PDF Service Manual Liebherr L524 L534 L538 Wheel Loader - 3 MB
This comprehensive service manual provides all the information needed to perform maintenance and repairs on Liebherr L524, L534, and L538 wheel loaders.
It contains detailed technical data, troubleshooting guides, and step-by-step repair instructions for all major systems.
This manual is an essential tool for technicians to keep these powerful machines operating at their best.
From routine service to complex overhauls, this guide has you covered.
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en
Service Manual
(20
Wheel Loader
(10 points)
L524 / L534 / L538(10
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Service Manual General Information
Safety regulations
1.1 Safety regulations
Working on the machine poses safety risks to the operator, driver or
maintenance engineers. You can prevent risks and accidents by regularly
reading and observing the various safety instructions.
This is especially important for personnel who only occasionally work on the
machine, for example, carrying out rigging or maintenance work. The safety
regulations listed below, if conscientiously followed, will ensure your own
safety and that of others, and will prevent the machine from being damaged.
Whenever tasks which could cause danger to personnel or damage to the
machine are described, the necessary safety precautions are explained in
this manual.
These are indicated by the headings Danger, Warning or Caution.
1.1.1 Introduction
1. The symbols below have the following meanings:
Danger Danger
Warning that without appropriate precautions, certain procedures could
result in fatal accidents.
Warning
Warning
Warning that without appropriate precautions, certain procedures could
result in severe physical injuries.
Caution Caution
Warning that without appropriate precautions, certain procedures could
result in minor physical injuries or damage to the machine.
2. Observance of these instructions does not exempt you from following
any additional rules and guidelines that may apply
The following should also be observed:
– The safety rules in force at the operating site
– Legally enforceable road traffic regulations
– Guidelines issued by trade associations
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L524 - 438 / from 0101
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Service Manual Product Description
Technical data
Description Value Unit
Bucket capacity as per ISO 7546 1.7 m³
Bucket width 2500 mm
Specific material weight 1.8 t/m³
A Dump height at maximum lifting height 2815 mm
and 45° tilt-out angle
B Dump height 3380 mm
C Maximum bucket base height 3500 mm
D Maximum bucket pivot point height 3750 mm
E Maximum bucket top height 4895 mm
F Reach at maximum lifting height and 42° 1030 mm
tilt-out angle
G Digging depth 55 mm
H Height above the cab 3150 mm
I Height above exhaust 3090 mm
J Ground clearance 520 mm
K Wheel base 2700 mm
L Overall length 6890 mm
Turning radius over bucket outer edge 5530 mm
Lifting force (SAE) 89 kN
Breakout force (SAE) 80 kN
Tipping load when straight 7100 kg
Tipping load articulated at 40° 6250 kg
Angle of articulation (to each side) 40 °
Swing angle (to each side) 6 °
Operating weight 10200 kg
Tractive force 76.2 kN
Travel speed in travel range 1, forward 0 - 8.0 km/h
and reverse
Travel speed in travel range 2, forward 0 - 33.0 km/h
and reverse
Sound pressure level in the cab – LpA 75 dB (A)
Wheel loader with Z lift arms Valid for: L534 - 434 / from 0101
The values stated refer to the standard version of the machine:
– With Z lift arms (2500 mm), without hydraulic quick-change device.
– With 20.5 R25 Goodyear GP-2B tyres.
– Tipping loads and weights include all lubricants, full fuel tank,
ROPS/FOPS cab and driver.
Tyre sizes and additional attachments affect the operating weight and
tipping load.
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Service Manual Product Description
Technical data
Description Value Unit
Starter operating voltage 24 V
Starter power consumption 5.4 kW
Alternator voltage output 28 V
Alternator current output 55 A
Auxiliary power take-off transmission 1:1.275
Weight 740 kg
Emission levels comply with EU – RL 97/68/EC Stage II
Fuel tank
Valid for: L524 - 438 / from 0101; L534 - 434 / from 0101; L538 - 432 / from 0101;
ID no. 7622943
Description Value Unit
Tank capacity, FULL 160 l
Tank capacity, RESERVE 30 l
Fuel pre-filter (stage I)
Valid for: L524 - 438 / 0101 - 8795; L534 - 434 / 0101 - 8961; ID no. 7090480
Description Value Unit
Filtration grade min. 0.6 mm
max. 0.8 mm
Valid for: L538 - 432 / 0101 -8507; ID no. 7381876
Description Value Unit
Filtration grade min. 0.6 mm
max. 0.8 mm
Fuel pre-filter (stage II)
Valid for: L524 - 438 / from 8796; L534 - 434 / from 8962; ID no. 7090562
Description Value Unit
Filtration grade 10 µm
Valid for: L538 - 432 / from 8508; ID no. 7382133
Description Value Unit
Filtration grade 30 µm
Fuel fine filter (stage I)
Valid for: L524 - 438 / from 0101; L534 - 434 / from 0101; ID no. 7090528
Description Value Unit
Filtration grade 5 µm
Valid for: L538 - 432 / 0101 - 8507; ID no. 7381643
Description Value Unit
Filtration grade 5 µm
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Service Manual Product Description
Technical data
Description Value Unit
Cardan speed at 34 km/h 2895 min-1
Speed sensor Inductive
Speed sensor
Description Value Unit
Type Inductive sensor -
Distance to spur gear “A” min. 1.2 mm
max. 1.8 mm
2.1.10 Axles and tyres
Front axle
Valid for: L524 - 438 / from 0101
Description Value Unit
Self-locking differential level 45 %
Width 1900 mm
Wheel lug tightening torque 650 Nm
Wheel lug spanner size 30 mm
Weight 490 kg
Valid for: L534 - 434 / from 0101; L538 - 432 / from 0101
Description Value Unit
Self-locking differential level 45 %
Width 1900 mm
Wheel lug tightening torque 650 Nm
Wheel lug spanner size 30 mm
Weight 600 kg
Rear axle
Valid for: L524 - 438 / from 0101
Description Value Unit
Self-locking differential level 45 %
Swing angle (to each side) 6 °
Width 1900 mm
Wheel lug tightening torque 650 Nm
Wheel lug spanner size 30 mm
Weight 600 kg
Valid for: L534 - 434 / from 0101; L538 - 432 / from 0101
Description Value Unit
Self-locking differential level 45 %
Swing angle (to each side) 6 °
Width 1900 mm
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Service Manual Maintenance
Maintenance and inspection schedule
Customer: ………………………………….. Machine type: ………...… Ser. no.: ……....…… Service hours: …….………. Date: ………..……
Maintenance / inspection
after service hours TASKS TO BE PERFORMED
By maintenance staff By authorised specialist staff
Once-only activity Once-only activity
Repeat interval Repeat interval
As necessary As necessary
Annually before the winter
Cooling system
Check the coolant level
Change the coolant filter (L538 only)
Check the coolant antifreeze concentration (L538 with DCA 4 component)
Clean the cooling system
3000h Change the coolant and antifreeze (L538 with DCA 4 component) (or every 2 years)
Working hydraulics
Check the hydraulic tank oil level (take an oil sample every 500 hours for bio oil)
Drain off condensate and sediment from the hydraulic tank
Change the oil in the hydraulic tank and check the return strainer
250h Check and clean the magnetic rod on the hydraulic tank
Change the hydraulic tank return suction filter
Change the hydraulic tank bleeder filter
Lubricate the pilot control device solenoids, universal joints and tappets
Steering system
Check that the steering is working
Lubricate the bearing points on the steering cylinders
Brake system
Check the service brake and parking brake
Check the gap and wear on the parking brake linings
Electrical system
Check the indicator lamps and lighting
Check the batteries, fluid level and terminals
Transfer gear
Check the transfer gear oil level
Change the transfer gear oil
Axles and tyres
Check the tightness of the wheels (once after 50, 100 and 250 h)
Check the axle oil levels
Change the axle oil
Check and lubricate the cardan shaft(s)
Check the tyre pressure
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L524 - 438 / from 0101
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Costumer: L 534 ÍñÒæ ìíì ñ
Ñ°»®¿¬·²¹ ¸±«®æ
̧°» ±º ¿°°´·½¿¬·±²æ
Job site: ݸ»½µ»¼ ¾§æ
ݸ»½µ»¼ ±² ¼¿¬»æ
Value Value
Adjust. Adjust. Test
Check / Adjustment Unit
values
before after
point point
adjust adjust
Diesel engine
Diesel engine RPM
Ô±© ·¼´» ÎÐÓ ³·²óï èëðo
ëð
ï
óï õèð
Ø·¹¸ ·²¼´» ÎÐÓ ³·² îëëð î
Cooling system
Cooling System øº¿² ½±²¬®±´÷
ا¼®¿«´·½ ±·´ íï ó ëë pÝ
ݱ±´¿²¬ ¾»´±© éè pÝ
Ú¿² ¿¬ ¸·¹¸ Ü·»»´ »²¹·²» ÎÐÓñ ¾¿® ïéëoë ï Ð
Í»²±® «²°´«¹¹»¼
ïð
Ú¿² ¿¬ ¸·¹¸ Ü·»»´ »²¹·²» ÎÐÓ ¾¿® êëo Ð
oïð
Ú¿² ¿¬ ´±© Ü·»»´ »²¹·²» ÎÐÓ ¾¿® íð Ð
Travel hydraulic
Replenisihing pressure
߬ ¸·¹¸ ·¼´» ÎÐÓ ¾¿® íîoî ì Ù
Ø·¹¸ °®»«®» ¾¿® ëð ëð ëð í Óß øÓÞ÷
óï oëð
Ü·»»´ »²¹·²» ÎÐÓ ³·² ïðëð
ݱ²¬®±´ °®»«®» ¾¿® êoî ÐÍÌ
Pump performance at 380 bar
Ø·¹¸ °®»«®» ¾¿® íèð íèð íèð ê Óß øÓÞ÷
óï
Ü·»»´ »²¹·²» ÎÐÓ ³·² ïçððoïðð
ݱ²¬®±´ °®»«®» ¾¿® ïêoî ÐÍÌ
High pressure relief valves
Ú±®©¿®¼ ¾¿® ìéðoïð î Óß
못®» ¾¿® ìéðoïð ë ÓÞ
Pressure cut off
Ø·¹¸ °®»«®» ¾¿® ìíðoë ï Óß øÓÞ÷
óï
Û²¹·²» °»»¼ ¼®±°ô ³¿¨ò ¼·ºº»®»²½» ³·² ëð
¬± ¸·¹¸ ·¼´» ÎÐÓ
ݱ²¬®±´ °®»«®» ¾¿® îîoî ÐÍÌ
Variable displ. motor 1 in
regulating range
ë
Ø·¹¸ °®»«®» ©¸»² ¬®¿ª»´´·²¹ ¿¬ ê ó é µ³ñ¸ ¾¿® îêðo é Óß
ßµ¬·ª¿¬·²¹ °®»«®» ¾¿® ïíð Óï
Variable displ. motor 2
Control pressure regulating
ßµ¬·ª¿¬·²¹ °®»«®» ¾¿® ð Óî
ݱ²¬®±´ °®»«®» ¾¿® êoï è ÐÍÌ
Pressure regulating
ßµ¬·ª¿¬·²¹ °®»«®» ¾¿® ëð ëð ëð Óî
Ø·¹¸ °®»«®» ¾¿® îçðoë ç Óß
ã Þ´±½µ»¼ Ó¿½¸·²»
L534 ó ìíì ñ ðïðï
Wednesday, ó êçìí
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MJFCIFSS
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Service Manual Maintenance
Lubrication chart and filling quantities
3.4 Lubrication chart and filling quantities
3.4.1 Table of filling quantities (L524)
Valid for: L524 - 438 / from 0101
Specifications in the medium column:
The standard lubricants and fuels required for central European climate
conditions are stated here.
Before you change or top up the oil in the hydraulic system (hydraulic
tank), always check if it is filled with petroleum or bio oil.
For more detailed information about the required lubricants and service
fuels, see the section on lubricants and fuels.
Specifications in the dosage column:
The values stated for the filling quantities in the table are only guide-
lines.
The dipstick and level markings are always mandatory.
Each time the oil is replaced or topped up, check the level in the unit
in question.
Description Medium Dosage Unit
Diesel engine cooling Coolant 24.5 l
system total capacity
Diesel engine Engine oil 12.0 l
(with filter change) SAE 10W - 40
Transfer gear Gear oil 2.1 l
SAE 90 LS
Front axle differential Gear oil 12.2 l
SAE 90 LS
Front axle wheel hub Gear oil 2.4 l
(each) SAE 90 LS
Rear axle differential Gear oil 12.7 l
SAE 90 LS
Rear axle wheel hub Gear oil 2.5 l
(each) SAE 90 LS
Hydraulic tank Engine oil 100 l
SAE 20W - 20
Hydraulic system Engine oil 130 l
total capacity SAE 20W - 20
Air-conditioning system Refrigerant 1400 g
R 134a
3.4.2 Table of filling quantities (L534)
Valid for: L534 - 434 / from 0101
Specifications in the medium column:
The standard lubricants and fuels required for central European climate
conditions are stated here.
Before you change or top up the oil in the hydraulic system (hydraulic
tank), always check if it is filled with petroleum or bio oil.
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L524 - 438 / from 0101
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Service Manual Maintenance
Maintenance tasks
3.5.5 Checking the engine oil level (L524, L534)
Valid for: L524 - 438 / 0101; L534 - 434 / 0101
The oil filler neck is on the top of the engine on the valve cover.
Make sure that:
– The machine is in maintenance position 1.
– The engine compartment hood is open.
– The engine is level and has not been running for 2 to 3 minutes.
Procedure
Pull out the dipstick 1, wipe it clean, and re-insert it.
Pull out the dipstick 1 once again and read off the oil level.
The oil level must be within the cross hatching 2.
Diesel engine dipstick
If the oil level is in the range 3 or below:
Top up with engine oil. For the oil quality, see the section on lubricants
and fuels.
Checking the engine oil level (L538)
Valid for: L538 - 432 / 0101
The oil filler neck is on the top of the engine on the valve cover.
Make sure that:
– The machine is in maintenance position 1.
– The engine compartment hood is open.
– The engine is level and has not been running for 1 to 2 minutes.
Procedure
Pull out the dipstick 3, wipe it clean, and re-insert it.
Pull out the dipstick 3 once again and read off the oil level.
The oil level must be within the cross hatching 2.
If the oil level is too low:
Top up with oil. For the oil quality, see the section on lubricants and fuels.
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Service Manual Maintenance
Maintenance tasks
Valve layout
S Flywheel end 2 Cylinder 2
A Outlet valve 3 Cylinder 3
E Inlet valve 4 Cylinder 4
1 Cylinder 1
Turn the crankshaft in the direction of rotation until the valves of the
fourth cylinder overlap.
Adjust the valves of the first cylinder.
Adjusting the valves
Push a feeler gauge 6 between the valve 5 and the rocker arm 4 and
check the valve play.
If the valve play is not correct:
Loosen the counter nut 3 of the adjusting screw for the rocker arm in
question 4 using a 17 mm ring spanner 1, and correct the setting using a
screwdriver 2. Tighten the counter nut again.
Check the valve play again after you tighten the counter nut 3.
Check the other cylinders and adjust them as necessary by turning the
crankshaft until the valves overlap as shown in the table.
After checking and adjusting the valves, put on the valve cover with
new seals.
Put the belt guard and intake line back on.
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Service Manual Maintenance
Maintenance tasks
Open the bleeder screw 6.
Push in the stop cock on the drain valve 10 and open it anticlockwise.
Drain the condensate into a suitable receptacle.