Wheel Loader Service Manual

Service Manual
(20
Wheel loader
(10 points)
L524 – L542 2plus1
en

Address
Address: LIEBHERR-WERK BISCHOFSHOFEN GMBH
Dr. Hans Liebherr – Straße 4
A – 5500 BISCHOFSHOFEN
Product ID
Manufacturer: LIEBHERR-WERK BISCHOFSHOFEN GMBH
Product group: Wheel loader
Type: L524 L528 L538 L542
Production number: 659 660 433 435
Serial number: 17890 17891 17893 17895
Document ID
Order number: 10411314
Author: LBH / Technical Documentation Department
Document version: 01
Manual number:
Owner:
Service Manual
(20
Wheel loader
(10 points)
L524 – L542 2plus1
(10
en

Preface
Intended readership This service manual is addressed to anyone whose task it is to ensure that the
machines are ready for everyday use. This especially includes mechanics and
workshop staff of Liebherr dealers and branches.
Contents The first chapter contains information on safety regulations and on the
special tools needed for maintenance and repairs.
Chapter 2 gives you an overview of all the most important technical data of
the machine as a whole and its individual assemblies.
Next comes the maintenance chapter, with the maintenance and inspection
schedule, the testing and adjustment checklists, lubrication charts, description
of maintenance tasks, testing and adjustment tasks and specifications of fuel
and lubricants.
The technical description of the machine is in the following chapters,
structured according to fifteen function groups. The layout, function and
technical data of the groups, components and parts are explained.
Chapter 19 contains information on troubleshooting, the service code table
and a description of the “SCULI” service software.
Chapter 20 will be gradually updated with the latest options.
Instructions on use This manual describes several types and versions of machines. The
information generally applies to the types and serial numbers stated at the
bottom of the page. The exception to this is information which only applies to
specific types and serial numbers, which are stated at the beginning of the
section concerned (for example technical data of parts).
Where possible, the ID numbers of parts and components are stated in
the heading.
This manual is available in German, English, French, Spanish, Italian and
Russian.
Working instructions Always follow the safety regulations whenever you work on the machine.
You will find a reference to this in the “General Information” section.
In order to perform these tasks you need a complete set of basic tools
andcertain special tools, all in perfect working order. All tasks require
absolute cleanliness.
Replace seals such as O-rings and surface seals during repairs.
DVD edition Please note that this manual is not only available in printed form, but is also
available as electronic documentation on DVD (Lidos).

General information 1
Product description 2
Maintenance 3
Diesel engine and pump distributor gear 4
Cooling system 5
Travel hydraulics 6
Working hydraulics 7
Steering system 8
Brake system 9
Electrical system 10
Transfer gear 11
Axles and cardan shaft 12
Machine frame and ballast weight 13
Central lubrication system 14
Coverings and access 15
Cab, heating and air-conditioning 16
Lift arms and quick-change device 17
Equipment and accessories 18
Service codes and diagnosis 19
Options 20

L524 - 659 / from 17890 1.0-1 o f 2
L528 - 660 / from 17890
L538 - 433 / from 17890
L542 - 435 / from 17890
copyright
MJFCIFSS
1 General informations
1.0
Chapter contents
1 General informations........................................................... 1.0-1
1.1 Safety regulations...........................................................................1.1-1
1.1.1 Introduction...........................................................................1.1-1
1.1.2 Overview of the safety regulations .......................................1.1-2
1.2 Special tools for maintenance and repair work...............................1.2-1
1.2.1 Special tools in general ........................................................1.2-1
1.2.2 Special tools for Liebherr diesel engines..............................1.2-1
1.2.3 Special tools for hydraulic cylinders .....................................1.2-2
1.2.4 Special tools for electronics..................................................1.2-3
1.2.5 Special tools for axles...........................................................1.2-3
1.2.6 Central lubrication system ....................................................1.2-4
1.2.7 Special tools for the air conditioning system ........................1.2-4
1.3 Standard .........................................................................................1.3-1
1.3.1 Anziehmomente für SchraubenFehler! Textmarke nicht definiert.

Service manual General informations
Safety regulations
L524 - 659 / from 17890 1.1-1 o f 2
L528 - 660 / from 17890
L538 - 433 / from 17890
L542 - 435 / from 17890
copyright
MJFCIFSS
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.
T These are indicated by the headings Danger, Warning, Caution or
Notice.
1.1.1 Introduction
1. The symbols below have the following meanings:
DANGER
Denotes an urgent, dangerous situation.
Will result in death or serious injury.
Actions to avert the danger.
WARNING
Denotes a dangerous situation.
Can result in death or serious injury.
CAUTION
Risk of personal injury.
Denotes a potentially dangerous situation which can lead to slight injury if
not avoided.
NOTICE
Risk of damage to the machine.
Denotes actions or circumstances which may result in damage to the machine.
Note
Useful information
Denotes information on correctly handling the machine and the lubricants
and fuels used.
Actions to implement.

General informations Service manual
Safety regulations
1.1-2 o f 2 L524 - 659 / from 17890
L528 - 660 / from 17890
L538 - 433 / from 17890
L542 - 435 / from 17890
copyright
MJFCIFSS
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
1.1.2 Overview of the safety regulations
A detailed description of these can be read in the relevant section of the
safety regulations chapter in the operating manual.
The following sections are included in the operating manual:
1 Introduction
2 General safety regulations
3 Proper use
4 Decals on the machine
5 Instructions on preventing crushing injuries and burns
6 Instructions on preventing fires and explosions
7 Safety instructions for start-up
8 Safety precautions during start-up
9 Instructions for safe working
10 Safety instructions for driving on slopes
11 Parking safely
12 Transporting the machine safely
13 Towing the machine safely
14 Measures for ensuring safe maintenance
15 Safety instructions for working on machines with hydro accumulators
16 Safety instructions for welding work on the machine
17 Instructions for working safely on the working attachment
18 Safety instructions for transporting the machine by crane
19 Safe maintenance of hydraulic hoses and hose lines
20 Attachments and accessories
21 Protection against vibrations

Safety regulations
L524 - 659 / from 17890 1.2-1 o f 4
L528 - 660 / from 17890
L538 - 433 / from 17890
L542 - 435 / from 17890
copyright
MJFCIFSS
1.2 Special tools for maintenance and
repair work
1.2.1 Special tools in general
Description ID no. Use Remarks
Anti-freeze and battery tester 7408922 All wheel loaders
For checking the acid concentration
(battery charging state) and anti-freeze
24 volt vacuum pump 7408148 All wheel loaders For preventing oil loss
Filling and testing device with case 8145359 All wheel loaders For checking the hydro accumulator
Manometer 0 - 40 bar 7361288 All wheel loaders For checking the hydraulic pressure
Manometer connection 7002436 All wheel loaders Connection for the manometer
High pressure hose 1500 mm 7002475 All wheel loaders High pressure hose for manometer
High pressure hose 4000 mm 7009134 All wheel loaders High pressure hose for manometer
Draining hose 7005660 All wheel loaders For draining oil via a drain valve
Drain piece 7402657 All wheel loaders For the drain hose
Safety cap 10 mm 7009315 All wheel loaders
For securing the valves on the variable
adjustment motor
Safety cap 13 mm 7615515 All wheel loaders For securing the valves on the pumps
Safety cap 17 mm 7622068 All wheel loaders
For securing the valves on the control
block
USB dongle 10333608 L524 - L586 With SERVICE authorisation
Diagnostic data cable 9067426 L524 - L586
For adjusting the travel hydraulics, and
testing the electrical system and options
Adapter cable RS232<>USB 693190714 All wheel loaders
For communicating with the wheel loader
electronics if there is an error with the
RS232 interface on the notebook.
1.2.2 Special tools for Liebherr diesel engines
Compression tester 8008782 Engine For checking the compression
Nozzle tester 7361236 L538, L542 engine For checking the injection valves
Adapter for compression tester 0524044 L538, L542 engine Instead of the injection valve
Injection valve extraction tool 0524072 L538, L542 engine For removing the injection valves
Extraction tool adapter 0524029 L538, L542 engine For use with the extraction tool
Piston ring tensioning belt 8000952 All wheel loaders
For pushing the piston rings together
during installation of the pistons
Krikit 2 V-belt tester 8042829 L524 - L542 engine For testing the V-belt tension
Flywheel cranking device 0524045 L538, L542 engine For cranking the engine via the flywheel
Shaft seal ring installation tool 7090373 L524, L528 engine For installing the front crankshaft oil seal
Extractor tool 7090377 L524, L528 engine For removing the front wear ring
Extractor tool 7090395 L524, L528 engine For removing the front wear ring
Seal remover 7090372 L524, L528 engine For removing the front crankshaft oil seal
Installation set 7090378 L524, L528 engine
For installing the rear oil seal ring and
wear ring

Special tools for maintenance and repair work
1.2-2 o f 4 L524 - 659 / from 17890
L528 - 660 / from 17890
L538 - 433 / from 17890
L542 - 435 / from 17890
copyright
MJFCIFSS
Depth gauge 7090370 L524 - L542 engine
For measuring the valve depth in the
cylinder head and for measuring the
piston and bushing height
Extractor tool 7090376 L524, L528 engine
For removing the rear crankshaft oil
seal ring and wear ring
Extractor tool 7090363 L524, L528 engine
For installing and removing the
cylinder bushings
Angle wrench 0524062 L538, L542 engine
For screws on cylinder head, main
bearing and big end bearing
1.2.3 Special tools for hydraulic cylinders
Assembly sleeve 80 mm 9227165
L524, L528 P kinematics tilt
cylinder
For fitting the seals
L524 - L542 steering cylinder
cylinder
Assembly sleeve 100 mm 9998626 L524, L528 lift cylinder For fitting the seals
Assembly sleeve 110 mm 9170509 L538, L542 lift cylinder For fitting the seals
L524, L528 Z kinematics tilt
cylinder
cylinder
Expansion sleeve 80 mm 9227166
cylinder
cylinder
Expansion sleeve 100 mm 9110405 L524, L528 lift cylinder For fitting the seals
Expansion sleeve 110 mm 9170511 L538, L542 lift cylinder For fitting the seals
cylinder
cylinder
Piston spanner 80/12 mm 8007364 L524 - L542 lift cylinder For fitting the piston
Piston spanner 88/12 mm 8007365
cylinder
For fitting the piston
cylinder
Piston nut spanner 9921123 L524 - L542 lift cylinder For fitting the piston nut
Piston nut spanner 9921124
L524 - L542 P Z kinematics
tilt cylinder
For fitting the piston nut
cylinder
Piston rod bearing spanner 9210219
cylinder
For fitting the piston rod bearing
cylinder
Piston rod bearing
spanner 76/9 mm
0541665
cylinder
For fitting the piston rod bearing

Safety regulations
L524 - 659 / from 17890 1.2-3 o f 4
L528 - 660 / from 17890
L538 - 433 / from 17890
L542 - 435 / from 17890
copyright
MJFCIFSS
1.2.4 Special tools for electronics
Digital multimeter 8502956 All wheel loaders
For measuring voltage, current,
resistance and frequency
Test probe, red 884191214 All wheel loaders For testing DEUTSCH connectors
Test probe, black 884191114 All wheel loaders For testing DEUTSCH connectors
Magnet tester 8145743 All wheel loaders For checking solenoid valves
Stripping and crimping pliers
0.5 - 6.0 mm
2 8460263 All wheel loaders For MATE-N-LOK connectors
Crimping pliers 8503647 All wheel loaders For DEUTSCH connectors
Wedge extractor tool 7026267 All wheel loaders For DEUTSCH connectors
Extraction tool size 12 for pin
and bushing
8145674 All wheel loaders For DEUTSCH connectors
and bushing
and bushing
Plug-in fuse tester 8145834 All wheel loaders For checking the fuses
Wide METRI-PACK
extractor tool
7091022 L524, L528
For removing terminals on the main
connector of the ECU engine controller
Narrow METRI-PACK
extractor tool
7091023 L524, L528
For removing terminals on the main
connector of the ECU engine controller
1.2.5 Special tools for axles
Hand pump 8145835
L524 - L542 axles For relieving the disc springs and for
testing the tightness of the disc brakes
Feeler gauge 8145535
L524 - L542 axles For inspecting the wear on the wet disc
brake (T1-2313)
Set of 5 spanners 10220617
L524 - L542 axles For gripping whilst installing or removing
the bevel gear shaft (T5-2386)
Driver, Øa=185 mm 10220623
L524 - L542 axles For installing the shaft seal ring in the hub
(T10-3502)
Slotted nut spanner 10220633
L524 - L542 axles For removing and fitting the differential
gear (T13-3333)
Handle for driver 10220624
L524 - L542 axles
Required for holding the driver
Slotted nut spanner with
adapter
10220626
L524 - L542 axles For removing and fitting the bevel gear
shaft (T22-3317/A)
Driver, Øa=62.5 mm 10220631
L524 - L542 axles For installing the shaft seal ring in the axle
casing (T34-2322)
Driver, Øa=90 mm 10220632
L524 - L542 axles For installing the shaft seal ring in the
bearing bushing of the axle (T5-3342)

Special tools for maintenance and repair work
1.2-4 o f 4 L524 - 659 / from 17890
L528 - 660 / from 17890
L538 - 433 / from 17890
L542 - 435 / from 17890
copyright
MJFCIFSS
1.2.6 Central lubrication system
BEKA MAX filling press 10009239 All wheel loaders For quickly filling the
BEKA MAX filling port 7029283 All wheel loaders For filling the reservoir
Groeneveld filling press 10333342 All wheel loaders For quickly filling the reservoir
Groeneveld central lubrication
data cable 7624289 All wheel loaders
For inspecting the
central lubrication system
plug adapter 7624290 All wheel loaders
For inspecting the
software As below All wheel loaders
For inspecting the
1.2.7 Special tools for the air conditioning system
Vacuum pump 7027552 All wheel loaders
For evacuating the air
conditioning system
4-valve test fitting 7027558 All wheel loaders
For testing, evacuating and filling the air
conditioning system
Filling hose, blue 1500 mm 7027553 All wheel loaders For the test fitting
Filling hose, yellow 1500 mm 7027554 All wheel loaders For the test fitting
Filling hose, red 1500 mm 7027555 All wheel loaders For the test fitting
Car coupling 253a 7027556 All wheel loaders For the test fitting
Car coupling 254a 7027557 All wheel loaders For the test fitting

Mjfcifss - Standard
This document must not be copied or reproduced without prior permission. This
document has been electronically prepared and is valid without requiring a signature.
Liebherr-Norm_DE_V001.dot
L524 - 659 / from 17890 1.3-1 o f 4
L528 - 660 / from 17890
L538 - 433 / from 17890
L542 - 435 / from 17890
copyright
MJFCIFSS
1.3 Standard
1.3.1 Tightening torques for screws
Pre-loading forces and tightening torques for screws with standard and fine
metric threads.
Standard and fine metric threads
All figures are for bolted connections with at least one Dacromet
500 coated element (screws, washers, nuts…)
Standard and fine metric threads. All figures are for bolted connections
without any Dacromet 500 coated elements (screws, washers, nuts…)
Surface:
- DACROMET 500
Surface:
- black finish or phosphated
- zinc-plated
Thread Class
Assembly pre-
loading forces
FM in N
Tightening
torques
MA in Nm
Thread Class
Assembly pre-
loading forces
FM in N
Tightening
torques MA in
Nm
for avg. coefficient of friction µG= 0.10 for avg. coefficient of friction µG= 0.12
M4
8.8
10.9
12.9
4 200
6 200
7 300
2,5
3,7
4,3
M4
8.8
10.9
12.9
4 050
6 000
7 000
2,8
4,1
4,8
M5
8.8
10.9
12.9
6 900
10 100
11 900
4,9
7,3
8,5
M5
8.8
10.9
12.9
6 600
9 700
11 400
5,5
8,1
9,5
M6
8.8
10.9
12.9
9 700
14 300
16 700
8,5
12,5
14,5
M6
8.8
10.9
12.9
9 400
13 700
16 100
9,5
14,0
16,5
M7
8.8
10.9
12.9
14 200
20 900
24 500
14,0
20,5
24,0
M7
8.8
10.9
12.9
13 700
20 100
23 500
15,5
23,0
27
M8
8.8
10.9
12.9
17 900
26 000
30 500
20,5
30
35
M8
8.8
10.9
12.9
17 200
25 000
29 500
23
34
40
M8x1
8.8
10.9
12.9
19 600
28 500
33 500
22
32
38
M8x1
8.8
10.9
12.9
18 800
27 500
32 500
24,5
36
43
M9x1
8.8
10.9
12.9
25 500
38 000
44 000
32
46
54
M9x1
8.8
10.9
12.9
24 800
36 500
42 500
36
53
62
M10
8.8
10.9
12.9
28 500
42 000
49 000
41
60
71
M10
8.8
10.9
12.9
27 500
40 000
47 000
46
68
79
M10x1
8.8
10.9
12.9
32 500
48 000
56 000
45
67
78
M10x1
8.8
10.9
12.9
31 500
46 500
54 000
52
76
89
M10x1,25
8.8
10.9
12.9
30 500
45 000
53 000
43
64
74
M10x1,25
8.8
10.9
12.9
29 500
43 000
51 000
49
72
84
M12
8.8
10.9
12.9
41 500
61 000
71 000
71
104
121
M12
8.8
10.9
12.9
40 000
59 000
69 000
79
117
135
M12x1,25
8.8
10.9
12.9
46 500
68 000
80 000
77
112
130
M12x1,25
8.8
10.9
12.9
45 000
66 000
77 000
87
125
150
M12x1,5
8.8
10.9
12.9
44 000
65 000
76 000
74
108
125
M12x1,5
8.8
10.9
12.9
42 500
62 000
73 000
83
122
145
M14
8.8
10.9
12.9
57 000
84 000
98 000
113
165
195
M14
8.8
10.9
12.9
55 000
80 000
94 000
125
185
215
M14x1,5
8.8
10.9
12.9
63 000
92 000
108 000
121
175
205
M14x1,5
8.8
10.9
12.9
61 000
89 000
104 000
135
200
235

Mjfcifss - Standard
1.3-2 o f 4 L524 - 659 / from 17890
L528 - 660 / from 17890
L538 - 433 / from 17890
L542 - 435 / from 17890
Thread Class
Assembly pre-
loading forces
FM in N
Tightening
torques
MA in Nm
Thread Class
Assembly pre-
loading forces
FM in N
Tightening
torques MA in
Nm
M16
8.8
10.9
12.9
78 000
115 000
134 000
170
250
300
M16
8.8
10.9
12.9
75 000
111 000
130 000
195
280
330
M16x1,5
8.8
10.9
12.9
85 000
125 000
147 000
180
270
310
M16x1,5
8.8
10.9
12.9
82 000
121 000
141 000
205
300
360
M18
8.8
10.9
12.9
98 000
140 000
164 000
245
350
410
M18
8.8
10.9
12.9
94 000
135 000
157 000
280
390
460
M18x1,5
8.8
10.9
12.9
114 000
163 000
191 000
270
390
450
M18x1,5
8.8
10.9
12.9
110 000
157 000
184 000
310
440
520
M18x2
8.8
10.9
12.9
106 000
151 000
177 000
260
370
430
M18x2
8.8
10.9
12.9
102 000
146 000
170 000
290
420
490
M20
8.8
10.9
12.9
126 000
180 000
210 000
350
490
580
M20
8.8
10.9
12.9
121 000
173 000
202 000
390
560
650
M20x1,5
8.8
10.9
12.9
144 000
206 000
240 000
380
540
630
M20x1,5
8.8
10.9
12.9
139 000
199 000
232 000
430
620
720
M22
8.8
10.9
12.9
157 000
224 000
260 000
470
670
780
M22
8.8
10.9
12.9
152 000
216 000
250 000
530
750
880
M22x1,5
8.8
10.9
12.9
177 000
255 000
295 000
510
720
840
M22x1,5
8.8
10.9
12.9
171 000
245 000
285 000
580
820
960
M24
8.8
10.9
12.9
182 000
260 000
305 000
600
850
1000
M24
8.8
10.9
12.9
175 000
249 000
290 000
670
960
1 120
M24x1,5
8.8
10.9
12.9
215 000
306 000
358 000
700
990
1170
M24x1,5
8.8
10.9
12.9
207 000
295 000
346 000
760
1 090
1 270
M24x2
8.8
10.9
12.9
203 000
290 000
340 000
640
920
1070
M24x2
8.8
10.9
12.9
196 000
280 000
325 000
730
1 040
1 220
M27
8.8
10.9
12.9
239 000
340 000
400 000
880
1250
1450
M27
8.8
10.9
12.9
230 000
330 000
385 000
1 000
1 400
1 650
M27x1,5
8.8
10.9
12.9
276 000
394 000
461 000
1010
1440
1690
M27x1,5
8.8
10.9
12.9
267 000
381 000
445 000
1 110
1 580
1 850
M27x2
8.8
10.9
12.9
265 000
375 000
440 000
940
1350
1550
M27x2
8.8
10.9
12.9
255 000
365 000
425 000
1 070
1 500
1 800
M30
8.8
10.9
12.9
290 000
415 000
485 000
1190
1700
2000
M30
8.8
10.9
12.9
280 000
400 000
465 000
1 350
1 900
2250
M30x1,5
8.8
10.9
12.9
346 000
493 000
576 000
1410
2000
2340
M30x1,5
8.8
10.9
12.9
335 000
477 000
558 000
1 540
2 190
2 560
M30x2
8.8
10.9
12.9
332 000
472 000
553 000
1370
1940
2270
M30x2
8.8
10.9
12.9
321 000
457 000
534 000
1 490
2 120
2 480
M33
8.8
10.9
12.9
360 000
520 000
600 000
1600
2300
2700
M33
8.8
10.9
12.9
350 000
495 000
580 000
1 850
2 600
3 000
M33x1,5
8.8
10.9
12.9
423 000
603 000
705 000
1880
2670
3130
M33x1,5
8.8
10.9
12.9
410 000
584 000
683 000
2 050
2 920
3 420
M33x2
8.8
10.9
12.9
410 000
580 000
680 000
1750
2500
2900
M33x2
8.8
10.9
12.9
395 000
560 000
660 000
2 000
2 800
3 300
M36
8.8
10.9
12.9
425 000
600 000
710 000
2100
3000
3500
M36
8.8
10.9
12.9
410 000
580 000
680 000
2 350
3 300
3 900

Mjfcifss - Standard
L524 - 659 / from 17890 1.3-3 o f 4
L528 - 660 / from 17890
L538 - 433 / from 17890
L542 - 435 / from 17890
copyright
MJFCIFSS
Thread Class
Assembly pre-
loading forces
FM in N
Tightening
torques
MA in Nm
Thread Class
Assembly pre-
loading forces
FM in N
Tightening
torques MA in
Nm
M36x1,5
8.8
10.9
12.9
508 000
724 000
847 000
2450
3490
4090
M36x1,5
8.8
10.9
12.9
492 000
701 000
820 000
2 680
3 820
4 470
M36x3
8.8
10.9
12.9
455 000
650 000
760 000
2200
3100
3600
M36x3
8.8
10.9
12.9
440 000
630 000
740 000
2 500
3 500
4 100
M39
8.8
10.9
12.9
510 000
730 000
850 000
2700
3800
4500
M39
8.8
10.9
12.9
490 000
700 000
820 000
3 000
4 300
5 100
M39x1,5
8.8
10.9
12.9
601 000
857 000
1 002 000
3140
4470
5230
M39x1,5
8.8
10.9
12.9
582 000
830 000
971 000
3 430
4 890
5 720
M39x3
8.8
10.9
12.9
550 000
780 000
910 000
2800
4000
4700
M39x3
8.8
10.9
12.9
530 000
750 000
880 000
3 200
4 600
5 300
Comments concerning this standard:
The tightening torques indicated on the drawings supersede the standard
works values.
These must be observed and adhered to.
This standard only applies to Liebherr wheel loaders.

L524 - 659 / from 17890 2.0-1 o f 2
L528 - 660 / from 17890
L538 - 433 / from 17890
L542 - 435 / from 17890
Copyright
MJFCIFSS
2 Product description
2.0
Chapter contents
2 Product description ............................................................. 2.0-1
2.1 Technical data ................................................................................2.0-1
2.1.1 Complete machine................................................................2.0-1
2.1.2 Engine and splitter box.........................................................2.0-6
2.1.3 Cooling system.....................................................................2.0-8
2.1.4 Travel hydraulics ..................................................................2.0-9
2.1.5 Working hydraulics .............................................................2.0-11
2.1.6 Steering system..................................................................2.0-15
2.1.7 Brake system......................................................................2.0-16
2.1.8 Electrical system.................................................................2.0-17
2.1.9 Transmission ......................................................................2.0-18
2.1.10 Axles and cardan shaft.......................................................2.0-18
2.1.11 Machine frame and ballast weight......................................2.0-20
2.1.12 Cab, heating and air-conditioning.......................................2.0-20
2.1.13 Lift arms and quick-change device.....................................2.0-22
2.1.14 Equipment and accessories ...............................................2.0-23

Service manual Product description
Technical data
L524 - 659 / from 17890 2.0-1 o f 2 3
L528 - 660 / from 17890
L538 - 433 / from 17890
L542 - 435 / from 17890
Copyright
MJFCIFSS
2.1 Technical data
2.1.1 Complete machine
Valid for: L524 - 659 / from 17890
The values stated refer to the standard version of the machine:
– With Z lift arms (2400 mm), without hydraulic quick-change device.
– With 17.5 5R25 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.
Dimensions of machine with Z and P lift arms
Item Description Unit Value
Load geometry Z bar P bar
Bucket capacity as per ISO 7546 m³ 2.0 1.7
Bucket width mm 2500 2500
Specific material weight t/m³ 1.8 1.8
A Dump height at maximum lifting height and 45° tilt-out angle mm 2870 2845
B Dump height mm 3335 3370
C Maximum bucket base height mm 3530 3590
D Maximum bucket pivot point height mm 3775 3830
E Maximum bucket top height mm 4860 4980
F Reach at maximum lifting height and 42° tilt-out angle mm 850 1010
G Digging depth mm 80 61
H Height above the cab mm 3200 3200
I Height above exhaust mm 2860 2860
J Ground clearance mm 460 460

Product description Service manual
Technical data
2.0-2 o f 2 3 L524 - 659 / from 17890
L528 - 660 / from 17890
L538 - 433 / from 17890
L542 - 435 / from 17890
Copyright
MJFCIFSS
K Wheel base mm 2750 2750
L Overall length mm 6720 6965
Turning radius over bucket outer edge mm 5520 5610
Lifting force (SAE) kN 100 71
Breakout force (SAE) kN 91 83
Tipping load when straight kg 8310 7150
Tipping load articulated at 40° kg 7300 6300
Angle of articulation (to each side) ° 40 40
Swing angle (to each side) ° 6 6
Operating weight kg 10300 10525
Tractive force daN 81.48 81.48
Travel speed in travel range 1, forward and reverse km/h 0 - 6 0 - 6
Sound pressure level in cab according to ISO 6396 – LpA dB (A) 69 69
Valid for: L528 - 660 / from 17890
– With 17.5 R25 Goodyear GP-2B tyres
tipping load.

Technical data
L524 - 659 / from 17890 2.0-3 o f 2 3
L528 - 660 / from 17890
L538 - 433 / from 17890
L542 - 435 / from 17890
Copyright
MJFCIFSS
Valid for: L538 - 433 / from 17890
tipping load.

Technical data
2.0-4 o f 2 3 L524 - 659 / from 17890
L528 - 660 / from 17890
L538 - 433 / from 17890
L542 - 435 / from 17890
Copyright
MJFCIFSS

Technical data
L524 - 659 / from 17890 2.0-5 o f 2 3
L528 - 660 / from 17890
L538 - 433 / from 17890
L542 - 435 / from 17890
Copyright
MJFCIFSS
Valid for: L542 - 435 / from 17890
tipping load.

Technical data
2.0-6 o f 2 3 L524 - 659 / from 17890
L528 - 660 / from 17890
L538 - 433 / from 17890
L542 - 435 / from 17890
Copyright
MJFCIFSS
2.1.2 Engine and splitter box
Engine
Valid for: L524 - 659 / from 17890; L528 - 660 / from 17890;
Description Value Unit
Engine model Liebherr D 504 TI / John Deere CD 4045
Number of cylinders 4 4
Capacity 4500 4500 cm³
Rated power as per ISO 9249 86 / 117 86 / 117 kW /
hp
Rated speed 2400 2400 min
-1
Maximum torque at 1500 min
-1
430 430 Nm
Lower idle speed 850
10
850
10
min
-1
Upper idle speed 2550 20
2550 20
min
-1
Inlet valve play (cold) 0,36 0,36 mm
Outlet valve play (cold) 0,46 0,46 mm
Control thermostat opening temperature 82 82 °C
Longitudinal / traverse inclinability 30 / 30 30 / 30 °
Starter operating voltage 24 24 V
Starter power consumption 7 7 kW
Alternator voltage output 27,8 27,8 V
Alternator current output 55 55 A
Emission thresholds comply with EU – RL 97/68 EC Stage IIIa
Engine
Valid for: L538 - 433 / from 17890; L542 - 435 / from 17890; ID 1011 8823
Engine model D 934 S A6
Number of cylinders 4
Firing order 1-3-4-2
Capacity 6360 cm³
Cylinder bore 122 mm
Stroke 136 mm

Technical data
L524 - 659 / from 17890 2.0-7 o f 2 3
L528 - 660 / from 17890
L538 - 433 / from 17890
L542 - 435 / from 17890
Copyright
MJFCIFSS
Rated power as per ISO 9249 105 / 143 kW / hp
Rated speed 2000 min-1
Maximum torque at 1000 - 1300 min
-1
770 Nm
Lower idle speed 900
10
min
-1
Upper idle speed 2060
20
min-1
Start of delivery Electronic
Compression ratio 17:1
Combustion pressure 20 - 34 bar
Injection nozzle pressure 300
+8/-3
bar
Inlet valve play (cold) 0.30 mm
Outlet valve play (cold) 0.40 mm
Direction of rotation, looking at flywheel Anticlockwise
Number of teeth on flywheel gear 147 Qty.
Control thermostat opening temperature 79 °C
Longitudinal / traverse inclinability 45 / 45 °
Starter operating voltage 24 V
Starter power consumption 5.4 kW
Alternator voltage output 27,8 V
Alternator current output 80 A
Auxiliary power take-off transmission 1:1.234
Weight 965 kg
Emission levels comply with EU – RL 97/68/EC Stage IIIa
Fuel tank
Tank capacity, FULL 180 l
Tank capacity, RESERVE 30 l
Fuel pre-filter
Filtration grade 30 µm
Fuel fine filter

Technical data
2.0-8 o f 2 3 L524 - 659 / from 17890
L528 - 660 / from 17890
L538 - 433 / from 17890
L542 - 435 / from 17890
Copyright
MJFCIFSS
Vacuum switch
Air filter contamination vacuum switch
activation point
50 mbar
Clutch
Torsion damper screw adhesive 241 Loctite
Torsion damper screw tightening torque 49 Nm
Hub star fastening screw tightening torque 86 Nm
Torsion damper screw adhesive 241 Loctite
Torsion damper screw tightening torque 117 Nm
2.1.3 Cooling system
Gear pump
Capacity 16 cm³
Rotary speed at rated engine speed 2323 min
-1
Valid for: L538 - 433 / 17890 - 19018; L542 - 435 / 17890 - 19018; ID 1029 5259
Capacity 14 cm³
-1
Capacity 16 cm³
-1
Gear motor
Valid for: ID 5717 099
Gear motor displacement 16 cm³
Pressure relief valve 175 5
bar
Coil resistance 4.5 Ohm
Screw tightening torque 124
41
Nm

Technical data
L524 - 659 / from 17890 2.0-9 o f 2 3
L528 - 660 / from 17890
L538 - 433 / from 17890
L542 - 435 / from 17890
Copyright
MJFCIFSS
Temperature sensor (B8, B21)
Measuring range min. -30
max. 130
°C
°C
Resistance at 0 °C 1000 Ohm
Screw thread M 14 x 1.5 mm
Protection class IP 65
Max. tightening torque 30 Nm
Plug connection Bosch Jet plug,
2-pin (Gold contacts)
2.1.4 Travel hydraulics
Variable displacement pump
Valid for: L524 - 659 / from 17890; L528 - 660 / from 17890
Control type EP
Maximum capacity 90 cm³
Flow rate at rated speed 212 l/min
Power 72 kW
Replenishing pump capacity 19.6 cm³
Replenishing pump flow rate (at rated speed) 43 l/min
Inlet restrictor 1.8 mm
Travel direction solenoid current consumption 1.2 A
Travel direction solenoid resistance 22 Ohm
Control pressure proportional valve resistance 12 Ohm
Pressure relief and replenishing valves 470
10
bar
Pressure cut-off 440 5
bar
Weight 60 kg
Control type EP
Power 90 kW

Technical data
2.0-10 o f 2 3 L524 - 659 / from 17890
L528 - 660 / from 17890
L538 - 433 / from 17890
L542 - 435 / from 17890
Copyright
MJFCIFSS
Replenishing pump capacity 28.3 cm³
Replenishing pump flow rate (at rated speed) 53 l/min
Inlet restrictor 1.8 mm
Travel direction solenoid current consumption 1.2 A
Travel direction solenoid resistance 22 Ohm
Control pressure proportional valve resistance 12 Ohm
Pressure relief and replenishing valves 470
10
bar
Pressure cut-off 440
5
bar
Weight 75 kg
Variable displacement motor 1
Control type HA1R
Maximum displacement 55 cm³
Minimum displacement 40 cm³
Maximum swivel angel 25 °
Minimum swivel angle 18.1 °
Maximum speed 5220 min
-1
Torque ( p 400 bar) 356 Nm
Start of regulation 250
5
bar
Current consumption of travel direction
solenoid valve
1,2 A
Resistance of travel direction solenoid
valve
22 Ohm
Current consumption of travel range 1
solenoid valve
1,4 A
Resistance of travel range 1 solenoid valve 19 Ohm
Weight 26 kg
Control type HA1R
Minimum displacement 52 cm³
Minimum swivel angle 16.3 °
Maximum speed 4560 min-1
Start of regulation 250
5
bar
Current consumption of travel direction
solenoid valve
1,2 A
Resistance of travel direction solenoid
valve
22 Ohm

Technical data
L524 - 659 / from 17890 2.0-11 o f 2 3
L528 - 660 / from 17890
L538 - 433 / from 17890
L542 - 435 / from 17890
Copyright
MJFCIFSS
Current consumption of travel range 1
solenoid valve
1,4 A
Resistance of travel range 1 solenoid valve 19 Ohm
Weight 34 kg
Control type EP
Minimum swivel angle 0 °
-1
Maximum discharge valve capacity 15 l/min
Discharge valve orifice diameter 2.5 mm
Weight 47 kg
Control type EP
Minimum swivel angle 0 °
-1
Maximum discharge valve capacity 15 l/min
Discharge valve orifice diameter 2.5 mm
Weight 60 kg
2.1.5 Working hydraulics
Working hydraulics pump
Control type DFLR
Power 40 kW
Flow regulator (delta p) 32 2
bar
Weight 21 kg
  

Technical data
2.0-12 o f 2 3 L524 - 659 / from 17890
L528 - 660 / from 17890
L538 - 433 / from 17890
L542 - 435 / from 17890
Copyright
MJFCIFSS
Control type LRDS
Power 51 kW
Power controller start of regulation 190 bar
Flow regulator (delta p) 32
2
bar
Weight 45 kg
Control block
Piston diameter 18 mm
Lift arm up/down control piston flow 140 / 60 l/min
Tilt in/out control piston
(Z kinematics) flow rate
120 / 80 l/min
Tilt in/out control piston
(P kinematics) flow rate
140 / 90 l/min
LS pressure cut-off / L524, L528
Working hydraulics L538, L542
315 5
330 5
bar
bar
LS pressure cut-off / L524, L528
Steering L538, L542
230
5
250 5
bar
bar
Pressure relief valve pre-tension 16
3
bar
Weight 32 kg
Pilot control valve
Retaining solenoid current consumption 0,4 A
Retaining solenoid resistance 70 Ohm
Weight 5,7 kg
Working hydraulics lockout solenoid valve
Current consumption 0,7 A
Resistance 40 Ohm
Pilot control hydro accumulator
Hydro accumulator volume 320 cm³
Preload pressure (nitrogen filling) 15 bar

Technical data
L524 - 659 / from 17890 2.0-13 o f 2 3
L528 - 660 / from 17890
L538 - 433 / from 17890
L542 - 435 / from 17890
Copyright
MJFCIFSS
Stabilisation module
Control piston diameter 16 mm
Cut-off pressure (LFD off) 120
20
bar
Safety valve 330
10
bar
Restrictor check valve diameter 2.0 / 0.4 mm
Solenoid valve current consumption 0.7 A
Solenoid valve resistance 40 Ohm
Weight 13 kg
Ride control hydro accumulator
Preload pressure (nitrogen filling) 25
2
bar
Oil filling 350 cm³
Lift cylinder
Rod diameter 60 mm
Stroke length 735 mm
Minimum installation length 1170 mm
Weight 80 kg
Lifting at rated load 6.0 sec
Lowering empty 4.0 sec
Piston rod bearing tightening torque (hex
screws)
290 Nm
Piston tightening torque WN - 4121-091 -
Rod diameter 60 mm
Weight 89 kg
Lifting at rated load 6.0 sec
Lowering empty 4.0 sec
Piston rod bearing tightening torque
(hex screws)
290 Nm

Technical data
2.0-14 o f 2 3 L524 - 659 / from 17890
L528 - 660 / from 17890
L538 - 433 / from 17890
L542 - 435 / from 17890
Copyright
MJFCIFSS
Z kinematics tilt cylinder
Rod diameter 70 mm
Weight 70 kg
Tilt in/out empty 3.0 sec
(hex screws)
290 Nm
Rod diameter 80 mm
Weight 110 kg
(hex screws)
290 Nm
P kinematics tilt cylinder
Rod diameter 50 mm
Weight 53.5 kg
Rod diameter 50 mm
Weight 57 kg

Technical data
L524 - 659 / from 17890 2.0-15 o f 2 3
L528 - 660 / from 17890
L538 - 433 / from 17890
L542 - 435 / from 17890
Copyright
MJFCIFSS
Filter unit
Pre-tension valve 0.5 bar
Replenishing valve 0.05 bar
Replenishing strainer 160 µm
Bypass valve 2.5 bar
Return strainer 80 µm
Bleeder filter
Filtration grade 10 m
Inlet opening pressure 0.03 bar
Outlet opening pressure 0.5 bar
Thread 3/4 inch
2.1.6 Steering system
Servostat
Displacement 370 cm³
Secondary pressure relief 285
10
bar
Flow booster 1 : 1.6
Steering cylinder
Rod diameter 45 mm
Weight 26.2 kg
Emergency steering pump
Capacity 11 cm²
Pressure relief valve 55
±5
bar
Emergency steering pump pressure switch
Type Electronic
pressure switch
Switch type Normally open
Switching point 16 2
bar

Technical data
2.0-16 o f 2 3 L524 - 659 / from 17890
L528 - 660 / from 17890
L538 - 433 / from 17890
L542 - 435 / from 17890
Copyright
MJFCIFSS
Thread M 12 x 1.5 mm
Emergency steering check pressure switch
Type Electronic
pressure switch
Switching point 16
2
bar
2.1.7 Brake system
Brake system gear pump
Capacity 4 cm³
Flow rate at rated speed 9.3 l/min
Speed at rated speed 2322 min
-1
Capacity 4 cm³
Flow rate at rated speed 9.9 l/min
Speed at rated speed 2474 min
-1
Compact brake valve
Accumulator charge valve
activation pressure
130
±5
bar
Accumulator charge valve
deactivation pressure
160
±5
bar
Maximum service brake pressure 60
±5
bar
Parking brake solenoid valve current
consumption
0.6 A
Parking brake solenoid valve resistance 40 Ohm
Pedal start angle 42°
Pedal stop angle 15°

Technical data
L524 - 659 / from 17890 2.0-17 o f 2 3
L528 - 660 / from 17890
L538 - 433 / from 17890
L542 - 435 / from 17890
Copyright
MJFCIFSS
Service brake hydro accumulator
Number of hydro accumulators 2 Qty.
Brake light pressure switch
Switch point, rising 5
±0.5
bar
Disc brake
Brake pad gap 1.0
±0.5
mm
Brake lining thickness, new 4.5 mm
Minimum brake lining thickness 1.0 mm
Parking brake hydro accumulator
Accumulator charge pressure switch
Type Electronic
pressure switch
Switching point, falling 90
±5
bar
2.1.8 Electrical system
Battery
Battery voltage 12 V
Battery capacity 135 Ah
Acid density of charged battery 1.26 - 1.28 kg/l
Cold test current (at -18 °C EN 60095-1) 950 A

Technical data
2.0-18 o f 2 3 L524 - 659 / from 17890
L528 - 660 / from 17890
L538 - 433 / from 17890
L542 - 435 / from 17890
Copyright
MJFCIFSS
2.1.9 Transmission
Transmission
Type 319
transmission
1.55 -
transmission
3.83 -
Cardan speed at 40 km/h 3098 min
-1
Type 319
Variable displacement motor 1 transmission 1.55 -
Variable displacement motor 2 transmission 3.83 -
Cardan speed at 40 km/h 2795 min
-1
Speed sensors
Type Inductive sensor -
Resistance at 20 °C 1050
±100
Ohm
2.1.10 Axles and cardan shaft
Front axle
Type 123/60
Self-locking differential level 45 %
Width 1960 mm
Overall transmission 18.6
Differential transmission 10/31
Wheel hub transmission 1/6
Wheel lug tightening torque 650 Nm
Wheel lug spanner size 30 mm
Flange size 1920 mm
Weight 570 kg
Type 113/58
Width 1900 mm

Technical data
L524 - 659 / from 17890 2.0-19 o f 2 3
L528 - 660 / from 17890
L538 - 433 / from 17890
L542 - 435 / from 17890
Copyright
MJFCIFSS
Flange size 1920 mm
Weight 720 kg
Rear axle
Type 123/51
Width 1960 mm
Swing angle (to each side) 6 °
Flange size 1920 mm
Weight 680 kg
Type 113/50
Width 1900 mm
Swing angle (to each side) 6 °
Flange size 1920 mm
Weight 840 kg
Cardan shaft
Minimum length 1875 mm
Width 2020 mm
Weight 27.5 kg

Technical data
2.0-20 o f 2 3 L524 - 659 / from 17890
L528 - 660 / from 17890
L538 - 433 / from 17890
L542 - 435 / from 17890
Copyright
MJFCIFSS
Minimum length 1967 mm
Width 2122 mm
Weight 30.5 kg
2.1.11 Machine frame and ballast weight
Ballast weight
Left ballast weight 515 kg
Right ballast weight 565 kg
Valid for: L528 - 660 / from 17890
Valid for: L542 - 435 / from 17890
2.1.12 Cab, heating and air-conditioning
Heating, ventilation, air conditioning
Rated voltage 24 V
Number of blower levels 6
Maximum fan current consumption 15.7 A
Maximum air flow 600 m³/h
Heating power 11 kW
Air conditioning system
Refrigerant R134a
Refrigerant oil (PAG oil) ZXL 100 PG
Coolant quantity 1050
+50
g
Cooling power 9.7
10%
kW

Technical data
L524 - 659 / from 17890 2.0-21 o f 2 3
L528 - 660 / from 17890
L538 - 433 / from 17890
L542 - 435 / from 17890
Copyright
MJFCIFSS
Refrigerant R134a
Coolant quantity 1250
+50
g
Cooling power 9.7
10%
kW
Air conditioning compressor
Type SD7H15
Capacity 154.9 cm³
(SP 10)
Filling quantity 200 cm³
Maximum current consumption 2.63 A
Weight without oil 6.9 kg
Condenser
Maximum air flow 4000 m³/h
Heating power 9.7
±1
kW
Test pressure 35 bar
Dryer collector unit
Contents 0.70 l
Leak test 30 bar
Dryer water consumption 16 g
Burst pressure 130 bar
Pressure switch
Low pressure OFF 1.5
±0.5
bar
Low pressure ON 3.5 bar
High pressure OFF 25
±2
bar
High pressure ON 18 ±1.5
bar
Fan OFF 15 ±1
bar
Fan ON 19
±1
bar

Technical data
2.0-22 o f 2 3 L524 - 659 / from 17890
L528 - 660 / from 17890
L538 - 433 / from 17890
L542 - 435 / from 17890
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MJFCIFSS
Evaporator
Cooling power 9.7 kW
Temperature sensor activation temperature 5.5 ±10%
°C
Temperature sensor deactivation temperature 4.5
±10%
°C
Temperature sensor B26
Operating temperature -40 - +125 °C
Resistance at -5 °C 42330 Ohm
Protection class IP 68
2.1.13 Lift arms and quick-change device
Lift arms with Z kinematics
L – length 2400 mm
Weight 962 kg
Weight 1072 kg
Lift arms with P kinematics
L – high lift length 3000 mm
Weight (without QCD) 1165 kg
L – high lift length 3000 mm
Weight (without QCD) 1165 kg

Technical data
L524 - 659 / from 17890 2.0-23 o f 2 3
L528 - 660 / from 17890
L538 - 433 / from 17890
L542 - 435 / from 17890
Copyright
MJFCIFSS
Hydraulic quick-change device for Z lift arms.
A – system connection size 1000 mm
Weight 300 kg
Hydraulic quick-change device for P lift arms.
A – system connection size 1000 mm
Weight 230 kg
2.1.14 Equipment and accessories
Bucket
Valid for: L524 - 659 / from 17890
B – bucket width 2500 mm
Specific material weight 1.8 t/m³
Heaped bucket capacity (ISO 7546) 2 m³
Valid for: L528 - 660 / from 17890
Heaped bucket capacity (ISO 7546) 2.2 m³
Valid for: L538 - 433 / from 17890
Valid for: L542 - 435 / from 17890
Forklift
Fork carrier prong size FEM III
Prong length 1200 mm

L524 - 659 / from 17890 3.0-1 o f 4
L528 - 660 / from 17890
L538 - 433 / from 17890
L542 - 435 / from 17890
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MJFCIFSS
3 Maintenance
3.0
Chapter contents
3 Maintenance........................................................................ 3.0-1
3.1 Maintenance and inspection schedule ...........................................3.1-1
3.2 Testing and adjustment plan...........................................................3.2-1
3.3 Testing and adjustment checklists..................................................3.3-1
3.4 Lubrication chart and filling quantities ............................................3.4-1
3.4.1 Table of filling quantities L524, L528....................................3.4-1
3.4.2 Table of filling quantities L538, L542....................................3.4-2
3.4.3 Lubrication chart L524, L528................................................3.4-4
3.4.4 Lubrication chart L538, L542................................................3.4-6
3.5 Maintenance tasks..........................................................................3.5-1
3.5.1 Preparatory tasks for maintenance ......................................3.5-1
3.5.2 Removing loose parts, dirt, ice and snow from the
machine ................................................................................3.5-5
3.5.3 Checking the machine for external damage.........................3.5-5
3.5.4 Making sure the bolted connections are tight.......................3.5-5
3.5.5 Sealing leaks ........................................................................3.5-5
3.5.6 Checking the engine oil level L524, L528.............................3.5-6
3.5.7 Checking the engine oil level L538, L542.............................3.5-6
3.5.8 Changing the engine oil L524, L528.....................................3.5-7
3.5.9 Changing the engine oil L538, L542.....................................3.5-8
3.5.10 Changing the engine oil filterL524, L528..............................3.5-9
3.5.11 Changing the engine oil filterL538, L542............................3.5-10
3.5.12 Checking the V-ribbed belt L524, L528..............................3.5-11
3.5.13 Checking the V-ribbed belt L538, L542..............................3.5-12
3.5.14 Checking the valve play L524, L528 ..................................3.5-14
3.5.15 Checking the valve play L538, L542 ..................................3.5-16
3.5.16 Checking the heating flange L524, L528............................3.5-18
3.5.17 Checking the heating flange L538, L542............................3.5-18
3.5.18 Greasing the ring gear on the flywheel L538, L542 ...........3.5-19
3.5.19 Changing the oil separator filter insert L538, L542 ............3.5-20
3.5.20 Checking the bearings and condition of the engine
control units L524, L528 .....................................................3.5-20

Maintenance Service manual
3.0-2 o f 4 L524 - 659 / from 17890
L528 - 660 / from 17890
L538 - 433 / from 17890
L542 - 435 / from 17890
Copyright
MJFCIFSS
3.5.21 Checking the bearings and condition of the engine
control units L538, L542 .................................................... 3.5-21
3.5.22 Checking the sensors and cable connections L524,
L528................................................................................... 3.5-21
3.5.23 Checking the sensors and cable connections L538,
L542................................................................................... 3.5-22
3.5.24 Changing the fuel pre-filter L524, L528 ............................. 3.5-23
3.5.25 Changing the fuel pre-filter L538, L542 ............................. 3.5-24
3.5.26 Changing the fuel fine filter L524, L528............................. 3.5-25
3.5.27 Changing the fuel fine filter L538, L542............................. 3.5-26
3.5.28 Draining off condensate from the fuel filter L524,L52........ 3.5-27
3.5.29 Draining off condensate from the fuel filter L538,L542...... 3.5-28
3.5.30 Bleeding the fuel system L524, L528 ................................ 3.5-29
3.5.31 Bleeding the fuel system L538, L542 ................................ 3.5-30
3.5.32 Draining off condensate and sediment from the fuel
tank .................................................................................... 3.5-32
3.5.33 Cleaning the air filter service cap and dust extraction
valve................................................................................... 3.5-32
3.5.34 Test the air filter vacuum switch ........................................ 3.5-33
3.5.35 Changing the air filter main element when indicated by
the vacuum switch ............................................................. 3.5-33
3.5.36 Changing the air filter secondary element......................... 3.5-34
3.5.37 Checking the air suction hoses for leaks and tight fitting .. 3.5-35
3.5.38 Checking the exhaust lines for leaks and tight fitting ........ 3.5-36
3.5.39 Checking the coolant antifreeze and corrosion inhibitor
concentration ..................................................................... 3.5-36
3.5.40 Cleaning the cooling system.............................................. 3.5-40
3.5.41 Changing the coolant L524, L528...................................... 3.5-41
3.5.42 Changing the coolant L538, L542...................................... 3.5-42
3.5.43 Checking the oil level in the hydraulic tank........................ 3.5-43
3.5.44 Draining off condensate and sediment from the
hydraulic tank..................................................................... 3.5-43
3.5.45 Changing the oil in the hydraulic tank................................ 3.5-44
3.5.46 Checking and cleaning the magnetic rod on the
hydraulic tank..................................................................... 3.5-46
3.5.47 Changing the hydraulic tank return suction filter ............... 3.5-46
3.5.48 Changing the hydraulic tank bleeder filter ......................... 3.5-47
3.5.49 Lubricating the pilot control device solenoids, universal
joints and tappets............................................................... 3.5-47
3.5.50 Testing the steering ........................................................... 3.5-48
3.5.51 Lubricating the bearing points on the steering cylinders ... 3.5-48
3.5.52 Testing the service brake and parking brake..................... 3.5-48
3.5.53 Checking the gap and wear on the parking brake linings.. 3.5-49
3.5.54 Checking the indicator lamps and lighting......................... 3.5-50

Service manual Maintenance
L524 - 659 / from 17890 3.0-3 o f 4
L528 - 660 / from 17890
L538 - 433 / from 17890
L542 - 435 / from 17890
Copyright
MJFCIFSS
3.5.55 Checking the batteries, fluid level and terminals................3.5-51
3.5.56 Checking the transfer gear oil level....................................3.5-52
3.5.57 Changing the transmission oil ............................................3.5-52
3.5.58 Checking the wheel tightness.............................................3.5-53
3.5.59 Checking the axle oil levels ................................................3.5-53
3.5.60 Changing the axle oil..........................................................3.5-55
3.5.61 Checking the tyre pressure ................................................3.5-56
3.5.62 Lubricating the articulation bearing and rear oscillating
bearing................................................................................3.5-57
3.5.63 Greasing the cab door hinges ............................................3.5-57
3.5.64 Checking / topping up the windscreen washer reservoir....3.5-58
3.5.65 Cleaning the fresh air and recirculated air filter..................3.5-58
3.5.66 Changing the fresh air and recirculated air filter ................3.5-59
3.5.67 Checking the indicator and filling level beads in the
dryer-collector unit (optional) of the air conditioner............3.5-60
3.5.68 Lubricating the lift arms and attachment (Z kinematics).....3.5-61
3.5.69 Lubricating the lift arms and attachment (P kinematics) ....3.5-61
3.5.70 Checking the lift arm bearing bushings ..............................3.5-62
3.5.71 Checking the lift arm bucket stops (Z kinematics)..............3.5-63
3.5.72 Lubricating and testing the quick-change device ...............3.5-64
3.6 Testing and adjustment tasks.........................................................3.6-1
3.6.1 Preparing for testing and adjustment ...................................3.6-1
3.6.2 Bringing the machine up to operating temperature..............3.6-2
3.6.3 Checking the fan motor and fan control pressure
relief valve ............................................................................3.6-2
3.6.4 Calibrating the pedals...........................................................3.6-4
3.6.5 Checking the engine speed..................................................3.6-4
3.6.6 Checking the replenishing pressure of the variable
displacement pump L524, L528 ...........................................3.6-5
3.6.7 Checking the replenishing pressure of the variable
3.6.8 Checking the pressure relief and replenishing valve of
the variable displacement pump...........................................3.6-5
3.6.9 Checking the pressure cut-off of the variable
3.6.10 Checking the pressure cut-off of the variable
3.6.11 Calibrating the block curve L524, L528................................3.6-8
3.6.12 Calibrating the block curve L538, L542................................3.6-9
3.6.13 Checking the start of regulation for variable
displacement motor 1 L524, L528......................................3.6-10
3.6.14 Checking the start of regulation for variable
displacement motor 1 L538, L542......................................3.6-10

Maintenance Service manual
3.0-4 o f 4 L524 - 659 / from 17890
L528 - 660 / from 17890
L538 - 433 / from 17890
L542 - 435 / from 17890
Copyright
MJFCIFSS
3.6.15 Calibrating variable displacement motor 2 ........................ 3.6-11
3.6.16 Checking the engine output............................................... 3.6-12
3.6.17 Checking the secondary pressure relief valves on the
control block L524, L528.................................................... 3.6-13
3.6.18 Checking the secondary pressure relief valves on the
control block L538, L542.................................................... 3.6-14
3.6.19 Checking the LS pressure cut-off on the control block
L524, L528......................................................................... 3.6-14
3.6.20 Checking the LS pressure cut-off on the control block
L538, L542 ......................................................................... 3.6-15
3.6.21 Checking the flow controller of the working
hydraulics pump L524, L528.............................................. 3.6-15
3.6.22 Checking the flow controller of the working
hydraulics pumpL538, L542............................................... 3.6-16
3.6.23 Depressurising ride control and the hydro accumulators .. 3.6-16
3.6.24 Checking the cut-off pressure in the stabilisation
module ............................................................................... 3.6-16
3.6.25 Checking the nitrogen in the ride control hydro
accumulator........................................................................ 3.6-17
3.6.26 Checking the opening and closing pressure of the
compact brake valve.......................................................... 3.6-18
3.6.27 Checking the brake pressure at the axles ......................... 3.6-18
3.6.28 Checking the capacity of the brake accumulators............. 3.6-19
3.6.29 Check the accumulator charge pressure........................... 3.6-19
3.6.30 Check the brake light pressure switch and brake lights .... 3.6-20
3.7 Lubricants and fuels....................................................................... 3.7-1
3.7.1 Diesel fuels .......................................................................... 3.7-2
3.7.2 Lubricating oils for diesel engines ....................................... 3.7-3
3.7.3 Coolant for the engine ......................................................... 3.7-5
3.7.4 Hydraulic fluid ...................................................................... 3.7-8
3.7.5 Lubricating oils for the transmission .................................. 3.7-11
3.7.6 Grease for general lubrication points................................. 3.7-12

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