Liebherr L506 Wheel Loader Service Repair Manual

en Service manual Wheel loader Document ID 11827669 06-2019 Order number: 07 Issued: LBH / Technical Documentation Department Version: Author: Liebherr-Werk Bischofshofen GmbH L 506-1577 Product ID Manufacturer: Valid for: Conformity: Contact Liebherr-Werk Bischofshofen GmbH Dr. Hans Liebherr-Straße 4 A – 5500 Bischofshofen

LBH/11827669/07/211-20190529_115753/en copyright © Liebherr-Werk Bischofshofen GmbH 2019 2 L506-1577

Preface LBH/11827669/07/211-20190529_115753/en Notes for users This service manual is designed for trained specialist staff of the Liebherr organisa- tion 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. Infor- mation 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”. This document may not be duplicated, even in part, without the permission of Lieb- herr. Technical changes are reserved. Warning symbols This is the warning symbol. It warns you of poten- tial injuries. To prevent injury or death, carry out all the measures identified by this warning symbol. The warning symbol always appears together with the signal words: DANGER WARNING CAUTION DANGER Indicates a extremely hazardous situation that will WARNING result in death or serious injury if it is not avoided. Indicates a hazardous situation that could result death or serious injury if it is not avoided. copyright © Liebherr-Werk Bischofshofen GmbH 2019 L506-1577 3

Preface Service manual CAUTION Indicates a hazardous situation that could result NOTICE in minor or moderate injury if it is not avoided. Indicates a hazardous situation that could result in damage to property if it is not avoided. Structure of warnings Warnings in this document are structured as follows: WARNING Here you will find information about the type and source of danger. Here you will be informed about possible consequences of not paying attention to the warning. u Here you will be called on to take measures to avoid the dangerous situation. Other designations Symbol Meaning Note useful tips and information. This symbol means: perform a task. This symbol means: a requirement must be fulfilled. This symbol means: the result of a task. - This symbol indicates a list. Symbols LBH/11827669/07/211-20190529_115753/en copyright © Liebherr-Werk Bischofshofen GmbH 2019 4 L506-1577

Contents 010 Introduction 010-1 010.1 Safety instructions 010-3 010.1.1 General safety instructions 010-3 010.1.2 Instructions on preventing crushing injuries and burns 010-4 010.1.3 Instructions on preventing fires and explosions 010-4 010.1.4 Safety instructions for start-up 010-5 010.1.5 Safety precautions during start-up 010-5 010.1.6 Instructions for safe working 010-6 010.1.7 Safety instructions for driving on slopes 010-7 010.1.8 Parking safely 010-7 010.1.9 Transporting the machine safely 010-7 010.1.10 Towing the machine safely 010-8 010.1.11 Measures for ensuring safe maintenance 010-8 010.1.12 Safety instructions for maintenance work on machines with hydro accumulators 010-11 010.1.13 Safety instructions for welding work on the machine 010-11 010.1.14 Safety instruction for working on the working attachment 010-11 010.1.15 Safety instructions for transporting the machine by crane 010-12 010.1.16 Safe maintenance of hydraulic hoses and hose lines 010-12 010.1.17 Roll over protective structure (ROPS) and falling object protection structure (FOPS) 010-13 LBH/11827669/07/211-20190529_115753/en 010.1.17.1 Preventing accidents 010-13 010.1.17.2 Preventing injuries 010-13 010.1.18 Attachments and accessories 010-13 010.1.19 Protection against vibrations 010-14 010.1.20 See and be seen 010-14 010.1.20.1 Field of view and visual aids 010-14 010.1.20.2 Measures during operation. 010-15 010.1.20.3 Modifications to the machine 010-15 010.1.21 Danger area of the machine 010-15 copyright © Liebherr-Werk Bischofshofen GmbH 2019 L506-1577 5

Contents Service manual 010.2 Special tools for maintenance and repair work 010-17 010.2.1 Special tools, general 010-17 010.2.2 Special tools for diesel engine 010-18 010.2.3 Special tools for Z kinematics hydraulic cylinders 010-19 010.2.4 Special tools for steering cylinders 010-20 010.2.5 Special tools for the electrical system 010-20 010.2.6 Special tools for axles 010-20 010.2.7 Special tools for the air conditioning system 010-21 010.2.8 Special tools for cab glazing 010-21 010.2.9 Special tools for the central lubrication system 010-21 010.3 Standards and regulations 010-23 010.3.1 Prestressing forces and tightening torques for bolts with metric 010-23 standard and fine threads as per DIN ISO 261 010.3.1.1 Range of application and purpose 010-23 010.3.1.2 Other applicable documents 010-23 010.3.1.3 Modifications and descriptions 010-24 010.3.1.4 Tightening torques 010-24 010.3.2 Liebherr standards for assembly instructions and tightening torques010-30 010.4 Preservation guidelines 010-31 010.4.1 General information 010-31 010.4.2 Machine out of service for an unknown period of time 010-31 010.4.3 Putting the machine out of service 010-32 010.4.3.1 Out of service for up to 2 months 010-32 010.4.3.2 Out of service for up to 12 months 010-33 010.4.3.3 Out of service for longer than 12 months 010-34 010.4.4 Putting back into service 010-34 010.4.4.1 After being out of service for 2 months 010-34 010.4.4.2 After being out of service for 12 months 010-35 LBH/11827669/07/211-20190529_115753/en 010.4.4.3 After being out of service for longer than 12 months 010-35 020 Technical data 020-1 020-4 020.1 Overall machine 020-4 020.1.1 Complete machine with loading bucket L506-1577/34874-; 020-5 020.1.2 Working attachment: 4 in 1 bucket L506-1577/34874-; copyright © Liebherr-Werk Bischofshofen GmbH 2019 6 L506-1577

Service manual Contents LBH/11827669/07/211-20190529_115753/en 020.1.3 Working attachment: forklift 020-7 L506-1577/34874-; 020-9 020-9 020.2 Drive group 020-10 020-10 020.2.1 Engine 020-10 L506-1577/34874-; 020-12 020-12 020.2.2 Fuel tank 020-13 L506-1577/34874-; 020-13 020-13 020.2.3 Air filter vacuum switch 020-14 L506-1577/34874-; 020-14 020-15 020.2.4 Clutch 020-15 L506-1577/34874-; 020-16 020-17 020.3 Cooling system 020-17 020-17 020.3.1 Water cooler 020-17 L506-1577/34874-; 020-18 020-18 020.4 Working hydraulics 020-18 020-19 020.4.1 Working hydraulics pump 020-19 L506-1577/34874-; 7 020.4.2 Control valve block L506-1577/34874-; 020.4.3 Z-bar kinematics lift cylinder L506-1577/34874-; 020.4.4 Z kinematics tilt cylinder L506-1577/34874-; 020.5 Travel hydraulics 020.5.1 Travel pump L506-1577/34874-; 020.5.2 Travel motor L506-1577/34874-; 020.6 Hydraulic components 020.6.1 Hydraulic oil temperature switch L506-1577/34874-; 020.6.2 Filter unit L506-1577/34874-; 020.6.3 Breather filter L506-1577/34874-; 020.7 Steering system 020.7.1 Servostat L506-1577/34874-; 020.7.2 Steering cylinder L506-1577/34874-; 020.8 Brake system 020.8.1 Drum brake L506-1577/34874-; copyright © Liebherr-Werk Bischofshofen GmbH 2019 L506-1577

Contents 020.8.2 Brake master cylinder Service manual LBH/11827669/07/211-20190529_115753/en 8 L506-1577/34874-; 020-19 020.8.3 Brake light pressure switch B12 020-19 L506-1577/34874-; 020-20 020-20 020.9 Electrical system 020-21 020-21 020.9.1 Battery 020-22 L506-1577/34874-; 020-22 020-22 020.10 Gearbox 020-23 020-23 020.10.1 Transmission 020-24 L506-1577/34874-; 020-25 020-25 020.11 Axles and drive shafts 020-26 020-26 020.11.1 Front axle 020-26 L506-1577/34874-; 020-27 020-27 020.11.2 Rear axle 020-27 L506-1577/34874-; 020-27 020-28 020.11.3 Drive shaft 020-28 L506-1577/34874-; 020-28 020-29 020.11.4 Tyres 020-29 L506-1577/34874-; 020-29 020.11.4.2 Special tyres L506-1577 020.12 Steel parts of the basic machine 020.12.1 Ballast weight L506-1577/34874-; 020.13 Working attachment 020.13.1 Lift arms for Z kinematics L506-1577/34874-; 020.13.2 Quick coupler L506-1577/34874-; 020.14 Operator's cab, heating and air conditioning 020.14.1 Heating, air conditioning L506-1577/34874-; 020.14.2.1 Air conditioning 020.14.3.1 Air conditioning compressor 020.14.4.1 Dryer 020.14.5.1 Air conditioning pressure switch 020.14.6 Anti-icing thermostat L506-1577/34874-; 020.15 Lubrication system 020.15.1 Central lubrication pump EP1 L506-1577/34874-; 020.15.2 Progressive distributor L506-1577/34874-; copyright © Liebherr-Werk Bischofshofen GmbH 2019

Service manual Contents 020.15.2.1 MX-F 020-29 020.15.2.2 MX-F 25 020-29 020.15.2.3 MX-F 45 020-30 020.15.2.4 MX-F 75 020-30 020.15.2.5 MX-F105 020-30 LBH/11827669/07/211-20190529_115753/en 030 Maintenance 030-1 030-8 030.1 Maintenance and inspection schedule 030-13 030.2 Filling quantities and lubrication chart 030-13 030.2.1 Recommended lubricants 030-13 L506-1577/34874-; 030-15 030-15 030.2.2 Recommended operating fluids L506-1577/34874-; 030-15 030.3 Lubricants and fuels 030-16 030-16 030.3.1 General information on changing lubricants and fuels 030-16 030.3.2 Converting hydraulic system from mineral oils to biodegradable 030-16 hydraulic fluids 030-16 030-16 030.3.3 Diesel fuels L506-1577; 030-17 030.3.3.1 Minimum quality requirement 030-17 030.3.3.2 Minimum quality requirement 030-17 030-17 030.3.4 Engine oils 030-18 L506-1577; 030.3.4.1 Liebherr recommendation 030-18 030-18 030.3.4.3 Minimum quality requirement 030-18 030-18 030.3.5 Refrigerant 030-19 L506-1577; 030.3.6 Coolant L506-1577/34874-; 030.3.6.1 Requirements for the water used 030.3.6.2 Antifreeze and corrosion inhibitor 030.3.6.3 Minimum quality requirement 030.3.7 Hydraulic oil L506-1577; 030.3.7.1 Liebherr recommendation 030.3.7.2 Minimum quality requirement 030.3.7.3 Oil analysis 030.3.7.4 Oil change copyright © Liebherr-Werk Bischofshofen GmbH 2019 L506-1577 9

Contents Service manual 10 030.3.8 Transmission 030-19 L506-1577; 030.3.8.1 Liebherr recommendation 030-19 030.3.8.2 Minimum quality requirement 030-19 030.3.9 Axle oil 030-20 L506-1577; 030.3.9.1 Liebherr recommendation 030-20 030.3.9.2 Minimum quality requirement 030-20 030.3.10 Brake oil 030-20 L506-1577; 030.3.10.1 Liebherr recommendation 030-20 030.3.11 Lubrication grease 030-20 L506-1577; 030.3.11.1 Liebherr recommendation 030-20 030.3.11.2 Minimum quality requirement 030-21 030.4 Maintenance tasks 030-22 030.4.1 Safety precautions 030-22 L506-1577/34874-; 030.4.2 Preparatory tasks for maintenance 030-22 030.4.2.1 Maintenance positions L506-1577/34874-; 030-23 030.4.2.2 Opening the service hatches L506-1577/34874-; 030-24 030.4.2.3 Turning off battery main switch L506-1577/34874-; 030-25 030.4.3 Overall machine 030-26 030.4.3.1 Checking the machine for external damage L506-1577/34874-; 030-26 030.4.3.2 Removing loose parts, dirt, ice and snow from the machine L506-1577/34874-; 030-26 030.4.3.3 Cleaning the machine LBH/11827669/07/211-20190529_115753/en L506-1577/34874-; 030-27 030.4.3.4 Checking the machine for leaks L506-1577/34874-; 030-28 030.4.3.5 Making sure the bolted connections are tight L506-1577/34874-; 030-28 030.4.3.6 Corrosion protection system for use with salt and arti- ficial fertilisers (optional): Carrying out corrosion protection L506-1577/34874-; 030-29 030.4.3.7 Oil analyses L506-1577/34874-; 030-29 copyright © Liebherr-Werk Bischofshofen GmbH 2019 L506-1577

Service manual Contents 030.4.4 Drive group 030-36 030.4.5 030.4.4.1 Checking diesel engine oil level L506-1577/34874-; 030-36 030.4.4.2 Changing diesel engine oil L506-1577/34874-; 030-37 030.4.4.3 Changing the engine oil filter L506-1577/34874-; 030-39 030.4.4.4 Checking diesel engine V-belt L506-1577/34874-; 030-40 030.4.4.5 Changing the engine V-belt L506-1577/34874-; 030-43 030.4.4.6 Checking the engine valve clearance L506-1577/34874-; 030-44 030.4.4.7 Draining condensate and sediment from fuel tank L506-1577/34874-; 030-48 030.4.4.8 Draining off condensate from the fuel pre-filter L506-1577/34874-; 030-49 030.4.4.9 Changing the fuel pre-filter insert L506-1577/34874-; 030-50 030.4.4.10 Changing the fuel fine filter 030-51 L506-1577/34874-; 030.4.4.11 Cleaning service cover and dust discharge valve of air filter system L506-1577/34874-; 030-53 030.4.4.12 Checking the air suction system for leaks and tight fitting L506-1577/34874-; 030-54 030.4.4.13 Testing the air filter vacuum switch 030-55 L506-1577/34874-; 030.4.4.14 Cleaning or changing the main filter element 030-56 L506-1577/34874-; 030.4.4.15 Changing the air filter safety element 030-59 L506-1577/34874-; 030.4.4.16 Checking the exhaust system for leaks and tight fitting LBH/11827669/07/211-20190529_115753/en L506-1577/34874-; 030-60 030.4.4.17 Cleaning or changing the diesel particulate filter 030-61 L506-1577/34874-; Cooling system 030-69 030.4.5.1 Checking coolant level in cooling system L506-1577/34874-; 030-69 030.4.5.2 Checking the coolant anti-freeze and corrosion inhib- itor concentration L506-1577/34874-; 030-70 copyright © Liebherr-Werk Bischofshofen GmbH 2019 L506-1577 11

Contents Service manual 12 030.4.5.3 Cleaning the cooling system L506-1577/34874-; 030-75 030.4.5.4 Changing coolant (at least once a year) L506-1577/34874-; 030-76 030.4.6 Hydraulic components 030-78 030.4.6.1 Checking oil level in hydraulic tank L506-1577/34874-; 030-78 030.4.6.2 Draining off condensate and sediment from the hydraulic tank L506-1577/34874-; 030-80 030.4.6.3 Hydraulic tank - changing the return-suction filter L506-1577/34874-; 030-81 030.4.6.4 Changing the hydraulic tank breather filter L506-1577/34874-; 030-83 030.4.6.5 Changing oil in hydraulic system L506-1577/34874-; 030-83 030.4.7 Steering system 030-85 030.4.7.1 Testing the steering L506-1577/34874-; 030-85 030.4.7.2 Lubricating steering cylinder bearing L506-1577/34874-; 030-86 030.4.8 Brake system 030-87 030.4.8.1 Testing service brake and parking brake L506-1577/34874-; 030-87 030.4.8.2 Checking oil level in brake system L506-1577/34874-; 030-88 030.4.8.3 Checking the gap and wear on the service brake linings L506-1577/34874-; 030-89 030.4.9 Electrical system 030-90 030.4.9.1 Checking the lights L506-1577/34874-; 030-90 030.4.9.2 Checking the batteries, fluid level and terminals L506-1577/34874-36021; 030-91 LBH/11827669/07/211-20190529_115753/en 030.4.9.3 Checking the batteries, fluid level and terminals L506-1577/36022-; 030-93 030.4.9.4 Changing the travel direction rocker switch and cap (optional) on the control lever L506-1577/34874-; 030-96 030.4.10 Gearbox 030-98 030.4.10.1 Checking the transmission oil level 030-98 L506-1577/34874-; 030.4.10.2 Changing the transmission oil 030-98 L506-1577/34874-; copyright © Liebherr-Werk Bischofshofen GmbH 2019 L506-1577

Service manual Contents L506-1577 030.4.11 Axles and drive shafts 030-99 030.4.11.1 Checking the axle oil levels 030-99 L506-1577/34874-; 030.4.11.2 Changing the axle oil 030-100 L506-1577/34874-; 030.4.11.3 Checking the tightening torque of the fastening bolts L506-1577/34874-; 030-101 030.4.11.4 Checking the cardan shafts 030-102 L506-1577/34874-; 030.4.11.5 Checking the tyre pressure 030-102 L506-1577/34874-; 030.4.11.6 Checking the wheel tightness 030-103 L506-1577/34874-37498; 030.4.11.7 Checking wheel tightness 030-103 L506-1577/37499-; 030.4.12 Steel parts of the basic machine 030-104 030.4.12.1 Lubricating articulated bearing 030-104 L506-1577/34874-; 030.4.12.2 Lubricating articulation stops 030-105 L506-1577/34874-; 030.4.12.3 Covering - lubricating locks and hinges 030-105 L506-1577/34874-; 030.4.13 Working attachment 030-106 030.4.13.1 Lubricating the lift arms and working attachment L506-1577/34874-; 030-106 030.4.13.2 Checking the lift arm bearing bushings 030-107 L506-1577/34874-; 030.4.13.3 Checking the lift arm bucket stops 030-107 L506-1577/34874-; 030.4.13.4 Lubricating and testing the quick-change device L506-1577/34874-; 030-108 030.4.14 Operator's cab, heating and air conditioning 030-109 LBH/11827669/07/211-20190529_115753/en 030.4.14.1 Cleaning operator's cab air filter 030-109 L506-1577/34874-; 030.4.14.2 Changing operator's cab air filter 030-110 L506-1577/34874-; 030.4.14.3 Checking the condition and function of the safety belt L506-1577/34874-; 030-111 030.4.14.4 Filling windscreen washer fluid in windscreen washer system L506-1577/34874-; 030-112 030.4.14.5 Checking the seals on the driver’s cab 030-112 L506-1577/34874-; copyright © Liebherr-Werk Bischofshofen GmbH 2019 13

Contents Service manual 14 030.4.14.6 Air conditioning: draining condensate 030-113 L506-1577/34874-; 030.4.14.7 Testing the air conditioning unit 030-113 L506-1577/34874-; 030.4.15 Lubrication system 030-115 030.4.15.1 Checking central lubrication system grease reservoir level L506-1577/34874-; 030-115 030.4.15.2 Checking the pipes, hoses and lubrication points of the lubrication system L506-1577/34874-; 030-115 030.4.15.3 Checking whether metered quantities are adequate at the bearing points (grease collars) of the lubrica- tion system L506-1577/34874-; 030-116 030.5 Testing and adjustment checklist 030-117 L506-1577/34874-; 030.6 Testing and adjustment tasks 030-120 030.6.1 Safety precautions 030-120 L506-1577/34874-; 030.6.2 Overall machine 030-121 030.6.2.1 Testing and adjusting: Preparation L506-1577/34874-; 030-121 030.6.2.2 Hydraulic system: operating temperature L506-1577/34874-; 030-122 030.6.3 Drive group 030-122 030.6.3.1 Diesel engine speed L506-1577/34874-; 030-122 030.6.3.2 Reading the diesel engine service files L506-1577/34874-; 030-124 030.6.3.3 Performing a service regeneration on diesel particu- late filter L506-1577; 030-126 030.6.3.4 Diesel engine: changing engine control unit (ECU) LBH/11827669/07/211-20190529_115753/en L506-1577; 030-127 030.6.4 Working hydraulics 030-137 030.6.4.1 Control valve block: Primary pressure relief valve L506-1577/34874-; 030-137 030.6.5 Hydraulic components 030-138 030.6.5.1 Checking the hydraulic lines for damage L506-1577; 030-138 030.6.6 Travel hydraulics 030-143 030.6.6.1 Travel pump: Replenishing pressure relief valve L506-1577/34874-; 030-143 copyright © Liebherr-Werk Bischofshofen GmbH 2019 L506-1577

Service manual Contents 030.6.6.2 Blocked condition L506-1577/34874-; 030-144 030.6.6.3 Travel pump: control valve 030-145 L506-1577/34874-; 030-146 030-148 030.6.6.4 Travel pump: pump power 030-150 L506-1577/34874-; 030-151 030-153 030.6.6.5 Travel pump: High pressure relief valves 030-153 L506-1577/34874-; 030-154 030-154 030.6.6.6 Travel pump: pressure cut-off 030-155 L506-1577/34874-; 030-155 030-155 030.6.6.7 Travel motor: regulation range L506-1577/34874-; 040-1 040-2 030.6.7 Steering system 040-2 030.6.8 040-10 030.6.7.1 Servostat: LS pressure relief valve 040-11 030.6.9 L506-1577/34874-; 040-12 040-14 Brake system 040-15 040-16 030.6.8.1 Inch/brake pedal: Idle path 040-16 L506-1577/34874-; 040-17 030.6.8.2 Inch/brake pedal: Inching valve leakage L506-1577/34874-; Operator's cab, heating and air conditioning 030.6.9.1 Setting the service hours in the display L506-1577/34874-; 040 Drive group Engine: General overview L506-1577/34874-; 040.1 Engine 040.1.1 Electrical components of diesel engine 040.1.2 L506-1577/34874-; 040.1.3 Fuel system 040.1.4 040.1.3.1 Fuel system:: General overview L506-1577/34874-; LBH/11827669/07/211-20190529_115753/en 040.1.3.2 Fuel level sensor L506-1577/34874-; 040.1.3.3 Fuel pre-filter L506-1577/34874-; 040.1.3.4 Fuel fine filter L506-1577/34874-; Air filter system 040.1.4.1 Air filter system: General overview L506-1577/34874-; copyright © Liebherr-Werk Bischofshofen GmbH 2019 L506-1577 15

Contents Service manual 040.1.4.2 Air filter L506-1577/34874-; 040-18 040.1.4.3 Vacuum switch for air filter 040-19 L506-1577/34874-; 040-19 040-20 040.1.5 Exhaust system 050-1 040.1.5.1 Overview of diesel particulate filter 050-2 L506-1577/34874-; 050-3 050-3 050 Cooling system 050-5 050-6 050.1 Overview of the cooling system L506-1577/34874-; 060-1 060-2 050.2 Cooler 060-5 060-8 050.2.1 Water cooler 060-12 L506-1577/34874-; 060-22 060-22 050.2.2 Hydraulic oil cooler 060-23 L506-1577/34874-; 060-27 060-28 050.2.3 Fuel cooler 060-28 L506-1577/34874-; 060-28 060-29 060 Working hydraulics 060-31 060.1 Overview of working hydraulics L506-1577/34874-36840; 060.2 Overview of working hydraulics L506-1577/36841-; 060.3 Working hydraulics pump L506-1577/34874-; 060.4 Control valve block L506-1577/34874-; 060.5 Ride control 060.5.1 Overview of the ride control system L506-1577/36841-; 060.5.2 Stabilisation module LBH/11827669/07/211-20190529_115753/en L506-1577/36841-; 060.5.3 Ride control hydro accumulator L506-1577/36841-; 060.6 Hydraulic cylinders of the working hydraulics 060.6.1 Hydraulic cylinders for Z kinematics 060.6.1.1 Z kinematics lift cylinder L506-1577/34874-; 060.6.1.2 Z kinematics tilt cylinder L506-1577/34874-; 060.7 3. Function with electrohydraulic pilot control copyright © Liebherr-Werk Bischofshofen GmbH 2019 16 L506-1577

Service manual Contents LBH/11827669/07/211-20190529_115753/en 060.7.1 Electrical overview of the working hydraulics with 3rd function 060-31 L506-1577/36841-; 070-1 070 Travel hydraulics 070-2 070-5 070.1 Travel hydraulics overview 070-19 L506-1577/34874-; 070-19 070.2 Travel pump 080-1 L506-1577/34874-; 080-2 080-2 070.3 Travel motors 080-4 080-10 070.3.1 Travel motor L506-1577/34874-; 090-1 090-2 080 Hydraulic components 090-5 090-9 080.1 Hydraulic tank 090-9 080.1.1 Overview of the hydraulic tank 100-1 L506-1577/34874-; 100-2 100-4 080.1.2 Filtration grade 100-4 L506-1577/34874-; 100-8 100-8 080.1.3 Breather filter 100-10 L506-1577/34874-; 090 Steering system 090.1 Steering system overview L506-1577/34874-; 090.2 Servostat L506-1577/34874-; 090.3 Steering cylinder 090.3.1 Steering cylinder overview L506-1577/34874-; 100 Brake system 100.1 Overview of the brake system L506-1577/34874-; 100.2 Service brake and parking brake 100.2.1 Drum brake L506-1577/34874-; 100.3 Service brake 100.3.1 Overview of the service brake L506-1577/34874-; 100.3.2 Inch/brake pedal L506-1577/34874-; copyright © Liebherr-Werk Bischofshofen GmbH 2019 L506-1577 17

Contents Service manual 100.3.3 Inching valve 100-11 LBH/11827669/07/211-20190529_115753/en L506-1577/34874-; 100-13 100-17 100.3.4 Brake master cylinder 100-18 L506-1577/34874-; 100-19 100-19 100.3.5 Brake light pressure switch 100-20 L506-1577/34874-; 110-1 100.3.6 Brake fluid equalising reservoir 110-2 L506-1577/34874-; 110-5 110-7 100.4 Parking brake 110-9 110-9 100.4.1 Overview of the parking brake 110-11 L506-1577/34874-; 110-12 110-16 100.4.2 Parking brake switch 110-16 L506-1577/34874-; 120-1 110 Electrical system 120-2 110.1 Overview of the electrical system 130-1 L506-1577/34874-; 130-2 130-2 110.2 Lighting 130-6 L506-1577/34874-; 130-10 110.3 Circuit diagrams L506-1577 L506-1577/34874-; 110.4 Electronic control unit 110.4.1 Overview of the electronic control system L506-1577/34874-; 110.5 Electrical components of the driver’s cab 110.5.1 Fuse and relay board L506-1577/34874-; 110.6 Electrical components in the rear section 110.6.1 Battery installation L506-1577/34874-; 120 Gearbox 120.1 Overview of the transmission L506-1577/34874-; 130 Axles and drive shafts 130.1 Axles 130.1.1 Front axle L506-1577/34874-; 130.1.2 Rear axle L506-1577/34874-; 130.2 Cardan shafts copyright © Liebherr-Werk Bischofshofen GmbH 2019 18

Service manual Contents 130.2.1 Cardan shaft 130-10 L506-1577/34874-; 140-1 140 Steel parts of the basic machine 140-2 140-2 140.1 Vehicle frame 140-3 140.1.1 Articulation bearing 150-1 L506-1577/34874-; 150-2 150-2 140.1.2 Articulation lock 150-4 L506-1577/34874-; 150-4 150 Working attachment 160-1 160-3 150.1 Lift arms for Z kinematics 160-5 160-5 150.1.1 Z kinematics lift arms 160-5 L506-1577/34874-; 160-7 160-11 150.2 Quick coupler 160-12 160-14 150.2.1 Quick coupler 160-14 L506-1577/34874-; 160-19 160-20 160 Operator's cab, heating and air conditioning 160-21 160-23 160.1 Overview of the cab, heating and air conditioning unit 160-23 L506-1577/34874-; 19 160.2 Display and control elements 160.2.1 Electrical components in the control panel 160.2.1.1 Starter switch L506-1577/34874-; 160.2.2 Display L506-1577/34874-; 160.2.3 Control lever L506-1577/34874-; 160.2.4 Accelerator pedal L506-1577/34874-; LBH/11827669/07/211-20190529_115753/en 160.3 Heating, ventilation, air conditioning 160.3.1 Overview of heating, ventilation and air conditioning system L506-1577; 160.3.2 Heating and air conditioning unit 160.3.2.1 Heating and air conditioning unit L506-1577/34874-; 160.3.2.2 Blower L506-1577/34874-; 160.4 Air conditioning 160.4.1 Basic function of the air conditioning unit L506-1577/34874-; copyright © Liebherr-Werk Bischofshofen GmbH 2019 L506-1577

Contents Service manual 160.4.2 Air conditioning compressor 160-24 160.4.3 L506-1577/34874-; 160.4.4 160-29 160.4.5 Condenser L506-1577/34874-; 160-29 Dryer 160-30 L506-1577; 170-1 Air conditioning pressure switch 170-2 L506-1577/34874-; 170-2 170 Lubrication system 170-6 170.1 Liebherr automatic central lubrication system 170-9 170.1.1 Automatic central lubrication system: overview L506-1577/34874-; 200-1 200-2 170.1.2 Central lubrication pump EP-1 200-2 L506-1577/34874-; 200-2 200-5 170.1.3 Progressive distributor MX-F 200-5 L506-1577/34874-; 200-5 200-7 200 Diagnosis 200-8 200.1 Malfunctions 200.1.1 Warning symbols 200.1.2 Service code indicator in the display 200.2 Troubleshooting 200.2.1 Replacing fuses 200.2.1.1 Fuses on fuse board in operator's cab 200.2.1.2 Fuses in the battery compartment 200.2.1.3 Plug-in fuses for LiDAT LBH/11827669/07/211-20190529_115753/en copyright © Liebherr-Werk Bischofshofen GmbH 2019 20 L506-1577

010 Introduction Contents 010.1 Safety instructions 010-3 010.1.1 General safety instructions 010-3 010.1.2 Instructions on preventing crushing injuries and burns 010-4 010.1.3 Instructions on preventing fires and explosions 010-4 010.1.4 Safety instructions for start-up 010-5 010.1.5 Safety precautions during start-up 010-5 010.1.6 Instructions for safe working 010-6 010.1.7 Safety instructions for driving on slopes 010-7 010.1.8 Parking safely 010-7 010.1.9 Transporting the machine safely 010-7 010.1.10 Towing the machine safely 010-8 010.1.11 Measures for ensuring safe maintenance 010-8 010.1.12 Safety instructions for maintenance work on machines with hydro accumulators 010-11 010.1.13 Safety instructions for welding work on the machine 010-11 010.1.14 Safety instruction for working on the working attachment 010-11 010.1.15 Safety instructions for transporting the machine by crane 010-12 010.1.16 Safe maintenance of hydraulic hoses and hose lines 010-12 010.1.17 Roll over protective structure (ROPS) and falling object protection structure (FOPS) 010-13 LBH/11827669/07/211-20190529_115753/en 010.1.17.1 Preventing accidents 010-13 010.1.17.2 Preventing injuries 010-13 010.1.18 Attachments and accessories 010-13 010.1.19 Protection against vibrations 010-14 010.1.20 See and be seen 010-14 010.1.20.1 Field of view and visual aids 010-14 010.1.20.2 Measures during operation. 010-15 010.1.20.3 Modifications to the machine 010-15 copyright © Liebherr-Werk Bischofshofen GmbH 2019 L506-1577 010-1

Introduction Service manual 010.1.21 Danger area of the machine 010-15 010.2 Special tools for maintenance and repair work 010-17 010.2.1 Special tools, general 010-17 010.2.2 Special tools for diesel engine 010-18 010.2.3 Special tools for Z kinematics hydraulic cylinders 010-19 010.2.4 Special tools for steering cylinders 010-20 010.2.5 Special tools for the electrical system 010-20 010.2.6 Special tools for axles 010-20 010.2.7 Special tools for the air conditioning system 010-21 010.2.8 Special tools for cab glazing 010-21 010.2.9 Special tools for the central lubrication system 010-21 010.3 Standards and regulations 010-23 010.3.1 Prestressing forces and tightening torques for bolts with metric 010-23 standard and fine threads as per DIN ISO 261 010.3.1.1 Range of application and purpose 010-23 010.3.1.2 Other applicable documents 010-23 010.3.1.3 Modifications and descriptions 010-24 010.3.1.4 Tightening torques 010-24 010.3.2 Liebherr standards for assembly instructions and tightening torques010-30 010.4 Preservation guidelines 010-31 010.4.1 General information 010-31 010.4.2 Machine out of service for an unknown period of time 010-31 010.4.3 Putting the machine out of service 010-32 010.4.3.1 Out of service for up to 2 months 010-32 010.4.3.2 Out of service for up to 12 months 010-33 010.4.3.3 Out of service for longer than 12 months 010-34 010.4.4 Putting back into service 010-34 010.4.4.1 After being out of service for 2 months 010-34 LBH/11827669/07/211-20190529_115753/en 010.4.4.2 After being out of service for 12 months 010-35 010.4.4.3 After being out of service for longer than 12 months 010-35 copyright © Liebherr-Werk Bischofshofen GmbH 2019 010-2 L506-1577

Service manual Introduction 010.1 Safety instructions LBH/11827669/07/211-20190529_115753/en 010.1.1 General safety instructions 1. Familiarise yourself with the operator's manual before starting up the machine. Make sure that you are in possession of additional instructions for any special equipment installed on your machine, and that you have read and understood them. 2. Only expressly authorised personnel may operate, service or repair the machine. Observe the legal minimum ages. 3. Only trained or instructed personnel may operate the machine. Clearly assign responsibility for operation, rigging, maintenance and repair work. 4. The operator of the machine must ensure that no persons are in the operating area of the machine on the basis of a risk assessment conducted in respect of the operating site. 5. Clearly establish the driver’s responsibilities (also with respect to traffic regula- tions) and authorise him to refuse to carry out unsafe instructions from third parties. 6. Personnel undergoing training and instruction, or who are not yet fully quali- fied, may only be allowed to work on the machine under constant supervision by an experienced person. 7. Now and again, check that your personnel are working safely and are aware of possible dangers in observance of the operator's manual. 8. Wear safe working clothes when working on the machine. Do not wear rings, wristwatches, ties, scarves, unbuttoned jackets, loose clothing or similar garments, as they can become caught in the machinery and cause injury. Certain tasks require: safety glasses, safety boots, hard hats, protective gloves, reflective vests, ear protection etc. 9. Ask the site manager about any special safety regulations in force on the construction site. 10. Do not hold onto the steering column, the control panel or the control levers when getting on or off the machine. You might inadvertently trigger movements which could lead to accidents. 11. Never jump down from the machine. Use the steps, ladders and platforms provided for getting on and off. 12. Keep all handles, steps, rails, gangways, platforms and ladders free from oil, grease, mud snow and ice. This reduces the risk of slipping, tripping up or falling. 13. Familiarise yourself with the emergency exit through the right cab door and/or the rear window. 14. Unless there are other instructions, perform maintenance and repair work as follows: Procedure: • Park the machine on firm, level ground and lower the working attachment to the ground. • Move all control levers to neutral. • Turn off the diesel engine and take out the ignition key. 15. Before all work on the hydraulic system, depressurise the hydraulic circuits and the hydraulic tank as described in the operator's manual. 16. Lock the working hydraulics to prevent accidental actuation before leaving the operator's seat. copyright © Liebherr-Werk Bischofshofen GmbH 2019 L506-1577 010-3

Introduction Service manual Lock the working hydraulics in accordance with the instructions in the opera- LBH/11827669/07/211-20190529_115753/en tor's manual. 17. Secure all loose parts of the machine. 18. Never start up a machine without first making a thorough tour of inspection and checking if any warning signs are missing or illegible. 19. Observe all signs with warnings or safety instructions. 20. Special safety apparatus must be fitted to the machine for certain applications. If this is the case, only work with this apparatus fitted and in working order. 21. Do not make any modifications, extensions or conversions to the machine which may impair safety. This also applies to installing and adjusting safety equipment and safety valves, as well as to welding on load-bearing compo- nents. 22. Avoid standing near the diesel engine while it is running. People who have a pacemaker must not stand next to the diesel diesel engine while it is running (minimum distance 50 cm). 23. Do no touch live components when the diesel engine is running! 010.1.2 Instructions on preventing crushing injuries and burns 1. Do not work under the attachment if it is not resting on the ground or supported. 2. Do not use any ropes or chains which are damaged or which have insufficient load bearing capacity. Wear protective gloves when handling wire ropes. 3. When working with the attachment, never align the boreholes with your fingers, instead, use a suitable mandrel for this purpose. 4. Make sure no objects come into contact with the fan when the diesel engine is running. Objects which fall or project into the fan will be thrown back out or destroyed and could damage the fan. 5. When the machine is near operating temperature, the engine cooler system is hot and pressurised. Do not touch parts carrying cooling water. This can lead to burns. 6. Only check the coolant level once the cap on the expansion tank has cooled down enough to touch. Carefully open the cap to let out excess pressure. 7. When running at or near the operating temperature, the engine oil and hydraulic oil are hot. Avoid touching hot oil or parts which carry oil. 8. Wear safety glasses and protective gloves when working on the battery. Avoid sparks and naked lights. 9. Never let anyone move the bucket or other working attachments into position by hand. 10. Any time you open the engine compartment, secure the compartment doors from falling shut. 11. Before starting up the machine, close and lock the engine compartment doors and the battery compartment cover. 12. Never lie under the machine when it is raised using the working attachment, unless the undercarriage is securely supported using wooden beams. 13. Avoid touching hot surfaces and liquids. This can lead to burns. 010.1.3 Instructions on preventing fires and explosions 1. When refuelling, the diesel engine must be turned off. Switch off the auxiliary heater, if installed. copyright © Liebherr-Werk Bischofshofen GmbH 2019 010-4 L506-1577

Service manual Introduction LBH/11827669/07/211-20190529_115753/en 2. Do not smoke. Avoid naked flames when refuelling or where batteries are being recharged. 3. Always follow the instructions in the operator's manual when starting the diesel engine. 4. Check the electrical system. Immediately eliminate all faults such as loose connections, worn cables or burnt out fuses and bulbs. 5. Do not carry combustible fluids on the machine outside the tanks provided. 6. Regularly check all lines, hoses and bolted connections for leaks and damage. 7. Repair the leaks immediately and replace the damaged components. Oil escaping from leaks can easily cause fires. 8. Make sure that all brackets and protective plates are properly installed to prevent vibrations, abrasion and heat build-up. 9. Starting agent (ether) is a particularly dangerous fire hazard. Never use ether starting agent near head sources, naked lights (such as ciga- rettes) or in poorly ventilated spaces. 10. Do not use starting agents containing ethers to start diesel diesel engines with preglow or flame glow systems. There is otherwise a RISK OF EXPLOSION. 11. Familiarise yourself with the location and use of fire extinguishers and find out about fire alarm and firefighting facilities on site. 12. Clean the machine before putting it into operation. Due to the risk of fire, watch out for combustible deposits around the diesel engine, particularly in fire hazard environments such as rubbish dumps or sawmills. 010.1.4 Safety instructions for start-up 1. Each time you start up the machine, make a thorough tour of inspection. 2. Check the machine for loose bolts, screws, cracks, wear, leaks and deliberate damage. 3. Never start up a damaged machine. 4. Make sure the damage is rectified immediately. 5. Ensure that all hoods and covers are closed and locked. Check that all the warning and instruction signs are in place. 6. Clean the windows and both interior and exterior mirrors, and secure the doors and windows against inadvertent movement. 7. Make sure no-one is working on or underneath the machine. Warn anyone in the danger area before you start up the machine. 8. After getting into the operator's cab, adjust the seat, the interior and exterior mirrors, the control lever and the safety belt so that you can work comfortably. 9. Sound insulation equipment on the machine must be in place during operation. 010.1.5 Safety precautions during start-up 1. Before starting, check that all control lamps and instruments are working prop- erly. 2. Move all control levers to neutral. 3. Before starting the diesel engine, briefly sound the horn to warn anyone else in the danger area. 4. Only start the machine when sitting in the driver’s seat. 5. Unless otherwise instructed, start the diesel engine in accordance with the instructions in the operator's manual. 6. Start the diesel engine and then check all display and monitoring equipment. 7. Only run the diesel engine in enclosed spaces when there is sufficient ventila- tion. If necessary, open the windows and doors to ensure adequate fresh air. copyright © Liebherr-Werk Bischofshofen GmbH 2019 L506-1577 010-5