-1778; 050-6
050.2.3 Fan motor
L509-1778; 050-7
050.3 Cooling system electronics 050-9
copyright ® Liebherr-Werk Bischofshofen GmbH 2021
1509-1778 LIEBHERR 19
Contents Service manual
050.3.1 General overview of electronic control system
L509-1778; 050-9
050.3.2 Hydraulic oil temperature sensor
1509-1778; 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; 060-3
060.2 Working pump
L509-1778; 060-7
060.3 Control block
L509-1778; 060-10
060.4 Pilot control 060-17
060.4.1 Pilot pressure for solenoid valve
L509-1778; 060-17
060.5 Ride control 060-19
060.5.1 Overview of ride control system
L509-1778; 060-19
060.5.2 Stabilisation module
L 509-1778; 060-22
060.6 Electronics of the working hydraulics 060-27
060.6.1 Overview of electrical controls the working hydraulics
L509-1778; 060-27
060.6.2 Working hydraulics angle sensors
1509-1778; 060-30
060.7 Regulated flow rate 060-32
060.7.1 Regulated flow rate: total overview
L509-1778; 060-32
060.7.2 Valve block for regulated flow rate
L509-1778; 060-34
060.8 Pipe break protection 060-36
060.8.1 Pipe break protection: overview
1509-1778; 060-36
060.9 High flow 060-40
copyright © Liebher-Werk Bischofshofen GmbH 2021
20 LIEBHERR L509-1778
LBH/M2261288/02/211-20210128_103447/en
LBH/M2261288/02/211-20210128_103447/en
LBH/M2261288/02/211-20210128_103447/en
Service manual
Contents
060.9.1 High Flow: total overview
L509-1778; 060-40
0609.2 High Flow pump
L509-1778; 060-43
060.9.3 Solenoid valve for High Flow
L509-1778; 060-44
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; 080-2
080.2 Hydraulic tank 080-5
0802.1 Overview of hydraulic tank
L509-1778; 080-5
080.2.2 Return suction filter
L509-1778; 080-7
080.2.3 Breather filter
L509-1778; 080-13
090 Steering system 090-1
090.1 Steering system overview
L509-1778; 090-2
090.2 Servostat
L509-1778; 090-4
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
L509-1778; 100-7
100.2.2 Inching function angle sensor
L509-1778; 100-13
100.2.3 Brake light pressure switch
L509-1778; 100-15
copyright ® Liebherr-Werk Bischofshofen GmbH 2021
1509-1778 LIEBHERR 21
Contents Service manual
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
L509-1778; 100-21
100.3.2 Orifice bypass solenoid valve
L509-1778; 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)
L509-1778; 110-10
110.3.3 Modules 110-12
110.3.3.1 Compact module: overview
1509-1778; 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
L 509-1778; 110-22
110.5 Electrical components in the rear section 110-23
110.5.1 Battery installation
L509-1778; 110-23
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
1509-1778; 120-12
120.2.3 Valve block for external servo pressure
L509-1778; 120-14
copyright © Liebher-Werk Bischofshofen GmbH 2021
22 LIEBHERR L509-1778
0609.2 High Flow pump
L509-1778; 060-43
060.9.3 Solenoid valve for High Flow
L509-1778; 060-44
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; 080-2
080.2 Hydraulic tank 080-5
0802.1 Overview of hydraulic tank
L509-1778; 080-5
080.2.2 Return suction filter
L509-1778; 080-7
080.2.3 Breather filter
L509-1778; 080-13
090 Steering system 090-1
090.1 Steering system overview
L509-1778; 090-2
090.2 Servostat
L509-1778; 090-4
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
L509-1778; 100-7
100.2.2 Inching function angle sensor
L509-1778; 100-13
100.2.3 Brake light pressure switch
L509-1778; 100-15
copyright ® Liebherr-Werk Bischofshofen GmbH 2021
1509-1778 LIEBHERR 21
Contents Service manual
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
L509-1778; 100-21
100.3.2 Orifice bypass solenoid valve
L509-1778; 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)
L509-1778; 110-10
110.3.3 Modules 110-12
110.3.3.1 Compact module: overview
1509-1778; 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
L 509-1778; 110-22
110.5 Electrical components in the rear section 110-23
110.5.1 Battery installation
L509-1778; 110-23
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
1509-1778; 120-12
120.2.3 Valve block for external servo pressure
L509-1778; 120-14
copyright © Liebher-Werk Bischofshofen GmbH 2021
22 LIEBHERR L509-1778
LBH/M2261288/02/211-20210128_103447/en
Service manual Contents
Service manual Contents
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
140 Steel parts of the basic machine 140-1
140.1 Vehicle frame 140-2
140.1.1 Articulation bearing
L509-1778; 140-2
140.1.2 Articulation lock
L509-1778; 140-3
150 Working attachment 150-1
5 150.1 Lift arms for Z kinematics 150-2
3 150.11 Lift arms
ao L509-1778; 150-2
5 150.2 Quick coupler 150-4
5 150.2.1 Quick coupler
£ L509-1778; 150-4
g 160.2.2 Quick coupler hydraulics 150-5
3 150.2.2.1 Overview of quick coupler hydraulics
L509-1778; 150-5
160.2.2.2 Valve block for quick couple
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
140 Steel parts of the basic machine 140-1
140.1 Vehicle frame 140-2
140.1.1 Articulation bearing
L509-1778; 140-2
140.1.2 Articulation lock
L509-1778; 140-3
150 Working attachment 150-1
5 150.1 Lift arms for Z kinematics 150-2
3 150.11 Lift arms
ao L509-1778; 150-2
5 150.2 Quick coupler 150-4
5 150.2.1 Quick coupler
£ L509-1778; 150-4
g 160.2.2 Quick coupler hydraulics 150-5
3 150.2.2.1 Overview of quick coupler hydraulics
L509-1778; 150-5
160.2.2.2 Valve block for quick couple
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
L 509-1778; 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
L509-1778; 160-8
160.3.2 Heating and air conditioning unit 160-14
160.3.2.1 Heating and air conditioning unit
1509-1778; 160-14
160.3.2.2 Blower
L509-1778; 160-17
160.4 Air conditioning 160-18
160.4.1 Air conditioning (optional)
L 509-1778; 160-18
160.4.2 Compressor magnetic coupling
1509-1778; 160-19
160.4.3 Air conditioning condenser
1509-1778; 160-21
160.4.4 Dryer-collector unit
L509-1778; 160-21
160.4.5 Air conditioning pressure switch
1509-1778; 160-23
170 Lubrication system 170-1
170.1 Liebherr automatic central lubrication system 170-2
170.1.1 Automatic central lubrication system: overview
L 509-1778; 170-2
170.1.2 Central lubrication pump EP-1
1509-1778; 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
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
L 509-1778; 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
L509-1778; 160-8
160.3.2 Heating and air conditioning unit 160-14
160.3.2.1 Heating and air conditioning unit
1509-1778; 160-14
160.3.2.2 Blower
L509-1778; 160-17
160.4 Air conditioning 160-18
160.4.1 Air conditioning (optional)
L 509-1778; 160-18
160.4.2 Compressor magnetic coupling
1509-1778; 160-19
160.4.3 Air conditioning condenser
1509-1778; 160-21
160.4.4 Dryer-collector unit
L509-1778; 160-21
160.4.5 Air conditioning pressure switch
1509-1778; 160-23
170 Lubrication system 170-1
170.1 Liebherr automatic central lubrication system 170-2
170.1.1 Automatic central lubrication system: overview
L 509-1778; 170-2
170.1.2 Central lubrication pump EP-1
1509-1778; 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
190.1.2 LiDAT on machine
L509-1778; 190-4
190.1.3 LiDAT module (LiTU3)
190.1.3 LiDAT module (LiTU3)
L509-1778; 190-5
200 Diagnosis 200-1
200.1 Malfunctions 200-2
200.1.1 Warning symbols 200-2
200.1.2 Service code indicator in the display 200-3
200.2 Troubleshooting 200-5
200 Diagnosis 200-1
200.1 Malfunctions 200-2
200.1.1 Warning symbols 200-2
200.1.2 Service code indicator in the display 200-3
200.2 Troubleshooting 200-5
010.1 Safety instructions 010-4
010.1.1 Information on these instructions 010-4
010.1.1.1 Representation of warning messages 010-4
010.1.1.2 Graphic symbols in these instructions 010-4
010.1.2 Intended use 010-5
010.1.2.1 Laws, rules, guidelines and safety regulations 010-5
010.1.2.2 Intended use 010-5
010.1.2.3 Foreseeable misuse 010-6
010.1.2.4 Operating conditions 010-6
010.1.2.5 Disposal 010-7
010.1.3 Description of staff 010-7
010.1.3.1 Personal protective equipment 010-7
010.1.3.2 Requirements for staff 010-8
010.1.3.3 Operating company 010-8
010.1.3.4 Operator 010-9
010.1.3.5 Maintenance staff 010-9
010.1.3.6 Refrigeration technician 010-10
010.1.3.7 Slinger 010-11
010.1.3.8 Spotter 010-12
010.1.4 Protective devices on the machine 010-12
010.1.4.1 Operator’s cab 010-12
010.1.4.2 Roll over protective structure (ROPS) 010-13
010.1.4.3 Falling object protective structures (FOPS) 010-13
010.1.5 Emergency equipment on the machine 010-13
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
copyright ® Liebherr-Werk Bischofshofen GmbH 2021
copyright ® Liebherr-Werk Bischofshofen GmbH 2021
1509-1778 LIEBHERR 010-1
Introduction Service manual
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 010-25
010.2.3 Special tools for lift cylinders 010-26
010.24 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 010-32
010.2.14 Special tools for air conditioning system 010-32
010.2.15 Special tools for cab glazing 010-34
010.2.16 Special tools for the central lubrication system (Liebherr) 010-34
010.3 Standards and regulations 010-35
Introduction Service manual
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 010-25
010.2.3 Special tools for lift cylinders 010-26
010.24 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 010-32
010.2.14 Special tools for air conditioning system 010-32
010.2.15 Special tools for cab glazing 010-34
010.2.16 Special tools for the central lubrication system (Liebherr) 010-34
010.3 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
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
010.3.1.3 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
Preservation guidelines 010-43
010.41 General information 010-43
0104.2 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
010.44.2 After being out of service for 12 months 010-47
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
Preservation guidelines 010-43
010.41 General information 010-43
0104.2 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
010.44.2 After being out of service for 12 months 010-47
0104.43 After being out of service for longer than 12 months 010-47
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