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Service manual
(20
Wheel loader
(10 points)
L506 - L510 Stereo
(10
en
Service manual
(20
Wheel loader
(10 points)
L506 - L510 Stereo
(10

Address
Address: LIEBHERR-WERK BISCHOFSHOFEN GMBH

Dr. Hans Liebherr – Straße 4


A – 5500 BISCHOFSHOFEN, AUSTRIA

Product identification
Manufacturer: LIEBHERR-WERK BISCHOFSHOFEN GMBH
Product group: Wheel loader
Type: L506 L507 L508 L509 L510
Construction number: 776 777 778 779 782
Serial number: 9099 9099 9099 9099 9099

Document identification
Order number: 1011 2640
Author: LBH / T-DOK department
Document version: 02
Manual number:
Owner:
Foreword

Target group This Service Manual has been written for those whose job it is to make sure
that the machines remain operational on a daily basis. This specifically
includes the mechanics and workshop specialists at Liebherr dealers and
Liebherr branch offices.

Contents In the first chapter you will find information about safety regulations as well
as specifications of the special tools needed for maintenance and repair.
Chapter 2 provides an overview of all important technical data for the entire
machine and the individual assemblies.
The following chapter, entitled Maintenance, contains the maintenance and
inspection schedule, inspection and setting logs, lubrication schedules and
filling quantity tables, a description of maintenance procedures and speci-
fications for prescribed lubricants and fuels.
The technical description of the machine in the following chapters is divided
into 15 functional groups. The design, function, and technical data for each
group, component and part are explained.

How to use this manual This manual describes a variety of types and finished forms. In general, this
information applies to the types and serial number groups specified in the
footnotes. One exception is that specific type and serial number data are
indicated at the beginning of each section (e.g. the technical specifications of
the components).
Whenever possible, parts and components are supplemented by indication
of the identification number in the heading.
This manual is available in German, English and French.

Working instructions It is imperative that safety regulations be observed with all tasks done on the
machine. You will find information on this in the General Information
chapter.
A complete set of tools in perfect condition is required for work on the
machine, along with any special tools that might be needed. Absolute
cleanliness must be observed with all tasks!
Sealing material such as O-rings and surface seals should be replaced
whenever repairs are carried out.

DVD edition We would particularly like to draw your attention to the fact that this book is
available not only in printed form, but also as an electronic document on
DVD (Lidos).
General information 1
Product description 2
Maintenance 3
Diesel engine 4
Cooling system 5
Travel hydraulics 6
Working hydraulics 7
Steering system 8
Brake system 9
Electrical system 10
Transfer gear 11
Axles, drive shafts 12
Machine frame, ballast weight 13
Central lubrication system 14
Covering, cab access 15
Cab, heating, air-conditioning 16
Lift arm, quick-change device 17
Attachments, accessories 18
Repair work, troubleshooting 19
 
 


   

  


  
  

 
  
 
  
 
 
  
  
  

           


  
 
 
 

 
           
         



         

           
         



 
 

  




 




 



 


 
 
 

           


  
 
 
 

 
             



 
 
 
 
 
 
 
 
 
 
 
 
 
 
         

 
 
 
 
 

           


  
   
 
 

 

 
   

  


   

   
   

  

   
   
   
   
   
   
   
   
   

  

   
   
   

  


 
   

  


  

   


  



  


  

   

   


           


  
 
 
 

   




   


 
 
 
 
   
 


  


 
 
 

  



  



  


  

 
 
 

  


  


  

   
 
 
 
   
 
 
 
 
 
 

   

   
   

  


           


  
   
 
 

 
   
   
   

  


  


  


  


  

 
 
 
 
 
 
  


 
   

  

   
   
   

   
 
   
   
   
   

  


  


  


  



  




  



           


  
 
 
 

 
   

  


  


  


   

 
 
 

  


  


  

   
 
 
 

  


  


 
   
   
   
 
 
 
 
 
 
 
 
 

           


  
   
 
 

 
   

  


  

   
   
   
   
   

 
   

  


           


  
 
2 Product Description
2.0

Chapter contents
2 Product Description............................................................. 2.0-1

2.1 Technical data ................................................................................2.1-1


2.1.1 Complete machine................................................................2.1-1
2.1.2 Diesel engine........................................................................2.1-8
2.1.3 Cooling system ...................................................................2.1-12
2.1.4 Travel hydraulics ................................................................2.1-13
2.1.5 Working hydraulics .............................................................2.1-15
2.1.6 Steering system..................................................................2.1-18
2.1.7 Brake system......................................................................2.1-18
2.1.8 Electrical system.................................................................2.1-19
2.1.9 Transfer gear ......................................................................2.1-19
2.1.10 Axles and cardan shaft .......................................................2.1-20
2.1.11 Machine frame and ballast weight......................................2.1-22
2.1.12 Automatic central lubrication system..................................2.1-23
2.1.13 Cab, heating and air-conditioning.......................................2.1-24
2.1.14 Lift arms and quick-change device.....................................2.1-25
2.1.15 Equipment and accessories ...............................................2.1-26

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Technical Data

2.1 Technical data


2.1.1 Complete machine
Valid for: L506 - 776 / from 9099
The values stated refer to the standard version of the machine:
– with 365 / 70 R18 tyres
– tipping loads and weights include all lubricants, full fuel tank, ROPS/
FOPS cab and driver.

Description Value Unit


Bucket capacity as per ISO 7546 0.8 m³
Bucket width 1900 mm
Specific material weight 1.8 t/m³
A Dump height at maximum lifting height 2550 mm
and 45° tilt-out angle
B Dump height 2872 mm
C Maximum bucket base height 3011 mm
D Maximum bucket pivot point height 3211 mm
E Maximum bucket top height 4040 mm
F Reach at maximum lifting height and 42° 818 mm
tilt-out angle
Fmax. Reach at 42° tilt-out angle 1517 mm
G Digging depth 80 mm
H Height above the cab 2725 mm
I Height above exhaust 2600 mm
J Ground clearance 295 mm
K Wheel base 2150 mm

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Description Value Unit


L Overall length 5295 mm
Turning radius over bucket outer edge 3690 mm
Lifting force (SAE) 39 kN
Breakout force (SAE) 43 kN
Tipping load when straight 3540 kg
Tipping load articulated at 30° 3231 kg
Angle of articulation (to each side) 30 °
Operating weight 5160 kg
Tractive force 4587 daN
Travel speed in travel range 1, 0 - 6 km/h
forward and reverse
Travel speed in travel range 2, 0 - 20 km/h
forward and reverse
Sound pressure level in cab in L pA 70 dB (A)
according to ISO 6396

Valid for: L507 - 777 / from 9099


The values stated refer to the standard version of the machine:
– with 365 / 70 R18 tyres
– tipping loads and weights include all lubricants, full fuel tank, ROPS/
FOPS cab and driver.

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Service Manual Product Description
Technical Data

Description Value Unit


Bucket capacity as per ISO 7546 0.9 m³
Bucket width 2050 mm
Specific material weight 1.8 t/m³
A Dump height at maximum lifting height 2550 mm
and 45° tilt-out angle
B Dump height 2872 mm
C Maximum bucket base height 3011 mm
D Maximum bucket pivot point height 3211 mm
E Maximum bucket top height 4040 mm
F Reach at maximum lifting height and 42° 818 mm
tilt-out angle
Fmax. Reach at 42° tilt-out angle 1517 mm
G Digging depth 80 mm
H Height above the cab 2725 mm
I Height above exhaust 2600 mm
J Ground clearance 295 mm
K Wheel base 2150 mm
L Overall length 5295 mm
Turning radius over bucket outer edge 3690 mm
Lifting force (SAE) 44 kN
Breakout force (SAE) 48 kN
Tipping load when straight 3836 kg
Tipping load articulated at 30° 3501 kg
Angle of articulation (to each side) 30 °
Operating weight 5240 kg
Tractive force 4593 daN
Travel speed in travel range 1, 0 - 6 km/h
forward and reverse
Travel speed in travel range 2, 0 - 20 km/h
forward and reverse
Sound pressure level in cab in L pA 70 dB (A)
according to ISO 6396

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Technical Data

Valid for: L508 - 778 / from 9099


The values stated refer to the standard version of the machine:
– with 405 / 70 R18 tyres
– tipping loads and weights include all lubricants, full fuel tank, ROPS/
FOPS cab and driver.

Description Value Unit


Bucket capacity as per ISO 7546 1.0 m³
Bucket width 2100 mm
Specific material weight 1.8 t/m³
A Dump height at maximum lifting height 2555 mm
and 45° tilt-out angle
B Dump height 2896 mm
C Maximum bucket base height 3035 mm
D Maximum bucket pivot point height 3235 mm
E Maximum bucket top height 4115 mm
F Reach at maximum lifting height and 42° 817 mm
tilt-out angle
Fmax Reach at 42° tilt-out angle 1515 mm
G Digging depth 56 mm
H Height above the cab 2749 mm
I Height above exhaust 2624 mm
J Ground clearance 319 mm
K Wheel base 2150 mm
L Overall length 5371 mm
Turning radius over bucket outer edge 3820 mm
Lifting force (SAE) 48 kN
Breakout force (SAE) 49 kN

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Service Manual Product Description
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Description Value Unit


Tipping load when straight 4190 kg
Tipping load articulated at 30° 3824 kg
Angle of articulation (to each side) 30 °
Operating weight 5480 kg
Tractive force 4364 daN
Travel speed in travel range 1, forward and 0 - 6 km/h
reverse
Travel speed in travel range 2, forward and 0 - 20 km/h
reverse
Sound pressure level in cab in L pA 70 dB (A)
according to ISO 6396

Valid for: L509 - 779 / from 9099


The values stated refer to the standard version of the machine:
– with 405 / 70 R18 tyres
– tipping loads and weights include all lubricants, full fuel tank, ROPS/
FOPS cab and driver.

Description Value Unit


Bucket capacity as per ISO 7546 1.1 m³
Bucket width 2200 mm
Specific material weight 1.8 t/m³
A Dump height at maximum lifting height 2641 mm
and 45° tilt-out angle
B Dump height 3000 mm
C Maximum bucket base height 3139 mm
D Maximum bucket pivot point height 3339 mm

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Description Value Unit


E Maximum bucket top height 4235 mm
F Reach at maximum lifting height and 42° 909 mm
tilt-out angle
Fmax. Reach at 42° tilt-out angle 1640 mm
G Digging depth 95 mm
H Height above the cab 2750 mm
I Height above exhaust 2625 mm
J Ground clearance 335 mm
K Wheel base 2300 mm
L Overall length 5760 mm
Turning radius over bucket outer edge 4150 mm
Lifting force (SAE) 54 kN
Breakout force (SAE) 55 kN
Tipping load when straight 4645 kg
Tipping load articulated at 30° 4225 kg
Angle of articulation (to each side) 30 °
Operating weight 6080 kg
Tractive force 5592 daN
Travel speed in travel range 1, 0 - 6 km/h
forward and reverse
Travel speed in travel range 2, 0 - 20 km/h
forward and reverse
Sound pressure level in cab in L pA 70 dB (A)
according to ISO 6396

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Service Manual Product Description
Technical Data

Valid for: L510 - 782 / from 9099


The values stated refer to the standard version of the machine:
– With 405 / 70 R20 tyres
– Tipping loads and weights include all lubricants, full fuel tank, ROPS/
FOPS cab and driver.

Description Value Unit


Bucket capacity as per ISO 7546 1.2 m³
Bucket width 2330 mm
Specific material weight 1.8 t/m³
A Dump height at maximum lifting height 2676 mm
and 45° tilt-out angle
B Dump height 3035 mm
C Maximum bucket base height 3174 mm
D Maximum bucket pivot point height 3374 mm
E Maximum bucket top height 4270 mm
F Reach at maximum lifting height and 42° 874 mm
tilt-out angle
Fmax Reach at 42° tilt-out angle 1605 mm
G Digging depth 60 mm
H Height above the cab 2785 mm
I Height above exhaust 2660 mm
J Ground clearance 370 mm
K Wheel base 2300 mm
L Overall length 5760 mm
Turning radius over bucket outer edge 4190 mm
Lifting force (SAE) 60 kN
Breakout force (SAE) 62 kN

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Description Value Unit


Tipping load when straight 5036 kg
Tipping load articulated at 30° 4581 kg
Angle of articulation (to each side) 30 °
Operating weight 6250 kg
Tractive force 5002 daN
Travel speed in travel range 1, 0 - 6 km/h
forward and reverse
Travel speed in travel range 2, 0 - 20 km/h
forward and reverse
Sound pressure level in cab in L pA 70 dB (A)
according to ISO 6396

2.1.2 Diesel engine

Diesel engine
Valid for: L506 - 776 / from 9099
Description Value Unit
Engine model D404T-00
Type / cylinders 4-cylinder inline
Combustion Four-stroke
direct injection
Capacity 2440 cm³
Rated power as per ISO 9249 42 / 57 kW / PS
Rated speed 2800 min-1
Maximum torque at 1680 min-1 209 Nm
Lower idle speed 850 50
min-1
Upper idle speed 3040 +80 min-1
Cylinder bore 86 mm
Stroke 105 mm
Compression ratio 18:1
Combustion pressure 24 - 28 bar
Injection nozzles / operating pressure 220 bar
Firing order 1-3-4-2
Inlet and outlet valve lash Hydraulic
adjustment
Injection pump Pump elements
Controller Mechanical
Turbocharger Constant
Longitudinal / traverse inclinability 30 °
Current / power consumption of starter 12 / 2.2 V / kW
Alternator voltage output 12 V
Alternator current output 65 A
Conversion factor 4.115
Frequency KL.W / engine speed
Coolant thermostat opening temperature 82.2 °C

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Technical Data

Description Value Unit


Minimum pressure in cooling system after 0.7 bar
pump
Auxiliary drive transmission 1.03 i
Weight 232 kg
Emission thresholds comply with EU – RL 97/68 EC Stage II

Valid for: L506 - 777 / from 9099; L508 - 778 / from 9099
Description Value Unit
Engine model D404T-01
Type / cylinders 4-cylinder inline
Combustion Four-stroke
direct injection
Capacity 2440 cm³
Rated power as per ISO 9249 46 / 63 kW / PS
Rated speed 2800 min-1
Maximum torque at 1680 min-1 227 Nm
Lower idle speed 850 50
min-1
Upper idle speed 3040 +80 min-1
Cylinder bore 86 mm
Stroke 105 mm
Compression ratio 18:1
Combustion pressure 24 - 28 bar
Injection nozzles / operating pressure 220 bar
Firing order 1-3-4-2
Inlet and outlet valve lash Hydraulic
adjustment
Injection pump Pump elements
Controller Mechanical
Turbocharger Constant
Longitudinal / traverse inclinability 30 °
Current / power consumption of starter 12 / 2.2 V / kW
Alternator voltage output 12 V
Alternator current output 65 A
Conversion factor 4.115
Frequency KL.W / engine speed
Coolant thermostat opening temperature 82.2 °C
Minimum pressure in cooling system after 0.7 bar
pump
Auxiliary drive transmission 1.03 i
Weight 232 kg
Emission thresholds comply with EU – RL 97/68 EC Stage II

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Technical Data

Valid for: L509 - 779 / from 9099


Description Value Unit
Engine model D405T-00
Type / cylinders 5-cylinder inline
Combustion Four-stroke
direct injection
Capacity 3050 cm³
Rated power as per ISO 9249 54 / 74 kW / PS
Rated speed 2800 min-1
Maximum torque at 1680 min-1 262 Nm
Lower idle speed 850 50
min-1
Upper idle speed 3040 +80 min-1
Cylinder bore 86 mm
Stroke 105 mm
Compression ratio 18:1
Combustion pressure 24 - 28 bar
Injection nozzles / operating pressure 220 bar
Firing order 1-2-4-5-3
Inlet and outlet valve lash Hydraulic
adjustment
Injection pump Pump elements
Controller Mechanical
Turbocharger Constant
Longitudinal / traverse inclinability 30 °
Current / power consumption of starter 12 / 2.2 V / kW
Alternator voltage output 12 V
Alternator current output 65 A
Conversion factor 4.115
Frequency KL.W / engine speed
Coolant thermostat opening temperature 82.2 °C
Minimum pressure in cooling system after 1.4 bar
pump
Auxiliary drive transmission 1.03 i
Weight 237 kg
Emission thresholds comply with EU – RL 97/68 EC Stage II

Valid for: L510 - 782 / from 9099


Description Value Unit
Engine model D405T-01
Type / cylinders 5-cylinder inline
Combustion Four-stroke
direct injection
Capacity 3050 cm³
Rated power as per ISO 9249 58 / 79 kW / PS
Rated speed 2800 min-1
Maximum torque at 1680 min-1 281 Nm
Lower idle speed 850 50
min-1

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Service Manual Product Description
Technical Data

Description Value Unit


Upper idle speed 3040 +80 min-1
Cylinder bore 86 mm
Stroke 105 mm
Compression ratio 18:1
Combustion pressure 24 - 28 bar
Injection nozzles / operating pressure 220 bar
Firing order 1-2-4-5-3
Inlet and outlet valve lash Hydraulic
adjustment
Injection pump Pump elements
Controller Mechanical
Turbocharger Constant
Longitudinal / traverse inclinability 30 °
Current / power consumption of starter 12 / 2.2 V / kW
Alternator voltage output 12 V
Alternator current output 65 A
Conversion factor 4.115
Frequency KL.W / engine speed
Coolant thermostat opening temperature 82.2 °C
Minimum pressure in cooling system after 1.4 bar
pump
Auxiliary drive transmission 1.03 i
Weight 237 kg
Emission thresholds comply with EU – RL 97/68 EC Stage II

Coupling
Description Value Unit
Type CF-K-100-10- -
64137
Tightening torque for elastic element fixing 40 Nm
bolts (8 pcs.)
Tightening torque for start coupling fixing 45+5 Nm
bolts (2 pcs.)

Fuel system
Description Value Unit
Tank capacity, FULL 80 l
Tank capacity, RESERVE 20 l

Fuel pre-filter
Description Value Unit
Type In-line filter -
Filtration grade 700 µ

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Fuel fine filter


Description Value Unit
Type Replaceable -
cartridge
Filtration grade 5 µ

Vaccum switch
Description Value Unit
Air filter contamination vacuum switch 50 mbar
activation point

Pre-glow system
Description Value Unit
Resistance 1

2.1.3 Cooling system

Cooling system
Description Value Unit
Fan speed (depending on engine speed and 470 - 3100 min-1
temperature)
Operating pressure, fan speed at 1100 mA
Coolant up to 87 °C, Hydraulic oil up to 57 °C
At low idle: 6 ±3 bar
470 ±50 min-1
At high idle: 10 ±3 bar
580 ±50 min-1
Operating pressure, fan speed at 380 mA
Coolant 92 °C to 100 °C
Hydraulic oil 75 °C to 90 °C
At low idle: 20 ±3 bar
1000 ±100 min-1
At high idle: 140 ±10 bar
2600 ±100 min-1
Proportional pressure relief valve resistance 4,8
at 20 °C
Pressure relief valve 210 bar

Hydraulic oil and coolant temperature sensors


Description Value Unit
Measuring range -30 to +130 °C
Resistance at 20°C 1112

Gear pump
Description Value Unit
Capacity 9 cm³
Flow rate (at rated speed) 26 l/min

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Service Manual Product Description
Technical Data

Gear motor
Description Value Unit
Displacement 8 cm³
Maximum pressure 210 bar

2.1.4 Travel hydraulics

Variable displacement pump


Valid for: L506 - 776 / from 9099; L507 - 777 / from 9099; L508 - 778 / from 9099;
ID 10023219
Description Value Unit
Control type DA
Maximum capacity 40 cm³
Flow rate at rated speed 109 l/min
Maximum swivel angle (both sides) 20 °
Speed (at rated speed) 2800 min-1
Power L506 37.5 kW
Power L507, L508 41.5 kW
Replenishing pump capacity 8.6 cm³
Replenishing pump flow rate 22 l/min
(at rated speed)
Inlet restrictor diameter 1.8 mm
Swivel restrictor diameter 0.8 mm
Travel direction solenoid current 2.5 A
consumption
Travel direction solenoid resistance 5 Ohm
2
Replenishing pressure at upper idle speed 31 bar
±50
Start of regulation 1100 min-1
±100
Pump output at 400 bar 2300 min-1
10
Pressure relief and replenishing valves 460 bar
5
Pressure cut-off 430 bar
Weight 31 kg

Valid for: L509 - 779 / from 9099; L510 - 782 / from 9099; ID 5717294
Description Value Unit
Control type DA
Maximum capacity 56 cm³
Flow rate at rated speed 154 l/min
Maximum swivel angle (both sides) 20 °
Speed (at rated speed) 2800 min-1
Power L508 41.5 kW
Power L509 48.5 kW
Power L510 52.2 kW
Replenishing pump capacity 11.6 cm³
Replenishing pump flow rate 29.5 l/min

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Product Description Service Manual
Technical Data

Description Value Unit


(at rated speed)
Inlet restrictor diameter 1.8 mm
Swivel restrictor diameter 1.0 mm
Travel direction solenoid current consumption 2.5 A
Travel direction solenoid resistance 5 Ohm
2
Replenishing pressure at upper idle speed 30 bar
±50
Start of regulation 1100 min-1
±100
Pump output at 400 bar 2300 min-1
10
Pressure relief and replenishing valves 490 bar
5
Pressure cut-off 460 bar
Weight 38 kg

Variable displacement motor


Valid for: L506 - 776 / from 9099; L507 - 777 / from 9099; L508 - 778 / from 9099;
ID 10023569
Description Value Unit
Type A6VM 80 DA
Maximum displacement 80 cm³
Minimum displacement 19.2 cm³
Maximum swivel angel 25 °
Minimum swivel angle 5.8 °
Maximum speed 5230 min-1
Torque ( p 400 bar) 509 Nm
Swivel restrictor (size) 0.30 mm
Regulating piston surface ratio 8 :100
Maximum discharge valve capacity 5.0 l
Discharge valve orifice diameter 1.4 mm
Current consumption of travel direction and
2.5 A
travel range 1 solenoid valves
Resistance of travel direction and travel
5 Ohm
range 1 solenoid valves
Weight 34 kg
±10
Control range while driving L506 220 bar
±10
Control range while driving L507, L508 230 bar

Valid for: L509 - 779 / from 9099; L510 - 782 / from 9099; ID 10023204
Description Value Unit
Type A6VM 107 DA
Maximum displacement 107 cm³
Minimum displacement 32.3 cm³
Maximum swivel angel 25 °
Minimum swivel angle 7.3 °
Maximum speed 4480 min-1
Torque ( p 400 bar) 681 Nm
Swivel restrictor (size) 0.45 mm

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Service Manual Product Description
Technical Data

Description Value Unit


Regulating piston surface ratio 8 :100
Maximum discharge valve capacity 8 l
Discharge valve orifice diameter 1.8 mm
Current consumption of travel direction and 2.5 A
travel range 1 solenoid valves
Resistance of travel direction and travel 5 Ohm
range 1 solenoid valves
Weight 47 kg
±10
Control range while driving 210 bar

2.1.5 Working hydraulics

Working hydraulics pump


Valid for: L506 - 776 / from 9099; L507 - 777 / from 9099; ID 10023207
Description Value Unit
Capacity 23 cm³
Flow rate at rated speed 64.4 l/min
Speed at rated speed 2800 min -1
Power L506 22.5 KW
Power L507 24.7 KW
10
LS steering pressure relief valve 180 bar

Valid for: L508 - 778 / from 9099; L509 - 779 / from 9099; L510 - 782 / from 9099;
ID 10023228
Description Value Unit
Capacity 33 cm³
Flow rate at rated speed 92.4 l/min
Speed at rated speed 2800 min -1
Power L508, L509 29.3 KW
Power L510 33.8 KW
10
LS steering pressure relief valve 180 bar

Control block
Description Value Unit
Spool valve diameter 14 mm
Piston stroke, both sides 7.13 mm
5
Primary pressure relief valve L506, L507 230 bar
5
Primary pressure relief valve L508, L509 190 bar
5
Primary pressure relief valve L510 210 bar
Secondary pressure relief valve / lifting 5
220 bar
(+ 1 turn)
Secondary pressure relief valve / tilting in 5
220 bar
(+ 1 turn)
Secondary pressure relief valve / tilting out 5
170 bar
(+ 1 turn)

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Product Description Service Manual
Technical Data

Description Value Unit


Secondary pressure relief valve / additional 5
195 bar
equipment (+ 1 turn)
Weight 13.7 kg

Pilot control valve


Description Value Unit
Retaining solenoid voltage 12 V
Retaining solenoid current consumption 1.22 A
Retaining solenoid resistance 60 Ohm
Weight 5.25 kg

Pilot control hydro accumulator


Description Value Unit
Hydro accumulator volume 320 cm³
Preload pressure (nitrogen filling) 15 bar

Lift cylinder
Valid for: L506 - 776 / from 9099; L507 - 777 / from 9099
Description Value Unit
Piston diameter 80 mm
Rod diameter 40 mm
Stroke length 510 mm
Minimum installation length 835 mm
Lifting at rated load 4.9 sec
Lowering empty 4.2 sec
Piston rod bearing tightening torque WN 4122-026
Piston tightening torque 650 Nm
Weight 28.5 kg

Valid for: L508 - 778 / from 9099; L509 - 779 / from 9099; L510 - 782 / from 9099
Description Value Unit
Piston diameter 100 mm
Rod diameter 50 mm
Stroke length 510 mm
Minimum installation length 835 mm
Lifting at rated load 4.9 sec
Lowering empty 4.5 sec
Piston rod bearing tightening torque WN 4122-026
Piston tightening torque 650 Nm
Weight 36.8 kg

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Service Manual Product Description
Technical Data

Tilt cylinder
Valid for: L506 - 776 / from 9099; L507 - 777 / from 9099
Description Value Unit
Piston diameter 80 mm
Rod diameter 40 mm
Stroke length 450 mm
Minimum installation length 790 mm
Tilting out at rated load 1.5 sec
Piston rod bearing tightening torque WN 4122-026
Piston tightening torque 650 Nm
Weight 27.3 kg

Valid for: L508 - 778 / from 9099


Description Value Unit
Piston diameter 100 mm
Rod diameter 50 mm
Stroke length 450 mm
Minimum installation length 790 mm
Tilting out at rated load 1.5 sec
Piston rod bearing tightening torque WN 4122-026
Piston tightening torque 650 Nm
Weight 34 kg

Valid for: L509 - 779 / from 9099; L510 - 782 / from 9099
Description Value Unit
Piston diameter 100 mm
Rod diameter 50 mm
Stroke length 450 mm
Minimum installation length 875 mm
Tilting out at rated load 1.5 sec
Piston rod bearing tightening torque WN 4122-026
Piston tightening torque 650 Nm
Weight 35.5 kg

Hydraulic tank
Valid for: L506 - 776 / from 9099; L507 - 777 / from 9099; L508 - 778 / from 9099
Description Value Unit
Hydraulic tank capacity 55 l
Weight 145 kg

Valid for: L509 - 779 / from 9099; L510 - 782 / from 9099
Description Value Unit
Hydraulic tank capacity 75 l
Weight 200 kg

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Product Description Service Manual
Technical Data

Return suction filter


Description Value Unit
Type RKM 201 -
Filtration grade 10 µm
Pre-tension valve 0.5 bar
Replenishing valve Yes -
Replenishing strainer 125 µm
Bypass valve 2.5 bar
Temperature valve 55 - 60 C°

Bleeder filter
Description Value Unit
Bleeder filtration grade 7 µm
Inlet opening pressure 0.03 bar
Outlet opening pressure 0.35 bar
Filler strainer filtration grade 800 µm

2.1.6 Steering system


Servostat
Description Value Unit
Displacement 250 cm³
Displacement in emergency operation 250 cm³
10
Secondary pressure relief valves 240 bar
Weight 6.25 kg

Steering cylinder
Description Value Unit
Piston diameter 70 mm
Rod diameter 30 mm
Stroke length 300 mm
Minimum installation length 552 mm
Piston rod bearing tightening torque WN 4122-011
Piston tightening torque 350 Nm
Weight 13.4 kg

2.1.7 Brake system

Main brake cylinder


Description Value Unit
Type SAFIM -
Maximum brake pressure 80 bar
(at 60 kg pedal force)

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Service Manual Product Description
Technical Data

Drum brake
Description Value Unit
Drum diameter 203 mm
Brake pads with 60 mm

Equalising reservoir
Description Value Unit
Filling quantity 0.2 l
Oil specification Hydraulic oil HLPD -
SAE 10 W

Brake light pressure switch


Description Value Unit
Switch type Normally open -
Switching point, falling 10 ±1 bar
Thread M10 x 1 mm

2.1.8 Electrical system

Batteries
Description Value Unit
Number of batteries 1 Unit
Voltage 12 V
Capacity 100 Ah
Cold test current (at -18°C – EN 60095-1) 760 A

2.1.9 Transfer gear

Transfer gear
Valid for: L506 - 776 / from 9099; L507 - 777 / from 9099; L508 - 778 / from 9099
Description Value Unit
Type 315 -
Transmission 2.23 -
Gear cover screw tightening torque 48 - 53 Nm
Drive flange cover screw tightening 52 - 58 Nm
torque
Input shaft screw tightening torque 250 - 270 Nm

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Product Description Service Manual
Technical Data

Valid for: L509 - 779 / from 9099; L510 - 782 / from 9099
Description Value Unit
Type 311 -
Transmission 2.28 -
Gear cover screw tightening torque 48 - 53 Nm
Drive flange cover screw 52 - 58 Nm
tightening torque
Input shaft screw tightening torque 250 - 270 Nm

2.1.10 Axles and cardan shaft

Front axle
Valid for: L506 - 776 / from 9099; L507 - 777 / from 9099; L508 - 778 / from 9099
Description Value Unit
Type 111/70 -
Self-locking differential 45 %
Width 1486 mm
Overall transmission 21.75 i
Differential transmission 3.63 i
Wheel hub transmission 6.0 i
Wheel lug tightening torque 450 Nm
Wheel lug spanner size 30 mm
Service brake Drum -
Cardan shaft flange DIN 120 -
Flange size 1530 mm
Weight 212 kg

Valid for: L509 - 779 / from 9099; L510 - 782 / from 9099
Description Value Unit
Type 112/163 -
Self-locking differential 45 %
Width 1660 mm
Overall transmission 19.09 i
Differential transmission 3.18 i
Wheel hub transmission 6.0 i
Wheel lug tightening torque 450 Nm
Wheel lug spanner size 30 mm
Service brake Drum -
Cardan shaft flange DIN 120 -
Flange size 1660 mm
Weight 280 kg

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Service Manual Product Description
Technical Data

Rear axle
Valid for: L506 - 776 / from 9099; L507 - 777 / from 9099; L508 - 778 / from 9099
Description Value Unit
Type 315/211/164 -
Locking value 25 %
Width 1486 mm
Overall transmission 48.5 i
Differential transmission 3.44 i
Wheel hub transmission 6.0 i
Wheel lug tightening torque 450 Nm
Wheel lug spanner size 30 mm
Service brake Drum -
Cardan shaft flange DIN 120 -
Flange size 1530 mm
Swing angle 5 °
Weight 290 kg

Valid for: L509 - 779 / from 9099; L510 - 782 / from 9099
Description Value Unit
Type 311/212/113 -
Locking value 25 %
Width 1660 mm
Overall transmission 43.53 i
Differential transmission 3.18 i
Wheel hub transmission 6.0 i
Wheel lug tightening torque 450 Nm
Wheel lug spanner size 30 mm
Service brake Drum -
Cardan shaft flange DIN 120 -
Flange size 1660 mm
Swing angle 5 °
Weight 408 kg

Cardan shaft
Valid for: L506 - 776 / from 9099; L507 - 777 / from 9099; L508 - 778 / from 9099
Description Value Unit
Minimum length 1533 mm
Maximum length 1593 mm
Flange tightening torque 60 Nm
Weight 22 kg

Valid for: L509 - 779 / from 9099; L510 - 782 / from 9099
Description Value Unit
Minimum length 1505 mm
Maximum length 1565 mm

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Product Description Service Manual
Technical Data

Description Value Unit


Flange tightening torque 60 Nm
Weight 21 kg

2.1.11 Machine frame and ballast weight

Articulation bearing
Description Value Unit
Tightening torque of bolts 70 Nm

Left ballast weight


Valid for: L506 - 776 / from 9099; L507 - 777 / from 9099
Description Value Unit
Weight 232 kg
Material GG10 -

Valid for: L508 - 778 / from 9099; L509 - 779 / from 9099
Description Value Unit
Weight per ballast weight 408 kg
Material GG10 -

Valid for: L510 - 782 / from 9099


Description Value Unit
Weight per ballast weight 567 kg
Material GG10 -

Right ballast weight


Valid for: L506 - 776 / from 9099
Description Value Unit
Weight per ballast weight 260 kg
Material GG10 -

Valid for: L506 - 777 / from 9099; L508 - 778 / from 9099
Description Value Unit
Weight per ballast weight 335 kg
Material GG10 -

Valid for: L509 - 779 / from 9099; L510 - 782 / from 9099
Description Value Unit
Weight per ballast weight 484 kg
Material GG10 -

2.1-22 of 28 copyright by L506 - 776 / from 9099 L508 - 778 / from 9099
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Service Manual Product Description
Technical Data

2.1.12 Automatic central lubrication system

Central lubrication pump EP-1


Description Value Unit
Flow per stroke 120 mm³
Transfer medium Greases up to
NLGI class 2
Maximum flow pressure 280 bar
System operating temperature min. -35 °C
(taking into account the pumped medium) max. +80 °C
Power system Electric
Power supply 12 V
Protection class IP 65
Reservoir position Upright
Direction of rotation of agitator Direction of
arrow
Default lubrication time 5 min
Default idle time 1 Hours
Adjustable lubrication time 1 - 16 min
Adjustable idle time 0.5 - 8 Hours

Progressive distributor

MX-F
Description Value Unit
Maximum operating pressure at input 300 bar
Distributor temperature range min. -35 °C
(taking into account transfer medium) max. +100 °C
Transfer medium Greases up to
NLGI class 2

MX-F 25
Description Value Unit
Flow per outlet 25 mm³
Flow per element 50 mm³
Piston diameter 3 mm

MX-F 45
Description Value Unit
Flow per outlet 45 mm³
Flow per element 90 mm³
Piston diameter 4 mm

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Product Description Service Manual
Technical Data

MX-F 75
Description Value Unit
Flow per outlet 75 mm³
Flow per element 150 mm³
Piston diameter 5 mm

MX-F 105
Description Value Unit
Flow per outlet 105 mm³
Flow per element 210 mm³
Piston diameter 6 mm

2.1.13 Cab, heating and air-conditioning

Heating and ventilation


Description Value Unit
Number of blower levels 3
Air flow at blower level 1 / 2 / 3 615 / 750 / 1000 m³/h
-1
Fan speed at blower level 1 / 2 / 3 2280 / 2735 / 3630 min
Current consumption, unhindered 1 / 2 / 3 10.1 / 13.8 / 22.3 A
Voltage 12 V
Heating power 11.3 kW

Fresh and circulated air filter


Description Value Unit
Filter class EU5
Filtration grade 10 µ
Filter surface (effective) 0.58 m²

Air-conditioning system
Description Value Unit
Refrigerant R134a
Coolant quantity 1400 g
Cooling power 6.4 kW
Coolant oil PAG ZXL 100PG
Coolant oil quantity 150 cm3

Pressure switch
Description Value Unit
Low pressure switch OFF 1.5 bar
Low pressure switch ON 2.9 bar
High pressure switch OFF 25.0 bar
High pressure switch ON 19.0 bar

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Service Manual Product Description
Technical Data

Temperature switch
Description Value Unit
Temperature switch adjustment range -1 to +14 °C
Temperature switch activation
5 ±1 °C
temperature
Temperature switch deactivation
1 ±1 °C
temperature

2.1.14 Lift arms and quick-change device

Lift arm
Valid for: L506 - 776 / from 9099; L507 - 777 / from 9099; L508 - 778 / from 9099
Description Value Unit
Lift arm length 2150 mm
Weight of complete lift arms (without 467 kg
cylinder)
Bucket arm weight 335 kg
Deflection lever weight 88 kg
Weight of complete connecting link 44 kg

Valid for: L509 - 779 / from 9099; L510 - 782 / from 9099
Description Value Unit
Lift arm length 2250 mm
Weight of complete lift arms 507 kg
(without cylinder)
Bucket arm weight 375 kg
Deflection lever weight 88 kg
Weight of complete connecting link 44 kg

Quick-change device
Description Value Unit
Additional control
Control, activation and operation -
lever
Lockout Changeover valve -
Lockout display Visual -
A - system connection size 852 mm
B - width 852 mm
H - height 382 mm
T - depth 119 mm
Weight 49 kg

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Technical Data

2.1.15 Equipment and accessories

Standard bucket

Valid for: L506 - 776 / from 9099


Description Value Unit
B - bucket width 1900 mm
B1 - loading size 1830 mm
H - height 863 mm
L - length with teeth 936 mm
L1 - length without teeth 820 mm
Specific material weight 1.8 t/m3
Heaped bucket capacity (ISO 7546) 0.8 m3
Weight 307 kg
Type of teeth ESCO V13 -
Number of teeth 7 Pc.

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Service Manual Product Description
Technical Data

Valid for: L507 -777 / from 9099


Description Value Unit
B - bucket width 2050 mm
B1 - loading size 1980 mm
H - height 863 mm
L - length with teeth 910 mm
L1 - length without teeth 820 mm
Specific material weight 1.8 t/m 3
Heaped bucket capacity (ISO 7546) 0.9 m3
Weight 321 kg
Type of teeth ESCO V13 -
Number of teeth 7 Pc.

Valid for: L508 - 778 / from 9099


Description Value Unit
B - bucket width 2100 mm
B1 - loading size 2030 mm
H - height 901 mm
L - length with teeth 1032 mm
L1 - length without teeth 820 mm
Specific material weight 1.8 t/m 3
Heaped bucket capacity (ISO 7546) 1.0 m3
Weight 356 kg
Type of teeth ESCO V13 -
Number of teeth 7 Pc.

Valid for: L509 - 779 / from 9099


Description Value Unit
B - bucket width 2200 mm
B1 - loading size 2130 mm
H - height 915 mm
L - length with teeth 1062 mm
L1 - length without teeth 946 mm
Specific material weight 1.8 t/m 3
Heaped bucket capacity (ISO 7546) 1.1 m3
Weight 408 kg
Type of teeth ESCO V13 -
Number of teeth 7 Pc.

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Product Description Service Manual
Technical Data

Valid for: L510 - 782 / from 9099


Description Value Unit
B - bucket width 2330 mm
B1 - loading size 2260 mm
H - height 915 mm
L - length with teeth 1062 mm
L1 - length without teeth 946 mm
Specific material weight 1.8 t/m3
Heaped bucket capacity (ISO 7546) 1.2 m3
Weight 422 kg
Type of teeth ESCO V13 -
Number of teeth 7 Pc.

Forklift

Description Value Unit


Prong length 1200 mm
L - Length (fork carrier + prongs) 1585 mm
K - Fork carrier width 1245 mm
H - Height (fork carrier + prongs) 860 mm
Weight (fork carrier + prongs) 255 kg

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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 .......................................................3.4-1
3.4.2 Lubrication chart ...................................................................3.4-3

3.5 Maintenance tasks..........................................................................3.5-1


3.5.1 Preparatory tasks for maintenance ......................................3.5-1
3.5.2 Checking the machine for external damage.........................3.5-4
3.5.3 Checking that all screw connections are tight ......................3.5-5
3.5.4 Sealing any leaks .................................................................3.5-5
3.5.5 Checking the oil level in the diesel engine ...........................3.5-5
3.5.6 Changing the engine oil........................................................3.5-6
3.5.7 Replacing the oil filter ...........................................................3.5-6
3.5.8 Draining off condensate from the fuel fine filter....................3.5-7
3.5.9 Replacing the fuel pre-filter ..................................................3.5-8
3.5.10 Cleaning the service cap and dust extraction valve on the
air filter ..................................................................................3.5-9
3.5.11 Changing the air filter main element when indicated by
the vacuum switch ................................................................3.5-9
3.5.12 Checking the coolant level .................................................3.5-10
3.5.13 Checking the antifreeze......................................................3.5-11
3.5.14 Cleaning the cooling system ..............................................3.5-13
3.5.15 Checking the oil level in the hydraulic tank ........................3.5-13
3.5.16 Lubricating the universal joints on the pilot control device .3.5-14
3.5.17 Changing the hydraulic oil ..................................................3.5-14
3.5.18 Changing the return suction filter .......................................3.5-15
3.5.19 Replacing the bleeder filter on the hydraulic tank ..............3.5-15
3.5.20 Checking the steering.........................................................3.5-16
3.5.21 Lubricating the bearing points on the steering cylinders ....3.5-16
3.5.22 Checking the service brake and parking brake ..................3.5-16

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Maintenance Service manual

3.5.23 Checking the oil level in the equalising reservoir of the


brake system...................................................................... 3.5-17
3.5.24 Checking the gap and wear on the brake linings............... 3.5-18
3.5.25 Checking the indicator lamps and lighting ......................... 3.5-18
3.5.26 Checking the oil level in the transfer gear ......................... 3.5-18
3.5.27 Changing the gear oil in the transfer gear ......................... 3.5-19
3.5.28 Checking the tightness of the wheel lugs (once after 50,
100 and 250 h)................................................................... 3.5-19
3.5.29 Checking the tightening torque of the front axle
fastening bolts.................................................................... 3.5-19
3.5.30 Greasing the lubrication points on the rear axle kingpin
bearings ............................................................................. 3.5-20
3.5.31 Checking the axle oil levels ............................................... 3.5-20
3.5.32 Changing the axle gear oil ................................................. 3.5-21
3.5.33 Checking and lubricating the drive shaft............................ 3.5-22
3.5.34 Checking and adjusting the tyre pressure ......................... 3.5-22
3.5.35 Lubricating the articulated oscillating bearing and the
rear oscillating bearing....................................................... 3.5-23
3.5.36 Lubriating the door hinges ................................................. 3.5-23
3.5.37 Cleaning or replacing the fresh air and recirculated air
filter .................................................................................... 3.5-23
3.5.38 Lubricating the lift arms and attachment............................ 3.5-24
3.5.39 Lubricating the quick-change device ................................. 3.5-25
3.5.40 Check the bearing bushings on the lift arms ..................... 3.5-25
3.5.41 Checking that the quick-change device is working
properly .............................................................................. 3.5-26

3.6 Testing and adjustment tasks ........................................................ 3.6-1


3.6.1 Preparing for testing and adjustment................................... 3.6-1
3.6.2 Safety precautions for testing and adjustment .................... 3.6-1
3.6.3 Bring the machine up to operating temperature .................. 3.6-2
3.6.4 Checking the diesel engine speed....................................... 3.6-2
3.6.5 Checking the fan motor pressure relief valve ...................... 3.6-3
3.6.6 Checking the travel hydraulics in a blocked condition......... 3.6-4
3.6.7 Check the replenishing pressure of the variable
displacement pump.............................................................. 3.6-5
3.6.8 Checking the start of regulation of the travel pump ............. 3.6-5
3.6.9 Checking the output of the travel pump............................... 3.6-6
3.6.10 Checking the pressure relief and replenishing valve of
the variable displacement pump.......................................... 3.6-7
3.6.11 Checking the pressure cut-off of the variable
displacement pump.............................................................. 3.6-7
3.6.12 Checking the variable displacement motor in the control
range.................................................................................... 3.6-8

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Service manual Maintenance

3.6.13 Checking the secondary pressure relief valves on the


control block .........................................................................3.6-9
3.6.14 Checking the primary pressure relief valves on the
control block .........................................................................3.6-9
3.6.15 Checking the pressure relief valve of the steering
system ................................................................................3.6-10
3.6.16 Checking the play of the inch/brake pedal .........................3.6-10

3.7 Lubricants and fuels........................................................................3.7-1


3.7.1 Lubricating oils for diesel engines ........................................3.7-2
3.7.2 Diesel fuels ...........................................................................3.7-3
3.7.3 Coolants for diesel engines ..................................................3.7-5
3.7.4 Hydraulic oils ........................................................................3.7-6
3.7.5 Lubricating oils for the transmission .....................................3.7-8
3.7.6 Brake oil................................................................................3.7-8
3.7.7 Grease for general lubrication points ...................................3.7-8

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Service manual Maintenance
Maintenance and inspection schedule

3.1 Maintenance and inspection schedule


The following abbreviations are used in this section:
– h = service hours
– OM = operating manual
– SM = service manual
Various symbols (solid or empty circles, boxes and stars) are used to
indicate the maintenance tasks, which fall into two main types.
The symbols have the following meanings:
Table with solid circle, box or star
– Responsibility for carrying out the maintenance work lies with the
machine operator or his maintenance personnel.
– This affects the maintenance intervals every 10 and 50 service hours (h)
and non-scheduled intervals.
The symbols have the following meanings:
Table with empty circle, box or star, or service hours (h)
– The maintenance and inspection work must be performed or supervised
by authorised engineers from LIEBHERR or its authorised dealers.
– This affects the maintenance intervals on delivery, every 500, 1000,
2000 service hours (h), and at unscheduled times.
You will find a list of the spare parts needed for maintenance and inspection
work in the “SERVICE PACKAGE” of the spare parts list.

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Maintenance Service manual
Maintenance and inspection schedule

Customer: ............................................... Machine type: .................... Ser. no.: ............................. Service hours: .............. Date: ......................
Maintenance / inspection
after service hours Tasks to be performed

by maintenance staff by authorised specialist staff


once-only activity once-only activity
repeat interval repeat interval
as necessary as necessary
annually before the winter

Complete machine
Have the driver lubricate the machine in accordance with the lubrication chart and instruct
him on proper maintenance
Instruct the driver in the operation of all functions
Check the machine for external damage
Check that all screw connections are tight
Seal any leaks
Check the hydraulic pressure according to the testing and adjustment plan
Diesel engine
Check the oil level in the diesel engine
Change the engine oil (NOTE: the operating hours stated here only apply to the
appropriate engine oil quality / for complicating factors see the lubricants and fuels
section)
Replace the oil filter
Check or replace the V-ribbed belt
Drain off condensate from the fuel fine filter
Change the fuel fine filter
Change the fuel pre-filter
Clean the service cap and dust extraction valve on the air filter
Check that the vacuum switch of the air filter works
Replace the air filter main element if indicated by the vacuum switch (replace the safety
element after having replaced the main element 3 times)
Check the air suction hoses for leaks and tight fitting
Check the exhaust system for leaks and tight fitting
Cooling system
Check the coolant level
Check the antifreeze concentration in the coolant
Replace the coolant and antifreeze (or every 2 years)
Clean the cooling system
Working hydraulics
Lubricate the pilot control device, universal joints and tappets
Check the oil level in the hydraulic tank
Change the hydraulic oil (take an oil sample every 500 hours for bio oil)
Change the return suction filter
Replace the bleeder filter on the hydraulic tank
Steering system
Check the steering
Lubricate the bearing points on the steering cylinders

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Service manual Maintenance
Maintenance and inspection schedule

Customer: ............................................... Machine type: .................... Ser. no.: ............................. Service hours: .............. Date: ......................

Maintenance / inspection
after service hours TASKS TO BE PERFORMED

by maintenance staff by authorised specialist staff


once-only activity once-only activity
repeat interval repeat interval
as necessary as necessary
annually before the winter

Brake system
Check the service brake and parking brake
Check the oil level in the equalising reservoir of the brake system
Check the gap and wear on the brake linings
Electrical system
Check the indicator lamps and lighting
Check the batteries, fluid level and terminals
Transfer gear
Check the oil level in the transfer gear
Change the gear oil in the transfer gear
Axles and tyres
Check the tightness of the wheel lugs (once after 50, 100 and 250 h) (450Nm)
Check the tightening torque of the front axle fastening bolts (750 Nm)
Grease the lubricating points on the rear axle kingpin bearings
Check the axle oil levels
Change the axle gear oil
Check and lubricate the drive shaft
Check and adjust the tyre pressure
Machine frame and ballast weight
Lubricate the articulated oscillating bearing and the rear oscillating bearing
Check the tightening torque of the bolts on the pressure flange
Check that the taper connection of the steering rods is tight
Cab, heating and air-conditioning (optional)
Check the indicator beads in the dryer-collector unit (optional)
Check that the air-conditioning system is working (optional)
Lubricate the door hinges
Clean or replace the fresh air and recirculated air filter
Lift arms and quick-change device
Lubricate the lift arms and attachment
Lubricate the quick-change device
Check the bearing bushings on the lift arms
Check the lift arms and bucket stops
Check that the quick-change device is working properly

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Service manual Maintenance
Testing and adjustment plan

3.2 Testing and adjustment plan


The tasks in the testing and adjustment plan may only be carried out by
authorised specialist staff of LIEBHERR or its contractual agents.
You can find brief instructions on performing these tasks in the section on
“testing and adjustment checklists.”
Detailed instructions can be found in the section on “testing and adjust-
ment tasks.”

Customer: ……………………… Machine type: ………...… Ser. no.: ……....…… Service hours: …….…….…… Date: ………..…………

Maintenance / inspection
after service hours
TASKS TO BE PERFORMED

by authorised specialist staff


once-only activity
repeat interval
as necessary

Diesel engine
Check the diesel engine speed
Cooling system
Check the pressure relief valve on the fan motor
Travel hydraulics
Check the replenishing pressure of the travel pump
Check the start of regulation of the travel pump
Check the output of the travel pump
Check the pressure relief and replenishing valve of the travel pump
Check the pressure cut-off of the travel pump
Check the variable displacement motor in the control range
Working hydraulics
Check the secondary pressure relief valves on the control block
Check the primary pressure relief valves on the control block
Steering system
Check the pressure relief valve of the steering system
Check the secondary pressure relief valves of the servostat
Brake system
Check the play of the inch/brake pedal

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Service manual Maintenance
Lubrication chart and filling quantities

3.3 Testing and adjustment checklists


The testing and adjustment checklists contain all testing and adjustment
tasks. You can find detailed descriptions of each activity in the section on
testing and adjustment tasks.

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Costumer: L506, L507, L508 S/N: /

Operating hours:

Type of application:
Job site: Checked by:

Checked on date:

Value Test
Adjust. Value at Adjust.
Check / Adjustment Unit after
values check adjust.
point point 1
Diesel Engine
Diesel engine RPM
12 -1 50
Low idle RPM HZ 205 min 850 1
+20 -1 +80
High idle RPM HZ 740 min 3040 1
Cooling System
Cooling system (fan control)
Fan at high diesel engine RPM / bar 14010 P
Sensor unplugged
Driving Hydraulic
Replenishing pressure
At low idle RPM bar 292 2 G
At high idle RPM bar 312 2 G

Regulation begin–var. displ. pump


High pressure bar 50 50 50 3 MA
12 -1 50
Diesel engine RPM HZ 265 min 1100
Control pressure bar 72 PST

Pump performance / 400 bar High


pressure
High pressure bar 400 400 400 4 MA
Diesel engine RPM HZ 56025 min-1 2300100
Control pressure bar 192 PST

High pressure relief valve

Forward bar 46010 1 MA

Pressure cut-off
High pressure
Engine speed drop, max. difference
bar 4305 5 MA
-1
to high idle RPM HZ 15 min 60

Variable displ. motor in regulating


range
Diesel engine RPM HZ 67512 min-1 278050
High pressure when accelerating bar 21010 7 MA
L506
High pressure when accelerating bar 23010 7 MA
L507, L508

= Blocked Machine

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Adjust. Value at Value after Adjust. Test
Check / Adjustment Unit values check adjust. point point

Working Hydraulic
Control valve block
5
Secondary pressure relief valve, lift 1) bar 220 2 P
5
Secondary press. relief valve, tilt in 1) bar 220 1 P
Secondary press. rel. valve, tilt out 1) bar 170 5 5 P

Secondary pressure rel. valve –


additional equipment 1) bar 1955 3/4 P

Control valve block


5
Primary pressure relief valve bar 230 6 P
L506, L507
Primary pressure relief valve L508 bar 1905 6 P

Ride control
Pressure relief valve bar 16010 10 P
plus ½ turn
Steering System
Priority-valve working hydraulic -
pump
Pressure relief valve - steering bar 18010 7

Servostat
Secondary pressure relief valves bar 26010 8
Brake System
Idle mouvement of the Brake-
inching pedal
Push the Inch- brake pedal softly by mm 5 9
hand
Check at running engine

Remarks: Signature:

1) Attention: The working hydraulic pump must not be loaded with more than 235 bar.
Turn out secondary relief valves by 1 turn
Adjust the secondary relief valves to the value in the table
After check / adjustment turn in secondary relief valves by 1 turn
Checking the secondary valves and the primary valve must be conducted at a diesel
engine speed of approx. 1000 rpm (242 Hz).

Check and adjust only if required

3.3 copyright by L506 - 776 / from 9099


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L508 - 778 / from 9099
Costumer: L509, L510 S/N: /

Operating hours:

Type of application:
Job site: Checked by:

Checked on date:

Value Test
Adjust. Value at Adjust.
Check / Adjustment Unit after
values check adjust.
point point 1
Diesel Engine
Diesel engine RPM
12 -1 50
Low idle RPM HZ 205 min 850 1
+20 -1 +80
High idle RPM HZ 740 min 3040 1
Cooling System
Cooling system (fan control)
Fan at high diesel engine RPM / bar 14010 P
Sensor unplugged
Driving Hydraulic
Replenishing pressure
At low idle RPM bar 282 2 G
At high idle RPM bar 302 2 G

Regulation begin–var. displ. pump


High pressure bar 50 50 50 3 MA
12 -1 50
Diesel engine RPM HZ 265 min 1100
Control pressure bar 62 PST

Pump performance / 400 bar High


pressure
High pressure bar 400 400 400 4 MA
Diesel engine RPM HZ 56025 min-1 2300100
Control pressure bar 152 PST

High pressure relief valve

Forward bar 49010 1 MA

Pressure cut-off
5
High pressure bar 460 5 MA
-1
Engine speed drop, max. difference min 60
to high idle RPM HZ 15

Variable displ. motor in regulating


range
Diesel engine RPM HZ 67512 min-1 278050
High pressure when accelerating bar 21010 7 MA

= Blocked Machine

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MJFCIFSS
Adjust. Value at Value after Adjust. Test
Check / Adjustment Unit values check adjust. point point

Working Hydraulic
Control valve block
5
Secondary pressure relief valve, lift 1) bar 220 2 P
5
Secondary press. relief valve, tilt in 1) bar 220 1 P
Secondary press. rel. valve, tilt out 1) bar 170 5 5 P

Secondary pressure rel. valve –


additional equipment 1) bar 1955 3/4 P

Control valve block


5
Primary pressure relief valve L509 bar 190 6 P
5
Primary pressure relief valve L510 bar 210 6 P

Ride control
Pressure relief valve bar 16010 10 P
plus ½ turn
Steering System
Priority-valve working hydraulic -
pump
Pressure relief valve - steering bar 18010 7

Servostat
Secondary pressure relief valves bar 26010 8
Brake System
Idle mouvement of the Brake-
inching pedal
Push the Inch- brake pedal softly by mm 5 9
hand
Check at running engine

Remarks: Signature:

1) Attention: The working hydraulic pump must not be loaded with more than 235 bar.
Turn out relief valves by 1 turn
Adjust the secondary relief valves to the value in the table
After check / adjustment turn in secondary relief valves by 1 turn
Checking the secondary valves and the primary valve must be conducted at a diesel
engine speed of approx. 1000 rpm (242 Hz).

Check and adjust only if required

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Service manual Maintenance
Lubrication chart and filling quantities

3.4 Lubrication chart and filling quantities


3.4.1 Table of filling quantities
Specifications in the medium column:
– The standard “lubricants and fuels” required for central European climate
conditions are stated here.
– Before you change or top up the oil in the hydraulic system (hydraulic
tank), always check if it is filled with petroleum or bio oil.
– For more detailed information about the required lubricants and service
fuels, see the section on “lubricants and fuels.”
Specifications in the dosage column:
– The values stated for the filling quantities in the table are only guidelines.
– The dipstick and level markings are always mandatory.
– Each time the oil is replaced or topped up, check the level in the unit in
question.

Valid for: L506 - 476 / from 9099; L507 - 477 / from 9099; L508 - 478 / from 9099;
Description Medium Dosage Unit
Diesel engine Engine oil 8.0 l
(with filter change) SAE 10W - 40

Diesel engine cooling Coolant 10.0 l


system
Total capacity

Hydraulic system Engine oil 90.0 l


Total capacity SAE 20W - 20

Hydraulic tank Engine oil 55.0 l


SAE 20W - 20

Brake system Hydraulic oil HLPD 0.8 l


Total capacity (petroleum)
SAE 10W
Transfer gear Gear oil 0.6 l
SAE 90 LS

Front axle differential Gear oil 4.3 l


SAE 90 LS

Front axle wheel hubs Gear oil 2 x 0.9 l


SAE 90 LS

Rear axle differential Gear oil 3.7 l


SAE 90 LS

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Maintenance Service manual
Lubrication chart and filling quantities

Description Medium Dosage Unit


Rear axle wheel hubs Gear oil 2 x 0.9 l
SAE 90 LS

Air-conditioning system Refrigerant approx. g


R 134a 1400

Valid for: L509 - 779 / from 9099; L510 - 782 / from 9099
Description Medium Dosage Unit
Diesel engine Engine oil 11.25 l
(with filter change) SAE 10W - 40

Diesel engine cooling Coolant 12.0 l


system
Total capacity

Hydraulic system Engine oil 100.0 l


Total capacity SAE 20W - 20

Hydraulic tank Engine oil 75.0 l


SAE 20W - 20

Brake system Hydraulic oil 0.8 l


Total capacity HLPD
SAE 10W

Transfer gear Gear oil 0.7 l


SAE 90 LS

Front axle differential Gear oil 7.5 l


SAE 90 LS

Front axle wheel hubs Gear oil 2 x 0.85 l


SAE 90 LS

Rear axle differential Gear oil 6.3 l


SAE 90 LS

Rear axle wheel hubs Gear oil 2 x 0.85 l


SAE 90 LS

Air-conditioning system Refrigerant approx. 1400 g


R 134a

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Service manual Maintenance
Lubrication chart and filling quantities

3.4.2 Lubrication chart


The lubrication chart provides an overview of the location of the maintenan-
ce points on the machine and of the maintenance intervals.
You will find detailed information in the “maintenance and inspection schedule”,
as well as in the individual descriptions in the section on “maintenance tasks.”
For more detailed information about the required lubricants and service
fuels, see the section on “lubricants and fuels.”
For information about the required filling quantities, see the “tables of fil-
ling quantities.”

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Maintenance Service manual
Lubrication chart and filling quantities

Symbol Description Symbol Description

General lubrication points Lubrication

Check the oil level Check the coolant level

Oil change

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Service manual Maintenance
Maintenance tasks

3.5 Maintenance tasks


On completion of servicing, the machine should be returned to the
operating position.
See the description of the “operating position” in the “operation” section of
the operating manual.

3.5.1 Preparatory tasks for maintenance


Before performing the various maintenance tasks, move the machine to
maintenance position unless otherwise explicitly specified in the description.
The various maintenance tasks include:
– Lubricating the lift arms,
– Checking the oil level or changing the oil in the engine, gears, axles,
hydraulic tank, etc.,
– Replacing filters as well as adjustment and repair work on the
hydraulic system.

Safety precautions for maintenance


Always observe the accident prevention regulations during mainte-
nance work.
See the “safety regulations” section for measures to ensure safe maintenance.
Make sure that visual contact between the operator in the cab and main-
tenance personnel is always maintained.

Visual contact
There is a risk of accidents for maintenance personnel!
Danger
The presence of unauthorised persons on the machine can place the
maintenance personnel in extreme danger.
! Never enter a dangerous area of the machine without making your pre-
sence known.
Make sure you can be clearly seen before entering one of the machine's
danger areas.
Secure the machine against rolling away with wheel wedges.

Wheel wedges

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