en

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

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:
 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
 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 Tightening torques for screws .............................................. 1.3-1
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 Service manual General informations
Safety regulations

1.1 Safety regulations

Working on the machine poses safety risks to the operator, driver or
maintenance engineers. You can prevent risks and accidents by regularly
reading and observing the various safety instructions.
This is especially important for personnel who only occasionally work on the
machine, for example, carrying out rigging or maintenance work. The safety
regulations listed below, if conscientiously followed, will ensure your own
safety and that of others, and will prevent the machine from being damaged.
Whenever tasks which could cause danger to personnel or damage to the
machine are described, the necessary safety precautions are explained in
this manual.
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.
Actions to avert the danger.

CAUTION
Risk of personal injury.
Denotes a potentially dangerous situation which can lead to slight injury if
not avoided.
Actions to avert the danger.

NOTICE
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Risk of damage to the machine.

Denotes actions or circumstances which may result in damage to the machine.
Actions to avert the danger.

Note
Useful information
Denotes information on correctly handling the machine and the lubricants
and fuels used.
Actions to implement.

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General informations Service manual
Safety regulations

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
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 Service manual General informations
Safety regulations

1.2 Special tools for maintenance and

repair work
1.2.1 Special tools in general
Description ID no. Use Remarks
For checking the acid concentration
Anti-freeze and battery tester 7408922 All wheel loaders
(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 0 - 250 bar 5002932 All wheel loaders For checking the hydraulic pressure
Manometer 0 - 600 bar 5002866 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
For securing the valves on the variable
Safety cap 10 mm 7009315 All wheel loaders
adjustment motor
Safety cap 13 mm 7615515 All wheel loaders For securing the valves on the pumps
Safety cap 17 mm 7615589 All wheel loaders For securing the valves on the pumps
Safety cap 19 mm 7009317 All wheel loaders For securing the valves on the pumps
For securing the valves on the control
Safety cap 17 mm 7622068 All wheel loaders
block
USB dongle 10333608 L524 - L586 With SERVICE authorisation
For adjusting the travel hydraulics, and
Diagnostic data cable 9067426 L524 - L586
testing the electrical system and options
For communicating with the wheel loader
Adapter cable RS232<>USB 693190714 All wheel loaders electronics if there is an error with the
RS232 interface on the notebook.

1.2.2 Special tools for Liebherr diesel engines

Description ID no. Use Remarks
Compression tester 8008782 Engine For checking the compression
Nozzle tester 7361236 L538, L542 engine For checking the injection valves
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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
For pushing the piston rings together
Piston ring tensioning belt 8000592 All wheel loaders
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
For installing the rear oil seal ring and
Installation set 7090378 L524, L528 engine
wear ring

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General informations Service manual
Special tools for maintenance and repair work

Description ID no. Use Remarks

For measuring the valve depth in the
Depth gauge 7090370 L524 - L542 engine cylinder head and for measuring the
piston and bushing height
For removing the rear crankshaft oil
Extractor tool 7090376 L524, L528 engine
seal ring and wear ring
For installing and removing the
Extractor tool 7090363 L524, L528 engine
cylinder bushings
For screws on cylinder head, main
Angle wrench 0524062 L538, L542 engine
bearing and big end bearing

1.2.3 Special tools for hydraulic cylinders

Description ID no. Use Remarks
L524, L528 P kinematics tilt
Assembly sleeve 80 mm 9227165 For fitting the seals
cylinder
L524 - L542 steering cylinder
Assembly sleeve 90 mm 9227161 L538, L542 P kinematics tilt For fitting the seals
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
Assembly sleeve 120 mm 9998778 For fitting the seals
cylinder
L538, L542 Z kinematics tilt
Assembly sleeve 140 mm 9998623 For fitting the seals
cylinder
L524, L528 P kinematics tilt
Expansion sleeve 80 mm 9227166 For fitting the seals
cylinder
L524 - L542 steering cylinder
Expansion sleeve 90 mm 9227162 L538, L542 P kinematics tilt For fitting the seals
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
L524, L528 Z kinematics tilt
Expansion sleeve 120 mm 9110407 For fitting the seals
cylinder
L538, L542 Z kinematics tilt
Expansion sleeve 140 mm 9110409 For fitting the seals
cylinder
Piston spanner 80/12 mm 8007364 L524 - L542 lift cylinder For fitting the piston
L524, L528 Z kinematics tilt
Piston spanner 88/12 mm 8007365 For fitting the piston
cylinder
L538, L542 Z kinematics tilt
Piston spanner 100/14 mm 8007366 For fitting the piston
cylinder
Piston nut spanner 9921123 L524 - L542 lift cylinder For fitting the piston nut
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L524 - L542 P Z kinematics

Piston nut spanner 9921124 For fitting the piston nut
tilt cylinder
L524, L528 P kinematics tilt
Piston spanner 52/10 mm 9131359 For fitting the piston
cylinder
L524, L528 P kinematics tilt
Piston rod bearing spanner 9210219 For fitting the piston rod bearing
cylinder
L538, L542 P kinematics tilt
Piston spanner 60/14 mm 9131362 cylinder For fitting the piston
L524 - L542 steering cylinder
L538, L542 P kinematics tilt
Piston rod bearing
0541665 cylinder For fitting the piston rod bearing
spanner 76/9 mm
L524 - L542 steering cylinder

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 Service manual General informations
Safety regulations

1.2.4 Special tools for electronics

Description ID no. Use Remarks
For measuring voltage, current,
Digital multimeter 8502956 All wheel loaders
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
2 8460263 All wheel loaders For MATE-N-LOK connectors
0.5 - 6.0 mm
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
8145674 All wheel loaders For DEUTSCH connectors
and bushing
Extraction tool size 16 for pin
8145673 All wheel loaders For DEUTSCH connectors
and bushing
Extraction tool size 20 for pin
8503630 All wheel loaders For DEUTSCH connectors
and bushing
Plug-in fuse tester 8145834 All wheel loaders For checking the fuses
Wide METRI-PACK For removing terminals on the main
7091022 L524, L528
extractor tool connector of the ECU engine controller
Narrow METRI-PACK For removing terminals on the main
7091023 L524, L528
extractor tool connector of the ECU engine controller

1.2.5 Special tools for axles

Description ID no. Use Remarks
L524 - L542 axles For relieving the disc springs and for
Hand pump 8145835
testing the tightness of the disc brakes
L524 - L542 axles For inspecting the wear on the wet disc
Feeler gauge 8145535
brake (T1-2313)
L524 - L542 axles For gripping whilst installing or removing
Set of 5 spanners 10220617
the bevel gear shaft (T5-2386)
L524 - L542 axles For installing the shaft seal ring in the hub
Driver, Øa=185 mm 10220623
(T10-3502)
L524 - L542 axles For removing and fitting the differential
Slotted nut spanner 10220633
gear (T13-3333)
L524 - L542 axles
Handle for driver 10220624 Required for holding the driver
Slotted nut spanner with L524 - L542 axles For removing and fitting the bevel gear
10220626
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adapter shaft (T22-3317/A)

L524 - L542 axles For installing the shaft seal ring in the axle
Driver, Øa=62.5 mm 10220631
casing (T34-2322)
L524 - L542 axles For installing the shaft seal ring in the
Driver, Øa=90 mm 10220632
bearing bushing of the axle (T5-3342)

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Special tools for maintenance and repair work

1.2.6 Central lubrication system

Description ID no. Use Remarks
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
For inspecting the
data cable 7624289 All wheel loaders
central lubrication system
Groeneveld central lubrication
For inspecting the
plug adapter 7624290 All wheel loaders
central lubrication system
Groeneveld central lubrication
For inspecting the
software As below All wheel loaders
central lubrication system

1.2.7 Special tools for the air conditioning system

Description ID no. Use Remarks
For evacuating the air
Vacuum pump 7027552 All wheel loaders
conditioning system
For testing, evacuating and filling the air
4-valve test fitting 7027558 All wheel loaders
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

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 Service manual General informations
Mjfcifss - Standard

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
Standard and fine metric threads. All figures are for bolted connections
All figures are for bolted connections with at least one Dacromet
without any Dacromet 500 coated elements (screws, washers, nuts…)
500 coated element (screws, washers, nuts…)
Surface: Surface:
- DACROMET 500 - black finish or phosphated
- FLZN (Zinc disc coating according to Liebherr standard - zinc-plated
10021432)
Assembly pre- Tightening Assembly pre- Tightening
Thread Class loading forces torques Thread Class loading forces torques MA in
FM in N MA in Nm FM in N Nm
for avg. coefficient of friction µG= 0.10 for avg. coefficient of friction µG= 0.12
8.8 4 200 2,5 8.8 4 050 2,8
M4 10.9 6 200 3,7 M4 10.9 6 000 4,1
12.9 7 300 4,3 12.9 7 000 4,8
8.8 6 900 4,9 8.8 6 600 5,5
M5 10.9 10 100 7,3 M5 10.9 9 700 8,1
12.9 11 900 8,5 12.9 11 400 9,5
8.8 9 700 8,5 8.8 9 400 9,5
M6 10.9 14 300 12,5 M6 10.9 13 700 14,0
12.9 16 700 14,5 12.9 16 100 16,5
8.8 14 200 14,0 8.8 13 700 15,5
M7 10.9 20 900 20,5 M7 10.9 20 100 23,0
12.9 24 500 24,0 12.9 23 500 27
8.8 17 900 20,5 8.8 17 200 23
M8 10.9 26 000 30 M8 10.9 25 000 34
12.9 30 500 35 12.9 29 500 40
8.8 19 600 22 8.8 18 800 24,5
M8x1 10.9 28 500 32 M8x1 10.9 27 500 36
12.9 33 500 38 12.9 32 500 43
8.8 25 500 32 8.8 24 800 36
M9x1 10.9 38 000 46 M9x1 10.9 36 500 53
12.9 44 000 54 12.9 42 500 62
8.8 28 500 41 8.8 27 500 46
M10 10.9 42 000 60 M10 10.9 40 000 68
12.9 49 000 71 12.9 47 000 79
8.8 32 500 45 8.8 31 500 52
M10x1 10.9 48 000 67 M10x1 10.9 46 500 76
12.9 56 000 78 12.9 54 000 89
8.8 30 500 43 8.8 29 500 49
M10x1,25 10.9 45 000 64 M10x1,25 10.9 43 000 72
12.9 53 000 74 12.9 51 000 84
8.8 41 500 71 8.8 40 000 79
M12 10.9 61 000 104 M12 10.9 59 000 117
12.9 71 000 121 12.9 69 000 135
8.8 46 500 77 8.8 45 000 87
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M12x1,25 10.9 68 000 112 M12x1,25 10.9 66 000 125

12.9 80 000 130 12.9 77 000 150
8.8 44 000 74 8.8 42 500 83
M12x1,5 10.9 65 000 108 M12x1,5 10.9 62 000 122
12.9 76 000 125 12.9 73 000 145
8.8 57 000 113 8.8 55 000 125
M14 10.9 84 000 165 M14 10.9 80 000 185
12.9 98 000 195 12.9 94 000 215
8.8 63 000 121 8.8 61 000 135
M14x1,5 10.9 92 000 175 M14x1,5 10.9 89 000 200
12.9 108 000 205 12.9 104 000 235

Date Works Issued Reviewed Approved

04.08.2011 LBH Roland Weber Dr. Herbert Pfab Dr. Herbert Pfab
This document must not be copied or reproduced without prior permission. This Liebherr-Norm_DE_V001.dot
document has been electronically prepared and is valid without requiring a signature.
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General informations Service manual
Mjfcifss - Standard

Assembly pre- Tightening Assembly pre- Tightening

Thread Class loading forces torques Thread Class loading forces torques MA in
FM in N MA in Nm FM in N Nm
for avg. coefficient of friction µG= 0.10 for avg. coefficient of friction µG= 0.12
8.8 78 000 170 8.8 75 000 195
M16 10.9 115 000 250 M16 10.9 111 000 280
12.9 134 000 300 12.9 130 000 330
8.8 85 000 180 8.8 82 000 205
M16x1,5 10.9 125 000 270 M16x1,5 10.9 121 000 300
12.9 147 000 310 12.9 141 000 360
8.8 98 000 245 8.8 94 000 280
M18 10.9 140 000 350 M18 10.9 135 000 390
12.9 164 000 410 12.9 157 000 460
8.8 114 000 270 8.8 110 000 310
M18x1,5 10.9 163 000 390 M18x1,5 10.9 157 000 440
12.9 191 000 450 12.9 184 000 520
8.8 106 000 260 8.8 102 000 290
M18x2 10.9 151 000 370 M18x2 10.9 146 000 420
12.9 177 000 430 12.9 170 000 490
8.8 126 000 350 8.8 121 000 390
M20 10.9 180 000 490 M20 10.9 173 000 560
12.9 210 000 580 12.9 202 000 650
8.8 144 000 380 8.8 139 000 430
M20x1,5 10.9 206 000 540 M20x1,5 10.9 199 000 620
12.9 240 000 630 12.9 232 000 720
8.8 157 000 470 8.8 152 000 530
M22 10.9 224 000 670 M22 10.9 216 000 750
12.9 260 000 780 12.9 250 000 880
8.8 177 000 510 8.8 171 000 580
M22x1,5 10.9 255 000 720 M22x1,5 10.9 245 000 820
12.9 295 000 840 12.9 285 000 960
8.8 182 000 600 8.8 175 000 670
M24 10.9 260 000 850 M24 10.9 249 000 960
12.9 305 000 1000 12.9 290 000 1 120
8.8 215 000 700 8.8 207 000 760
M24x1,5 10.9 306 000 990 M24x1,5 10.9 295 000 1 090
12.9 358 000 1170 12.9 346 000 1 270
8.8 203 000 640 8.8 196 000 730
M24x2 10.9 290 000 920 M24x2 10.9 280 000 1 040
12.9 340 000 1070 12.9 325 000 1 220
8.8 239 000 880 8.8 230 000 1 000
M27 10.9 340 000 1250 M27 10.9 330 000 1 400
12.9 400 000 1450 12.9 385 000 1 650
8.8 276 000 1010 8.8 267 000 1 110
M27x1,5 10.9 394 000 1440 M27x1,5 10.9 381 000 1 580
12.9 461 000 1690 12.9 445 000 1 850
8.8 265 000 940 8.8 255 000 1 070
M27x2 10.9 375 000 1350 M27x2 10.9 365 000 1 500
12.9 440 000 1550 12.9 425 000 1 800
8.8 290 000 1190 8.8 280 000 1 350
M30 10.9 415 000 1700 M30 10.9 400 000 1 900
12.9 485 000 2000 12.9 465 000 2250
8.8 346 000 1410 8.8 335 000 1 540
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M30x1,5 10.9 493 000 2000 M30x1,5 10.9 477 000 2 190
12.9 576 000 2340 12.9 558 000 2 560
8.8 332 000 1370 8.8 321 000 1 490
M30x2 10.9 472 000 1940 M30x2 10.9 457 000 2 120
12.9 553 000 2270 12.9 534 000 2 480
8.8 360 000 1600 8.8 350 000 1 850
M33 10.9 520 000 2300 M33 10.9 495 000 2 600
12.9 600 000 2700 12.9 580 000 3 000
8.8 423 000 1880 8.8 410 000 2 050
M33x1,5 10.9 603 000 2670 M33x1,5 10.9 584 000 2 920
12.9 705 000 3130 12.9 683 000 3 420
8.8 410 000 1750 8.8 395 000 2 000
M33x2 10.9 580 000 2500 M33x2 10.9 560 000 2 800
12.9 680 000 2900 12.9 660 000 3 300
8.8 425 000 2100 8.8 410 000 2 350
M36 10.9 600 000 3000 M36 10.9 580 000 3 300
12.9 710 000 3500 12.9 680 000 3 900

This document must not be copied or reproduced without prior permission. This Liebherr-Norm_DE_V001.dot
document has been electronically prepared and is valid without requiring a signature.
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L538 - 433 / from 17890
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 Service manual General informations
Mjfcifss - Standard

Assembly pre- Tightening Assembly pre- Tightening

Thread Class loading forces torques Thread Class loading forces torques MA in
FM in N MA in Nm FM in N Nm
for avg. coefficient of friction µG= 0.10 for avg. coefficient of friction µG= 0.12
8.8 508 000 2450 8.8 492 000 2 680
M36x1,5 10.9 724 000 3490 M36x1,5 10.9 701 000 3 820
12.9 847 000 4090 12.9 820 000 4 470
8.8 455 000 2200 8.8 440 000 2 500
M36x3 10.9 650 000 3100 M36x3 10.9 630 000 3 500
12.9 760 000 3600 12.9 740 000 4 100
8.8 510 000 2700 8.8 490 000 3 000
M39 10.9 730 000 3800 M39 10.9 700 000 4 300
12.9 850 000 4500 12.9 820 000 5 100
8.8 601 000 3140 8.8 582 000 3 430
M39x1,5 10.9 857 000 4470 M39x1,5 10.9 830 000 4 890
12.9 1 002 000 5230 12.9 971 000 5 720
8.8 550 000 2800 8.8 530 000 3 200
M39x3 10.9 780 000 4000 M39x3 10.9 750 000 4 600
12.9 910 000 4700 12.9 880 000 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.
LBH/Version 01/06.2009/en/lbhhae0/05.02.2013

This document must not be copied or reproduced without prior permission. This Liebherr-Norm_DE_V001.dot
document has been electronically prepared and is valid without requiring a signature.
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copyright
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General informations Service manual
Mjfcifss - Standard

LBH/Version 01/06.2009/en/lbhhae0/05.02.2013

This document must not be copied or reproduced without prior permission. This Liebherr-Norm_DE_V001.dot
document has been electronically prepared and is valid without requiring a signature.
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 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 Engine and splitter box ......................................................... 2.1-6
2.1.3 Cooling system ..................................................................... 2.1-8
2.1.4 Travel hydraulics .................................................................. 2.1-9
2.1.5 Working hydraulics ............................................................. 2.1-11
2.1.6 Steering system .................................................................. 2.1-15
2.1.7 Brake system ...................................................................... 2.1-16
2.1.8 Electrical system ................................................................. 2.1-17
2.1.9 Transmission ...................................................................... 2.1-18
2.1.10 Axles and cardan shaft ....................................................... 2.1-18
2.1.11 Machine frame and ballast weight ...................................... 2.1-20
2.1.12 Automatic central lubrication system .................................. 2.1-20
2.1.13 Cab, heating and air-conditioning....................................... 2.1-21
2.1.14 Lift arms and quick-change device ..................................... 2.1-23
2.1.15 Equipment and accessories ............................................... 2.1-24
LBH/Version 01/07.2007/en/Trainotti Anton
(LBH)/06.02.2013

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Product description Service manual

LBH/Version 01/07.2007/en/Trainotti Anton

(LBH)/06.02.2013

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 Service manual Product description
Technical data

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
LBH/Version 01/07.2007/en/Trainotti Anton

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
(LBH)/06.02.2013

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

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Technical data

Item Description Unit Value

Load geometry Z bar P bar
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
Travel speed in travel range 2, forward and reverse km/h 0 - 16 0 - 16
Travel speed in travel range 3, forward and reverse km/h 0 - 40 0 - 40
Sound pressure level in cab according to ISO 6396 – LpA dB (A) 69 69

Valid for: L528 - 660 / 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 R25 Goodyear GP-2B tyres
– Tipping loads and weights include all lubricants, full fuel tank, ROPS/
FOPS cab and driver.
Tyre sizes and additional attachments affect the operating weight and
tipping load.

LBH/Version 01/07.2007/en/Trainotti Anton

(LBH)/06.02.2013

Dimensions of machine with Z and P lift arms

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 Service manual Product description
Technical data

Item Description Unit Value

Load geometry Z bar P bar
Bucket capacity as per ISO 7546 m³ 2.2 2.0
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 2800 2765
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 4960 4985
F Reach at maximum lifting height and 42° tilt-out angle mm 935 1090
G Digging depth mm 80 55
H Height above the cab mm 3200 3200
I Height above exhaust mm 2860 2860
J Ground clearance mm 460 460
K Wheel base mm 2850 2850
L Overall length mm 6930 7170
Turning radius over bucket outer edge mm 5660 5740
Lifting force (SAE) kN 99 70
Breakout force (SAE) kN 80 74
Tipping load when straight kg 9180 7780
Tipping load articulated at 40° kg 8100 6840
Angle of articulation (to each side) ° 40 40
Swing angle (to each side) ° 6 6
Operating weight kg 10710 11050
Tractive force daN 87.05 87.05
Travel speed in travel range 1, forward and reverse km/h 0-6 0-6
Travel speed in travel range 2, forward and reverse km/h 0 - 16 0 - 16
Travel speed in travel range 3, forward and reverse km/h 0 - 40 0 - 40
Sound pressure level in cab according to ISO 6396 – LpA dB (A) 69 69

Valid for: L538 - 433 / from 17890

The values stated refer to the standard version of the machine:
– With Z lift arms (2500 mm), without hydraulic quick-change device.
– With 20.5 R25 Goodyear GP-2B tyres
– Tipping loads and weights include all lubricants, full fuel tank, ROPS/
FOPS cab and driver.
LBH/Version 01/07.2007/en/Trainotti Anton

Tyre sizes and additional attachments affect the operating weight and
tipping load.
(LBH)/06.02.2013

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Product description Service manual
Technical data

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 2.5 2.2
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 2900 2770
B Dump height mm 3480 3430
C Maximum bucket base height mm 3680 3640
D Maximum bucket pivot point height mm 3930 3890
E Maximum bucket top height mm 5170 5190
F Reach at maximum lifting height and 42° tilt-out angle mm 960 1060
G Digging depth mm 80 55
H Height above the cab mm 3250 3250
I Height above exhaust mm 2910 2910
J Ground clearance mm 490 490
K Wheel base mm 2975 2975
LBH/Version 01/07.2007/en/Trainotti Anton

L Overall length mm 7150 7315

Turning radius over bucket outer edge mm 5840 5900
Lifting force (SAE) kN 145 95
Breakout force (SAE) kN 113 107
Tipping load when straight kg 10210 9300
(LBH)/06.02.2013

Tipping load articulated at 40° kg 9020 8200

Angle of articulation (to each side) ° 40 40
Swing angle (to each side) ° 6 6
Operating weight kg 12430 12410
Tractive force daN 96.05 96.05
Travel speed in travel range 1, forward and reverse km/h 0-6 0-6
Travel speed in travel range 2, forward and reverse km/h 0 - 16 0 - 16
Travel speed in travel range 3, forward and reverse km/h 0 - 40 0 - 40
Sound pressure level in cab according to ISO 6396 – LpA dB (A) 69 69

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 Service manual Product description
Technical data

Valid for: L542 - 435 / from 17890

The values stated refer to the standard version of the machine:
– With Z lift arms (2500 mm), without hydraulic quick-change device.
– With 20.5 R25 Goodyear GP-2B tyres
– Tipping loads and weights include all lubricants, full fuel tank, ROPS/
FOPS cab and driver.
Tyre sizes and additional attachments affect the operating weight and
tipping load.

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 2.7 2.4
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 2845 2725
B Dump height mm 3480 3430
LBH/Version 01/07.2007/en/Trainotti Anton

C Maximum bucket base height mm 3680 3640

D Maximum bucket pivot point height mm 3930 3890
E Maximum bucket top height mm 5260 5255
F Reach at maximum lifting height and 42° tilt-out angle mm 1005 1095
G Digging depth mm 80 55
(LBH)/06.02.2013

H Height above the cab mm 3250 3250

I Height above exhaust mm 2910 2910
J Ground clearance mm 490 490
K Wheel base mm 2975 2975
L Overall length mm 7225 7350
Turning radius over bucket outer edge mm 5870 5920
Lifting force (SAE) kN 144 94
Breakout force (SAE) kN 105 101

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Technical data

Item Description Unit Value

Load geometry Z bar P bar
Tipping load when straight kg 11040 10120
Tipping load articulated at 40° kg 9760 8940
Angle of articulation (to each side) ° 40 40
Swing angle (to each side) ° 6 6
Operating weight kg 13040 13070
Tractive force daN 100.47 100.47
Travel speed in travel range 1, forward and reverse km/h 0-6 0-6
Travel speed in travel range 2, forward and reverse km/h 0 - 16 0 - 16
Travel speed in travel range 3, forward and reverse km/h 0 - 40 0 - 40
Sound pressure level in cab according to ISO 6396 – LpA dB (A) 69 69

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
-1
Maximum torque at 1500 min 430 430 Nm
10 10 -1
Lower idle speed 850 850 min
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
LBH/Version 01/07.2007/en/Trainotti Anton

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
(LBH)/06.02.2013

Description Value Unit

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

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 Service manual Product description
Technical data

Description Value Unit

Rated power as per ISO 9249 105 / 143 kW / hp
Rated speed 2000 min-1
-1
Maximum torque at 1000 - 1300 min 770 Nm
Lower idle speed 900 10
min-1
20 -1
Upper idle speed 2060 min
Start of delivery Electronic
Compression ratio 17:1
Combustion pressure 20 - 34 bar
+8/-3
Injection nozzle pressure 300 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
Description Value Unit
Tank capacity, FULL 180 l
Tank capacity, RESERVE 30 l

Fuel pre-filter
Valid for: L524 - 659 / from 17890; L528 - 660 / from 17890; ID 9739 323
Description Value Unit
LBH/Version 01/07.2007/en/Trainotti Anton

Filtration grade 30 µm

Valid for: L538 - 433 / from 17890; L542 - 435 / from 17890; ID 1011 8823
Description Value Unit
Filtration grade 10 µm
(LBH)/06.02.2013

Fuel fine filter

Description Value Unit
Filtration grade 2 µm

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Technical data

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

Clutch
Valid for: L524 - 659 / from 17890; L528 - 660 / from 17890; ID 9739 323
Description Value Unit
Torsion damper screw adhesive 241 Loctite
Torsion damper screw tightening torque 49 Nm
Hub star fastening screw tightening torque 86 Nm

Valid for: L538 - 433 / from 17890; L542 - 435 / from 17890; ID 1011 8823
Description Value Unit
Torsion damper screw adhesive 241 Loctite
Torsion damper screw tightening torque 117 Nm

2.1.3 Cooling system

Gear pump
Valid for: L524 - 659 / from 17890; L528 - 660 / from 17890; ID 1029 6814
Description Value Unit
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
Description Value Unit
Capacity 14 cm³
Rotary speed at rated engine speed 2468 min-1

Valid for: L538 - 433 / from 19019; L542 - 435 / from 19019; ID 1041 2918
Description Value Unit
Capacity 16 cm³
LBH/Version 01/07.2007/en/Trainotti Anton

-1
Rotary speed at rated engine speed 2468 min

Gear motor
Valid for: ID 5717 099
(LBH)/06.02.2013

Description Value Unit

Gear motor displacement 16 cm³
5
Pressure relief valve 175 bar
Coil resistance 4.5 Ohm
41
Screw tightening torque 124 Nm

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Technical data

Temperature sensor (B8, B21)

Description Value Unit
Measuring range min. -30 °C
max. 130 °C
Resistance at 0 °C 1000 Ohm
Resistance at 20 °C 1112 Ohm
Resistance at 30 °C 1171 Ohm
Resistance at 55 °C 1322 Ohm
Resistance at 73 °C 1437 Ohm
Resistance at 78 °C 1469 Ohm
Resistance at 84 °C 1509 Ohm
Resistance at 94 °C 1577 Ohm
Resistance at 102 °C 1632 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
Description Value Unit
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
LBH/Version 01/07.2007/en/Trainotti Anton

Travel direction solenoid resistance 22 Ohm

Control pressure proportional valve resistance 12 Ohm
10
Pressure relief and replenishing valves 470 bar
5
Pressure cut-off 440 bar
(LBH)/06.02.2013

Weight 60 kg

Valid for: L538 - 433 / from 17890; L542 - 435 / from 17890
Description Value Unit
Control type EP
Maximum capacity 125 cm³
Flow rate at rated speed 246 l/min
Power 90 kW

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Technical data

Description Value Unit

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
10
Pressure relief and replenishing valves 470 bar
5
Pressure cut-off 440 bar
Weight 75 kg

Variable displacement motor 1

Valid for: L524 - 659 / from 17890; L528 - 660 / from 17890
Description Value Unit
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
5
Start of regulation 250 bar
Current consumption of travel direction 1,2 A
solenoid valve
Resistance of travel direction solenoid 22 Ohm
valve
Current consumption of travel range 1 1,4 A
solenoid valve
Resistance of travel range 1 solenoid valve 19 Ohm
Weight 26 kg

Valid for: L538 - 433 / from 17890; L542 - 435 / from 17890
Description Value Unit
LBH/Version 01/07.2007/en/Trainotti Anton

Control type HA1R

Maximum displacement 80 cm³
Minimum displacement 52 cm³
Maximum swivel angel 25 °
Minimum swivel angle 16.3 °
(LBH)/06.02.2013

Maximum speed 4560 min-1

Torque ( p 400 bar) 520 Nm
5
Start of regulation 250 bar
Current consumption of travel direction 1,2 A
solenoid valve
Resistance of travel direction solenoid 22 Ohm
valve

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 Service manual Product description
Technical data

Description Value Unit

Current consumption of travel range 1 1,4 A
solenoid valve
Resistance of travel range 1 solenoid valve 19 Ohm
Weight 34 kg

Variable displacement motor 2

Valid for: L524 - 659 / from 17890; L528 - 660 / from 17890
Description Value Unit
Control type EP
Maximum displacement 107 cm³
Maximum swivel angel 25 °
Minimum swivel angle 0 °
-1
Maximum speed 5490 min
Torque ( p 400 bar) 653 Nm
Maximum discharge valve capacity 15 l/min
Discharge valve orifice diameter 2.5 mm
Weight 47 kg

Valid for: L538 - 433 / from 17890; L542 - 435 / from 17890
Description Value Unit
Control type EP
Maximum displacement 140 cm³
Maximum swivel angel 25 °
Minimum swivel angle 0 °
Maximum speed 5030 min-1
Torque ( p 400 bar) 855 Nm
Maximum discharge valve capacity 15 l/min
Discharge valve orifice diameter 2.5 mm
Weight 60 kg

2.1.5 Working hydraulics

LBH/Version 01/07.2007/en/Trainotti Anton

Working hydraulics pump

Valid for: L524 - 659 / from 17890; L528 - 660 / from 17890
Description Value Unit
Control type DFLR
(LBH)/06.02.2013

Maximum capacity 45 cm³

Flow rate at rated speed 105 l/min
Power 40 kW
2
Flow regulator (delta p) 32 bar
Weight 21 kg

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Product description Service manual
Technical data

Valid for: L538 - 433 / from 17890; L542 - 435 / from 17890
Description Value Unit
Control type LRDS
Maximum capacity 75 cm³
Flow rate at rated speed 143 l/min
Power 51 kW
Power controller start of regulation 190 bar
2
Flow regulator (delta p) 32 bar
Weight 45 kg

Control block
Description Value Unit
Piston diameter 18 mm
Lift arm up/down control piston flow 140 / 60 l/min
Tilt in/out control piston
120 / 80 l/min
(Z kinematics) flow rate
Tilt in/out control piston
140 / 90 l/min
(P kinematics) flow rate
5
LS pressure cut-off / L524, L528 315 bar
5
Working hydraulics L538, L542 330 bar
5
LS pressure cut-off / L524, L528 230 bar
5
Steering L538, L542 250 bar
3
Pressure relief valve pre-tension 16 bar
Weight 32 kg

Pilot control valve

Description Value Unit
Retaining solenoid current consumption 0,4 A
Retaining solenoid resistance 70 Ohm
Weight 5,7 kg

Working hydraulics lockout solenoid valve

LBH/Version 01/07.2007/en/Trainotti Anton

Description Value Unit

Current consumption 0,7 A
Resistance 40 Ohm
(LBH)/06.02.2013

Pilot control hydro accumulator

Valid for: ID 7619 063
Description Value Unit
Hydro accumulator volume 320 cm³
Preload pressure (nitrogen filling) 15 bar

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Technical data

Stabilisation module
Description Value Unit
Control piston diameter 16 mm
20
Cut-off pressure (LFD off) 120 bar
10
Safety valve 330 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

Description Value Unit
Hydro accumulator volume 2000 cm³
2
Preload pressure (nitrogen filling) 25 bar
Oil filling 350 cm³

Lift cylinder
Valid for: L524 - 659 / from 17890; L528 - 660 / from 17890; ID 9609 285
Description Value Unit
Piston diameter 100 mm
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 290 Nm
screws)
Piston tightening torque WN - 4121-091 -

Valid for: L538 - 433 / from 17890; L542 - 435 / from 17890; ID 9655 214
Description Value Unit
LBH/Version 01/07.2007/en/Trainotti Anton

Piston diameter 110 mm

Rod diameter 60 mm
Stroke length 735 mm
Minimum installation length 1170 mm
(LBH)/06.02.2013

Weight 89 kg
Lifting at rated load 6.0 sec
Lowering empty 4.0 sec
Piston rod bearing tightening torque 290 Nm
(hex screws)
Piston tightening torque WN - 4121-092 -

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Technical data

Z kinematics tilt cylinder

Valid for: L524 - 659 / from 17890; L528 - 660 / from 17890; ID 9609 286
Description Value Unit
Piston diameter 120 mm
Rod diameter 70 mm
Stroke length 440 mm
Minimum installation length 870 mm
Weight 70 kg
Tilt in/out empty 3.0 sec
Piston rod bearing tightening torque 290 Nm
(hex screws)
Piston tightening torque WN - 4121-091 -

Valid for: L538 - 433 / from 17890; L542 - 435 / from 17890; ID 9655 215
Description Value Unit
Piston diameter 140 mm
Rod diameter 80 mm
Stroke length 440 mm
Minimum installation length 870 mm
Weight 110 kg
Tilt in/out empty 3.0 sec
Piston rod bearing tightening torque 290 Nm
(hex screws)
Piston tightening torque WN - 4121-173 -

P kinematics tilt cylinder

Valid for: L524 - 659 / from 17890; L528 - 660 / from 17890; ID 1030 1136
Description Value Unit
Piston diameter 80 mm
Rod diameter 50 mm
Stroke length 935 mm
Minimum installation length 1240 mm
Weight 53.5 kg
LBH/Version 01/07.2007/en/Trainotti Anton

Tilt in/out empty 3.5 sec

Valid for: L538 - 433 / from 17890; L542 - 435 / from 17890; ID 1030 1135
Description Value Unit
Piston diameter 90 mm
(LBH)/06.02.2013

Rod diameter 50 mm
Stroke length 935 mm
Minimum installation length 1240 mm
Weight 57 kg

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 Service manual Product description
Technical data

Filter unit
Description Value Unit
Filtration grade 10 µm
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
Description Value Unit
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
Description Value Unit
Displacement 370 cm³
10
Secondary pressure relief 285 bar
Flow booster 1 : 1.6

Steering cylinder
Valid for: ID 1029 1027
Description Value Unit
Piston diameter 90 mm
Rod diameter 45 mm
Stroke length 500 mm
Weight 26.2 kg
LBH/Version 01/07.2007/en/Trainotti Anton

Emergency steering pump

Description Value Unit
Capacity 11 cm²
(LBH)/06.02.2013

Pressure relief valve 55 ±5 bar

Emergency steering pump pressure switch

Description Value Unit
Type Electronic
pressure switch
Switch type Normally open

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Product description Service manual
Technical data

Description Value Unit

2
Switching point 16 bar
Thread M 12 x 1.5 mm

Emergency steering check pressure switch

Description Value Unit
Type Electronic
pressure switch
Switch type Normally open
2
Switching point 16 bar
Thread M 12 x 1.5 mm

2.1.7 Brake system

Brake system gear pump

Valid for: L524 - 659 / from 17890; L528 - 660 / from 17890
Description Value Unit
Capacity 4 cm³
Flow rate at rated speed 9.3 l/min
Speed at rated speed 2322 min-1

Valid for: L538 - 433 / from 17890; L542 - 435 / from 17890
Description Value Unit
Capacity 4 cm³
Flow rate at rated speed 9.9 l/min
Speed at rated speed 2474 min-1

Compact brake valve

Valid for: ID 1029 5965
Description Value Unit
±5
Accumulator charge valve 130 bar
activation pressure
LBH/Version 01/07.2007/en/Trainotti Anton

±5
Accumulator charge valve 160 bar
deactivation pressure
Maximum service brake pressure 60 ±5 bar
Parking brake solenoid valve current 0.6 A
consumption
(LBH)/06.02.2013

Parking brake solenoid valve resistance 40 Ohm

Pedal start angle 42°
Pedal stop angle 15°

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Technical data

Service brake hydro accumulator

Valid for: ID 7619 022
Description Value Unit
Number of hydro accumulators 2 Qty.
Hydro accumulator volume 750 cm³
Preload pressure (nitrogen filling) 50 bar

Brake light pressure switch

Valid for: ID 6905 535
Description Value Unit
Switch type Normally open
±0.5
Switch point, rising 5 bar
Thread M 12 x 1.5 mm

Disc brake
Description Value Unit
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

Valid for: ID 1028 8602
Description Value Unit
Hydro accumulator volume 320 cm³
Preload pressure (nitrogen filling) 80 bar

Accumulator charge pressure switch

Valid for: ID 1035 3432
Description Value Unit
Type Electronic
pressure switch
LBH/Version 01/07.2007/en/Trainotti Anton

Switch type Normally open

±5
Switching point, falling 90 bar

2.1.8 Electrical system

(LBH)/06.02.2013

Battery
Description Value Unit
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

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Technical data

2.1.9 Transmission

Transmission
Valid for: L524 - 659 / from 17890; L528 - 660 / from 17890
Description Value Unit
Type 319
Variable displacement motor 1 1.55 -
transmission
Variable displacement motor 2 3.83 -
transmission
-1
Cardan speed at 40 km/h 3098 min

Valid for: L538 - 433 / from 17890; L542 - 435 / from 17890
Description Value Unit
Type 319
Variable displacement motor 1 transmission 1.55 -
Variable displacement motor 2 transmission 3.83 -
-1
Cardan speed at 40 km/h 2795 min

Speed sensors
Description Value Unit
Type Inductive sensor -
±100
Resistance at 20 °C 1050 Ohm

2.1.10 Axles and cardan shaft

Front axle
Valid for: L524 - 659 / from 17890; L528 - 660 / from 17890
Description Value Unit
Type 123/60
Self-locking differential level 45 %
Width 1960 mm
Overall transmission 18.6
LBH/Version 01/07.2007/en/Trainotti Anton

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
(LBH)/06.02.2013

Weight 570 kg

Valid for: L538 - 433 / from 17890; L542 - 435 / from 17890
Description Value Unit
Type 113/58
Self-locking differential level 45 %
Width 1900 mm

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Technical data

Description Value Unit

Overall transmission 18.54
Differential transmission 11/34
Wheel hub transmission 1/6
Wheel lug tightening torque 650 Nm
Wheel lug spanner size 30 mm
Flange size 1920 mm
Weight 720 kg

Rear axle
Valid for: L524 - 659 / from 17890; L528 - 660 / from 17890
Description Value Unit
Type 123/51
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
Swing angle (to each side) 6 °
Flange size 1920 mm
Weight 680 kg

Valid for: L538 - 433 / from 17890; L542 - 435 / from 17890
Description Value Unit
Type 113/50
Self-locking differential level 45 %
Width 1900 mm
Overall transmission 18.54
Differential transmission 11/34
Wheel hub transmission 1/6
Wheel lug tightening torque 650 Nm
LBH/Version 01/07.2007/en/Trainotti Anton

Wheel lug spanner size 30 mm

Swing angle (to each side) 6 °
Flange size 1920 mm
Weight 840 kg
(LBH)/06.02.2013

Cardan shaft
Valid for: L524 - 659 / from 17890; L528 - 660 / from 17890
Description Value Unit
Minimum length 1875 mm
Width 2020 mm
Weight 27.5 kg

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Technical data

Valid for: L538 - 433 / from 17890; L542 - 435 / from 17890
Description Value Unit
Minimum length 1967 mm
Width 2122 mm
Weight 30.5 kg

2.1.11 Machine frame and ballast weight

Ballast weight
Valid for: L524 - 659 / from 17890; L538 - 433 / from 17890
Description Value Unit
Left ballast weight 515 kg
Right ballast weight 565 kg

Valid for: L528 - 660 / from 17890

Description Value Unit
Left ballast weight 795 kg
Right ballast weight 565 kg

Valid for: L542 - 435 / from 17890

Description Value Unit
Left ballast weight 795 kg
Right ballast weight 801 kg

2.1.12 Automatic central lubrication system

Central lubrication pump EP1

Description Value Unit
Flow per stroke 120 mm³
Transfer medium Greases up to
NLGI class 2
Maximum flow pressure 280 bar
Operating temperature min. - 35 °C
max. + 80 °C
LBH/Version 01/07.2007/en/Trainotti Anton

Power supply 24 V
Protection class IP 65
Container size 4 kg

Progressive distributor
(LBH)/06.02.2013

MX-F
Description Value Unit
Maximum operating pressure at input 300 bar
Temperature range min. -35 °C
max. +100 °C
Transfer medium Greases up to
NLGI class 2

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Technical data

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

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

Central lubrication pump controller EP-1

Description Value Unit
Default lubrication (cycles) 18 Cycles
Default cycle time 75% 40 min
Default cycle time 100% 30 min
Default cycle time 125% 20 min

2.1.13 Cab, heating and air-conditioning

LBH/Version 01/07.2007/en/Trainotti Anton

Heating, ventilation, air conditioning

Description Value Unit
(LBH)/06.02.2013

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

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Technical data

Air conditioning system

Valid for: L524 - 659 / from 17890; L528 - 660 / from 17890
Description Value Unit
Refrigerant R134a
Refrigerant oil (PAG oil) ZXL 100 PG
+50
Coolant quantity 1050 g
10%
Cooling power 9.7 kW

Valid for: L538 - 433 / from 17890; L542 - 435 / from 17890
Description Value Unit
Refrigerant R134a
Refrigerant oil (PAG oil) ZXL 100 PG
Coolant quantity 1250+50 g
10%
Cooling power 9.7 kW

Air conditioning compressor

Description Value Unit
Type SD7H15
Capacity 154.9 cm³
Refrigerant oil (PAG oil) ZXL 100 PG
(SP 10)
Filling quantity 200 cm³
Maximum current consumption 2.63 A
Weight without oil 6.9 kg

Condenser
Description Value Unit
Maximum air flow 4000 m³/h
±1
Heating power 9.7 kW
Test pressure 35 bar

Dryer collector unit

LBH/Version 01/07.2007/en/Trainotti Anton

Description Value Unit

Contents 0.70 l
Filtration grade 7 µm
Leak test 30 bar
(LBH)/06.02.2013

Dryer water consumption 16 g

Burst pressure 130 bar

Pressure switch
Description Value Unit
Low pressure OFF 1.5 ±0.5 bar

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Technical data

Description Value Unit

Low pressure ON 3.5 bar
High pressure OFF 25 ±2 bar
±1.5
High pressure ON 18 bar
±1
Fan OFF 15 bar
±1
Fan ON 19 bar

Evaporator
Description Value Unit
Cooling power 9.7 kW
±10%
Temperature sensor activation temperature 5.5 °C
±10%
Temperature sensor deactivation temperature 4.5 °C

Temperature sensor B26

Description Value Unit
Operating temperature -40 - +125 °C
Resistance at -5 °C 42330 Ohm
Resistance at 0 °C 32670 Ohm
Resistance at 5 °C 25410 Ohm
Resistance at 10 °C 19920 Ohm
Resistance at 15 °C 15730 Ohm
Resistance at 20 °C 12500 Ohm
Protection class IP 68

2.1.14 Lift arms and quick-change device

Lift arms with Z kinematics

Valid for: L524 - 659 / from 17890; L528 - 660 / from 17890
Description Value Unit
L – length 2400 mm
Weight 962 kg

Valid for: L538 - 433 / from 17890; L542 - 435 / from 17890
LBH/Version 01/07.2007/en/Trainotti Anton

Description Value Unit

L – length 2500 mm
Weight 1072 kg

Lift arms with P kinematics

(LBH)/06.02.2013

Valid for: L524 - 659 / from 17890; L528 - 660 / from 17890
Description Value Unit
L – length 2500 mm
L – high lift length 3000 mm
Weight (without QCD) 1165 kg

Valid for: L538 - 433 / from 17890; L542 - 435 / from 17890
Description Value Unit

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Technical data

Description Value Unit

L – length 2500 mm
L – high lift length 3000 mm
Weight (without QCD) 1165 kg

Hydraulic quick-change device for Z lift arms.

Description Value Unit
A – system connection size 1000 mm
Weight 300 kg

Hydraulic quick-change device for P lift arms.

Description Value Unit
A – system connection size 1000 mm
Weight 230 kg

2.1.15 Equipment and accessories

Bucket
Valid for: L524 - 659 / from 17890
Description Value Unit
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

Description Value Unit
B – bucket width 2500 mm
Specific material weight 1.8 t/m³
Heaped bucket capacity (ISO 7546) 2.2 m³

Valid for: L538 - 433 / from 17890

Description Value Unit
B – bucket width 2500 mm
Specific material weight 1.8 t/m³
LBH/Version 01/07.2007/en/Trainotti Anton

Heaped bucket capacity (ISO 7546) 2.5 m³

Valid for: L542 - 435 / from 17890

Description Value Unit
B – bucket width 2500 mm
(LBH)/06.02.2013

Specific material weight 1.8 t/m³

Heaped bucket capacity (ISO 7546) 2.7 m³

Forklift
Description Value Unit
Fork carrier prong size FEM III
Prong length 1200 mm

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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 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
LBH/Version 01/01.2008/en/lbhleh1/29.08.2014

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

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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
LBH/Version 01/01.2008/en/lbhleh1/29.08.2014

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 service brake discs for wear ........................ 3.5-49
3.5.54 Checking the gap and wear on the parking brake linings .. 3.5-51

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 Service manual Maintenance

3.5.55 Checking the indicator lamps and lighting .......................... 3.5-52

3.5.56 Checking the batteries, fluid level and terminals ................ 3.5-53
3.5.57 Replacing the travel direction switch control lever rocker
and the pushbutton cover (optional) ................................... 3.5-54
3.5.58 Checking the transfer gear oil level .................................... 3.5-56
3.5.59 Changing the transmission oil ............................................ 3.5-56
3.5.60 Checking the wheel tightness ............................................. 3.5-57
3.5.61 Checking the axle oil levels ................................................ 3.5-57
3.5.62 Changing the axle oil .......................................................... 3.5-59
3.5.63 Checking the tightening torque of the front axle
fastening bolts .................................................................... 3.5-60
3.5.64 Checking the tyre pressure ................................................ 3.5-61
3.5.65 Lubricating the articulation bearing and rear oscillating
bearing ................................................................................ 3.5-61
3.5.66 Lubricating the elongated hole on the accelerator pedal
and checking the bearing ................................................... 3.5-62
3.5.67 Greasing the cab door hinges ............................................ 3.5-63
3.5.68 Checking / topping up the windscreen washer reservoir.... 3.5-63
3.5.69 Cleaning the fresh air and recirculated air filter .................. 3.5-63
3.5.70 Changing the fresh air and recirculated air filter ................ 3.5-64
3.5.71 Checking the indicator and filling level beads in the
dryer-collector unit (optional) of the air conditioner ............ 3.5-65
3.5.72 Lubricating the lift arms and attachment (Z kinematics) ..... 3.5-66
3.5.73 Lubricating the lift arms and attachment (P kinematics) .... 3.5-66
3.5.74 Checking the lift arm bearing bushings .............................. 3.5-67
3.5.75 Checking the lift arm bucket stops (Z kinematics) .............. 3.5-68
3.5.76 Lubricating and testing the quick-change device ............... 3.5-69

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
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relief valve ............................................................................ 3.6-2

3.6.4 Calibrating the Inch pedal ..................................................... 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
displacement pump L538, L542 ........................................... 3.6-5
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
displacement pump L524, L528 ........................................... 3.6-6
3.6.10 Checking the pressure cut-off of the variable
displacement pump L538, L542 ........................................... 3.6-7

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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
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
3.6.31 Transmission - setting the rapid draining time ................... 3.6-20

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

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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
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

Special intervals
By maintenance staff By authorised specialist staff
On handover

Once-only activity Once-only activity

Every 1000
Every 2000

Repeat interval
Every 500

Repeat interval
Every 10
Every 50

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
Removing loose parts, dirt, ice and snow from the machine
Checking the machine for external damage
Making sure the bolted connections are tight
Sealing leaks
Check the hydraulic pressure according to the testing and adjustment plan see the
service manual
Engine
Checking the engine oil level
Change the engine oil (at least once a year): NOTE: See the section on lubricants and
fuels for the engine oil quality and complicating factors.
Change the engine oil filter
(at least once a year)
Check the V-ribbed belt and replace it if necessary
Check / adjust the engine valve play
Checking the engine heating flange
Lightly grease the ring gear on the engine starter flywheel
Valid for L538, L542
Change the engine oil separator filter insert
Valid for L538, L542
Check the bearings and condition of the engine control units
Check the state of sensors and cable connections
Replace the fuel pre-filter (or in the event of a lack of output)
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Replace the fuel fine filter (or in the event of a lack of output)
Drain off condensate from the fuel filter (or if the corresponding service code appears)
Bleed the fuel system (caution: do not detach the injection lines)
Draining off condensate and sediment from the fuel tank
Cleaning the air filter service cap and dust extraction valve
Test the air filter vacuum switch
Change the main air filter element when indicated by the vacuum switch
(or every year at the latest)
Clean or replace the air filter secondary element (after replacing the main element
3 times or every year at the latest)
Check the air suction hoses for leaks and tight fitting
Check the exhaust lines for leaks and tight fitting

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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

Special intervals
By maintenance staff By authorised specialist staff
On handover

Once-only activity Once-only activity

Every 1000
Every 2000
Repeat interval Repeat interval
Every 500
Every 10
Every 50

As necessary As necessary
Annually before the winter

Diesel particle filter (optional)

Check the diesel particle filter pressure monitor for function, leaks and blockages
Clean the diesel particle filter (at least once a year):
Cooling system
Check the coolant and antifreeze concentration
Clean the cooling system
Replace the coolant and antifreeze (at least every 2 years)
Working hydraulics
Check the oil level in the hydraulic tank
Drain off condensate and sediment from the hydraulic tank
Hydraulic tank - changing the oil in the hydraulic system. For the oil quality and
oil change intervals, see the section on lubricants and fuels hydraulic oil .
Check the oil in the hydraulic tank
(affects all environmentally compatible hydraulic fluids)
250h Check and clean the magnetic rod on the hydraulic tank
Change the hydraulic tank return suction filter insert
Change the hydraulic tank bleeder filter
Lubricate the pilot control device solenoids, universal joints and tappets
Steering system
Test the steering
Lubricate the bearing points on the steering cylinders
Brake system
Test the service brake and parking brake
3000 Checking the service brake discs for wear
Check the gap and wear on the parking brake linings
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Electrical system
Check the indicator lamps and lighting
Check the batteries, fluid level and terminals
Control lever - change travel direction switch rocker and cap (optional)
Transmission
Check the transmission oil level
Change the transmission oil
Axles and tyres
Check the tightness of the wheels (once after 50, 100 and 250 h)
Check the axle oil levels
Change the axle oil
Check the tyre pressure

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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

Special intervals
By maintenance staff By authorised specialist staff
On handover

Once-only activity Once-only activity

Every 1000
Every 2000

Repeat interval Repeat interval

Every 500
Every 10
Every 50

As necessary As necessary
Annually before the winter

Axles and tyres

Check the tightness of the wheels (once after 50, 100 and 250 h)
Check the axle oil levels
Change the axle oil
Checking the tightening torque of the front axle fastening bolts
Check the tyre pressure
Machine frame and ballast weight

Lubricate the articulation bearing and rear oscillating bearing

Lubrication system (optional)
Check the lubrication system grease reservoir level
Check the pipes, hoses and lubrication points of the lubrication system
Check whether metered quantities are adequate at the bearing points (grease collars)
of the central lubrication system
Cab, heating and air-conditioning
Lubricating the elongated hole on the accelerator pedal and checking the bearing
Grease the cab door hinges
Check / top up the windscreen washer reservoir
Clean the fresh air and recirculated air filter
Change the fresh air and recirculated air filter
Check the indicator and filling level beads in the dryer-collector unit (optional) of the
air conditioner
Lift arms and quick-change device
Lubricate the lift arms and attachment
Check the lift arm bearing bushings
Check the lift arm bucket stops (Z kinematics)
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Lubricate and test the quick-change device

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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
adjustment tasks.
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Maintenance Service manual
Testing and adjustment plan

Customer: .. Machine type: ... Ser. no.: .... Service hours: . Date: ..
Maintenance / inspection
after service hours
TASKS TO BE PERFORMED

Special intervals
By authorised specialist staff
On handover

Once-only activity
Every 1000
Every 2000

Repeat interval
Every 500
Every 10
Every 50

As necessary

Cooling system
Check the fan motor and fan control pressure relief valve
Engine
Calibrate the pedals
Check the engine speed
Travel hydraulics
Check the replenishing pressure of the variable displacement pump
Check the pressure relief and replenishing valve of the variable displacement pump
Check the pressure cut-off of the variable displacement pump
Calibrate the block curve
Check the start of regulation for variable displacement motor 1
Calibrate variable displacement motor 2
Check the engine output
Working hydraulics
Check the secondary pressure relief valves on the control block
Check the LS pressure cut-off on the control block
Check the flow controller of the working hydraulics pump
Check the cut-off valve in the stabilisation module (optional)
Check the nitrogen in the ride control hydro accumulator (optional)
Brake system
Check the opening and closing pressure of the compact brake valve
Check the brake pressure at the axles
Check the capacity of the brake accumulator
Check the accumulator charge pressure
Check the brake light pressure switch and brake lights
Transmission
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Adjust time for rapid draining

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 Service manual Maintenance
Testing and adjustment checklists

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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Maintenance Service manual
Testing and adjustment checklists

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Copyright
L528 - 660 / from 17890
MJFCIFSS L538 - 433 / from 17890
L542 - 435 / from 17890
Costumer: L524, L528 S/N /
Operating hours:
Type of application:
Checked by:
Job site:
Checked on date:

1000 Bh.
2000 Bh.
Adjust. Value Value Test
before after Adjust.
Check / Adjustment Unit values point point
adjust adjust

Operating temperature
5
Operating temperature °C 58
(Temperature sensor – hydraulic oil)
Cooling system
Cooling System (fan control)
10
Fan at high Diesel engine RPM / bar 75 P
Sensor unplugged
10
Fan at high Diesel engine RPM / bar 175 1 P
Prop. solenoid valve current less
Diesel engine
Adjustment - pedal
Inching pedal – angle sensor

Diesel engine RPM

-1 10
Low idle RPM min 850
-1 20
High idle RPM min 2550
Travel hydraulic
Replenishing pressure
1
At high idle RPM bar 34 3 G

High pressure relief valves

10
Forward bar 470 4 MA
10
Reverse bar 470 1 MB

Pressure cut off

5
High pressure bar 440 2 MA (MB)
-1
Engine speed drop, max. difference min 50 Display
to high idle RPM

Calibration block curve

-1 10
High pressure at 930 min bar 50 MA (MB)
-1 10
High pressure at 1300 min bar 180 MA (MB)
-1 10
High pressure at 1600 min bar 260 MA (MB)
-1 10
High pressure at 2000 min bar 350 MA (MB)
-1 5
High pressure at 2200 min bar 435 MA (MB)

Variable displacement motor 1 /

regulation begin
10
High pressure variable displ. pump bar 250 MA
10
Pressure variable displ. motor 1 bar 50 1 M1

Calibration variable
displacement motor 2
Automatically calibration of the
variable displacement motor 2

Engine performance at 250 bar

High pressure variable displ. pump bar 250 MA
-1 +50
Diesel engine RPM min 2300 -170 Display

= Blocked Maschine

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MJFCIFSS
 1000 Bh.
2000 Bh.
Adjust. Value Value Test
before after Adjust.
Check / Adjustment Unit values point point
adjust. adjust.

Working hydraulic
Control valve block
5
Secondary pressure relief valve, lift bar 1) 250 2 P
5
Secondary pressure rel. valve, tilt in bar 1) 220 3 P
5
Secondary pressure relief valve, tilt bar 1) 220 6 P
out / Z - bar linkage
5
Secondary pressure relief valve, tilt bar 150 6 P
out / P - bar linkage
5
Secondary pressure relief valve - bar 250 1/7 P
additional equipment

Control valve block

5
LS-Pressure cut off bar 315 4 P

Working hydraulic pump

2
Flow regulator - standby pressure bar 32 8 P

Stabilization module
20
Shut off pressure (LFD – turned off) bar 120 MX

Hydro accumulator LFD

Pretension pressure (nitrogen filling) bar 25
2
10 10
Steering system
Pressure relief valve / steering
5
LS- Pressure relief valve bar 250 5 P
(in control valve block)
Brake system
Compact brake valve
5
Cut in pressure bar 180 4 M3
5
Cut out pressure bar 210 4 M3
Brake pressure in axles bar 70
5 2 M4 / M5

Accumulator – service brake

After 9 braking actions bar > 50 M4 / M5

Pressure switch – brake system

5
Switching point bar 90 3 M3

Pressure switch – brake

light and lights
1
Switching point bar 5 1 M4

Transmission
Transmission
Adjust time for rapid draining ms - TransModTuning

Remarks: Signature:

1) The working hydraulic pump must not be loaded with more than 320 bar.
Procedure for testing the relief valves:
turn out relief valve by 1/2 turn
adjust the relief valve to the valve in the table
turn in relief valve by 1/2 turn
Check and adjust only if required

3.3 copyright by L524 - 659 / from 17890

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MJFCIFSS
Costumer: L538, L542 S/N /
Operating hours:
Type of application:
Checked by:
Job site:
Checked on date:

1000 Bh.
2000 Bh.
Adjust. Value Value Test
before after Adjust.
Check / Adjustment Unit values point point
adjust adjust

Operating temperature
5
Operating temperature °C 58
(Temperature sensor – hydraulic oil)
Cooling system
Cooling System (fan control)
10
Fan at high Diesel engine RPM / bar 120 P
Sensor unplugged
10
Fan at high Diesel engine RPM / bar 175 1 P
Prop. solenoid valve current less
Diesel engine
Adjustment - pedal
Inching pedal – angle sensor

Diesel engine RPM

-1 10
Low idle RPM min 900
-1 20
High idle RPM min 2060
Travel hydraulic
Replenishing pressure
1
At high idle RPM bar 34 2 G

High pressure relief valves

10
Forward bar 470 4 MA
10
Reverse bar 470 1 MB

Pressure cut off

5
High pressure bar 440 3 MA (MB)
-1
Engine speed drop, max. difference min 30 Display
to high idle RPM

Calibration block curve

-1 10
High pressure at 930 min bar 50 MA (MB)
-1 10
High pressure at 1200 min bar 180 MA (MB)
-1 10
High pressure at 1400 min bar 260 MA (MB)
-1 10
High pressure at 1700 min bar 350 MA (MB)

Variable displacement motor 1 /

regulation begin
10
High pressure variable displ. pump bar 250 MA
10
Pressure variable displ. motor 1 bar 50 1 M1

Calibration variable
displacement motor 2
Automatically calibration of the
variable displacement motor 2

Engine performance at 250 bar

High pressure variable displ. pump bar 250 MA
-1 +30
Diesel engine RPM min 1900 -150 Display

= Blocked Maschine

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MJFCIFSS
 1000 Bh.
2000 Bh.
Adjust. Value Value Test
before after Adjust.
Check / Adjustment Unit values point point
adjust. adjust.

Working hydraulic
Control valve block
5
Secondary pressure relief valve, lift bar 1) 250 2 P
5
Secondary pressure rel. valve, tilt in bar 1) 220 3 P
5
Secondary pressure relief valve, tilt bar 1) 220 6 P
out / Z - bar linkage
5
Secondary pressure relief valve, tilt bar 150 6 P
out / P - bar linkage
5
Secondary pressure relief valve - bar 250 1/7 P
additional equipment

Control valve block

5
LS-Pressure cut off bar 330 4 P

Working hydraulic pump

LS-Pressure cut off bar 350 9 P

Working hydraulic pump

2
Flow regulator - standby pressure bar 32 8 P

Stabilization module
20
Shut off pressure (LFD – turned off) bar 120 MX

Hydro accumulator LFD

Pretension pressure (nitrogen filling) bar 25
2
10 10
Steering system
Pressure relief valve / steering
5
LS- Pressure relief valve bar 250 5 P
(in control valve block)
Brake system
Compact brake valve
5
Cut in pressure bar 130 4 M3
5
Cut out pressure bar 160 4 M3
Brake pressure in axles bar 60 5 2 M4 / M5

Accumulator – service brake

After 9 braking actions bar > 50 M4 / M5

Pressure switch – brake system

5
Switching point bar 90 3 M3

Pressure switch – brake

light and lights
1
Switching point bar 5 1 M4

Transmission
Transmission
Adjust time for rapid draining ms - TransModTuning

Remarks: Signature:

1) The working hydraulic pump must not be loaded with more than 350 bar.
Procedure for testing the relief valves:
turn out relief valve by 1/2 turn
adjust the relief valve to the valve in the table
turn in relief valve by 1/2 turn

Check and adjust only if required

3.3 copyright by L538 - 433 / from 17890

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MJFCIFSS
 Service manual Maintenance
Lubrication chart and filling quantities

3.4 Lubrication chart and filling quantities

3.4.1 Table of filling quantities L524, L528
Valid for: L524 - 659 / from 17890; L528 - 660 / from 17890
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 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.

Note
Observe the data sheets and safety data sheets in “LH service
documentation” / “General information” / “Lubricants”.

Description Medium Viscosity Quantity

Diesel engine (with filter change) Liebherr engine oil SAE 10W-40 12.0 l

Engine cooling system Liebherr Antifreeze 32.0 l

Total capacity

Hydraulic system Liebherr Hydraulic Basic 68 ISO VG 68 170 l

Total capacity

Hydraulic tank Liebherr Hydraulic Basic 68 ISO VG 68 110 l

Transmission Liebherr Hydraulic Gear ATF SAE 5W-20 3.8 l

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Front axle differential Liebherr Gear Basic 90 LS SAE 85W-90 16.3 l

Front axle wheel hub (each) Liebherr Gear Basic 90 LS SAE 85W-90 2.6 l

Rear axle differential Liebherr Gear Basic 90 LS SAE 85W-90 15.0 l

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Maintenance Service manual
Lubrication chart and filling quantities

Description Medium Viscosity Quantity

Rear axle wheel hub (each) Liebherr Gear Basic 90 LS SAE 85W-90 2.6 l

Fuel tank Diesel 180.0 l

Fuel reserve in tank, approx. Diesel 30.0 l

Air conditioning system Refrigerant 1050 +50 g

R 134a

3.4.2 Table of filling quantities L538, L542

Valid for: L538 - 433 / from 17890; L542 - 435 / from 17890
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 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.

Note
Observe the data sheets and safety data sheets in “LH service
documentation” / “General information” / “Lubricants”.
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 Service manual Maintenance
Lubrication chart and filling quantities

Description Medium Viscosity Quantity

Diesel engine (with filter change) Liebherr engine oil SAE 10W-40 29.0 l

Engine cooling system Liebherr Antifreeze 42.0 l

Total capacity

Hydraulic system Liebherr Hydraulic Basic 68 ISO VG 68 180 l

Total capacity

Hydraulic tank Liebherr Hydraulic Basic 68 ISO VG 68 110 l

Transmission Liebherr Hydraulic Gear ATF SAE 5W-20 3.8 l

Front axle differential Liebherr Gear Basic 90 LS SAE 85W-90 16.3 l

Front axle wheel hub (each) Liebherr Gear Basic 90 LS SAE 85W-90 2.6 l

Rear axle differential Liebherr Gear Basic 90 LS SAE 85W-90 15.0 l

Rear axle wheel hub (each) Liebherr Gear Basic 90 LS SAE 85W-90 2.6 l

Fuel tank Diesel 180.0 l

Fuel reserve in tank, approx. Diesel 30.0 l

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Air conditioning system Refrigerant 1250 +50 g

R 134a

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Maintenance Service manual
Lubrication chart and filling quantities

3.4.3 Lubrication chart L524, L528

Valid for: L524 - 659 / from 17890; L528 - 660 / from 17890
The lubrication chart provides an overview of the location of the
maintenance 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 fuels, see
the section on lubricants and fuels.
For information about the required filling quantities, see the tables of
filling quantities.

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Symbol Description Symbol Description

Grease the general lubricating points Check the oil level

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 Service manual Maintenance
Lubrication chart and filling quantities

Symbol Description Symbol Description

Check the coolant level Change the coolant

Oil change First oil change

Gear oil Hydraulic tank

Engine Cooling system

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Maintenance Service manual
Lubrication chart and filling quantities

3.4.4 Lubrication chart L538, L542

Valid for: L538 - 433 / from 17890; L542 - 435 / from 17890
The lubrication chart provides an overview of the location of the
maintenance 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 fuels, see
the section on lubricants and fuels.
For information about the required filling quantities, see the tables of
filling quantities.

LBH/Version 01/01.2008/en/lbhleh1/29.08.2014

Symbol Description Symbol Description

Grease the general lubricating points Check the oil level

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 Service manual Maintenance
Lubrication chart and filling quantities

Symbol Description Symbol Description

Check the coolant level Oil change

First oil change Change the gear oil coolant

Hydraulic tank
Engine

Cooling system
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Maintenance Service manual
Lubrication chart and filling quantities

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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.

Make sure you are wearing safe working clothing.

Certain jobs not only require a hard hat and safety boots, but also goggles
and safety gloves.

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
maintenance work.
Make sure that visual contact between the operator in the cab and
maintenance personnel is always maintained.

Visual contact
DANGER
There is a risk of accidents for maintenance personnel
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
presence known.
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Make sure you can be clearly seen before entering one of the machine's
danger areas.
Wheel wedges Secure the machine against rolling away with wheel wedges.

Maintenance positions
The maintenance position depends on the maintenance task to be performed.
The two basic maintenance positions 1 and 2 are described below.
They enable you to access the individual maintenance points.

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Maintenance Service manual
Maintenance tasks

Maintenance position 1 To move the machine into maintenance position 1 proceed as follows.

Maintenance position 1
Park the machine on level ground.
Lower the lift arms.
Set the bucket down flat on the ground.
Engage the parking brake.
Turn off the engine.
Take out the ignition key.

Maintenance position 2 To move the machine into maintenance position 2 proceed as follows.

Maintenance position 2
Park the machine on level ground.
Engage the articulation lock.
Lower the lift arms.
Tilt the bucket out and set it down on the ground on its teeth or cutting edge.
Engage the parking brake.
Turn off the engine.
Take out the ignition key.

Opening the engine compartment hood and grille

Opening the engine When the hood is open, you can access the following units:
compartment hood Engine
Air filter
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Hydraulic pumps
Cooling system
Batteries
Battery main switch

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 Service manual Maintenance
Maintenance tasks

Engine compartment hood

1 Engine compartment hood 3 Gas-filled springs
2 Handle with lock

WARNING
Engine parts which are in motion can cause injury.
Rotating or moving engine parts, such as the fan blades or V-belts, can
cause injury.
Only open the engine compartment hood when the engine is shut down.

Open the lock with the ignition key.

Open the engine compartment hood 1 with the handle 2 and lift it up as
far as it will go.
The hood is held in this position by two gas-filled springs 3.

CAUTION
There is a risk of injuries if the hood falls shut.
Check that the gas-filled springs securely hold the hood fully open.

Check the function.

Troubleshooting
The function is not assured
Contact LIEBHERR CUSTOMER SERVICE.

Opening the grille

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Grille
1 Grille 2 Gas-filled spring

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Maintenance Service manual
Maintenance tasks

When the grille is open, you can access the following units:
Cooling system
Hydraulic tank
Lift the grille up as far as it will go.
The grille is held in this position by two gas-filled springs.

CAUTION
There is a risk of injuries if the grille falls shut.
Check that the gas-filled springs securely hold the hood fully open.

Check the function.

Troubleshooting
The function is not assured
Contact LIEBHERR CUSTOMER SERVICE.

Turning off the battery main switch

The battery main switch is located at the rear right of the engine
compartment.
For certain maintenance jobs, the battery main switch must first be
turned off.
Find out from the descriptions of the relevant maintenance tasks whether the
battery main switch must be turned on or off. See the section on
maintenance tasks.
Switch on the battery main switch after completing these maintenance tasks.

NOTICE
There is a risk of damaging the electrical system.
Do not turn off the battery main switch while the engine is running.

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Turning off the battery main switch

1 Battery main switch 3 Main key OFF position

2 Main key ON position

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 Service manual Maintenance
Maintenance tasks

WARNING
There is a risk of injury to maintenance personnel.
If unauthorised people are on the machine it can put the maintenance
personnel in extreme danger.
For safety reasons, it is essential that the battery main switch is turned off.
Pull out the key for safety reasons.

Turn the battery main switch off using the key.

3.5.2 Removing loose parts, dirt, ice and snow from the machine
Make sure that the machine is in maintenance position 1.

Procedure

Note
To ensure safe machine transport and easy maintenance:
Clean the machine after everyday work and before starting maintenance tasks.
Remove any loose parts, coarse dirt, mud, ice, snow etc.

Be careful when cleaning the machine with a high-pressure cleaner.

3.5.3 Checking the machine for external damage

Make sure that the machine is in maintenance position 1.

Procedure
Before starting up the machine, check for external damage which might
impair safe operation.
Repair any damage with safety implications immediately.

3.5.4 Making sure the bolted connections are tight

Make sure that:
The machine is in maintenance position 2.
The service doors and hoods are open.

Procedure
Tighten any loose screws or bolts with the required tightening torque.

3.5.5 Sealing leaks

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Make sure that:

The machine is in maintenance position 2.
The service doors and hoods are open.

Procedure
Check the entire hydraulic system for leaks.
Replace any damaged hydraulic seals.
Tighten any loose hydraulic couplings.
See also the section on safe maintenance of hydraulic hoses and hose
lines.

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Maintenance tasks

3.5.6 Checking the engine oil level L524, L528

Valid for: L524 - 659 / from 17890; L528 - 660 / from 17890
Make sure that:
The machine is in maintenance position 1.
The engine compartment hood is open.
The engine is level and has not been running for 2 to 3 minutes.

Procedure

Engine oil dipstick

Pull out the dipstick 1, wipe it clean, and re-insert it.
Pull out the dipstick 1 once again and read off the oil level. The oil level
must be within the range 2.
If the oil level is in the range 3 or below:
Top up with engine oil.
For the oil quality, see the section on lubricants and fuels.
Top up with oil via the oil filler neck 4.
Clean the sealing cap 5, place it on the filler neck and tighten it.

3.5.7 Checking the engine oil level L538, L542

Valid for: L538 - 433 / from 17890; L542 - 435 / from 17890
Make sure that:
The machine is in maintenance position 1.
The engine compartment hood is open.
The engine is level and has not been running for 2 to 3 minutes.

Procedure
LBH/Version 01/01.2008/en/lbhleh1/29.08.2014

Engine oil dipstick

Pull out the dipstick 1, wipe it clean, and re-insert it.
Pull out the dipstick 1 once again and read off the oil level. The oil level
must be within the range 2.

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Maintenance tasks

If the oil level is in the range 3 or below:

Top up with engine oil.
For the oil quality, see the section on lubricants and fuels.
Top up with oil via the oil filler neck 4.
Clean the sealing cap 5, place it on the filler neck and tighten it.

3.5.8 Changing the engine oil L524, L528

Valid for: L524 - 659 / from 17890; L528 - 660 / from 17890
Make sure that:
The machine is in maintenance position 1.
The engine compartment hood is open.
The engine is level.
The engine is warm.
A suitable receptacle, an oil drain hose and the specified engine oil are
at hand.

Procedure

Changing the engine oil

Remove the plastic plug 1.
Unscrew the cap of the oil drain valve 2 on the oil pan.
Screw the oil drain hose 7 onto the oil drain valve 2.
Drain off the oil into the receptacle.
Unscrew the oil drain hose 7 and unscrew the cap of the oil drain valve 2.
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Put on the plastic plug 1.

When changing the engine oil and the oil filter:

Change the filter as described in the section on changing the engine oil filter.
Top up the oil via the filler neck 4 to within the range 5 on the dipstick 6
(for the oil quality, see the section on lubricants and fuels).
Clean the filler cap 3, put it on the filler neck 4 and tighten it.
Start the engine and check the oil pressure.
Turn off the engine and after 1 or 2 minutes check the oil level on the
dipstick 6. The oil level must be within the range 5.

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Maintenance tasks

3.5.9 Changing the engine oil L538, L542

Valid for: L524 - 659 / from 17890; L528 - 660 / from 17890
Make sure that:
The machine is in maintenance position 1.
The engine compartment hood is open.
The engine is level.
The engine is warm.
A suitable receptacle, an oil drain hose and the specified engine oil are
at hand.

Procedure

Changing the engine oil

Remove the plastic plug 1.
Unscrew the cap of the oil drain valve 2 on the oil pan.
Screw the oil drain hose 7 onto the oil drain valve 2.
Drain off the oil into the receptacle.
Unscrew the oil drain hose 7 and unscrew the cap of the oil drain valve 2.
Put on the plastic plug 1.

When changing the engine oil and the oil filter:

Change the filter as described in the section on changing the engine oil filter.
Top up the oil via the filler neck 4 to within the range 5 on the dipstick 6
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(for the oil quality, see the section on lubricants and fuels).
Clean the filler cap 3, put it on the filler neck 4 and tighten it.
Start the engine and check the oil pressure.
Turn off the engine and after 1 or 2 minutes check the oil level on the
dipstick 6. The oil level must be within the range 5.

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Maintenance tasks

3.5.10 Changing the engine oil filterL524, L528

Valid for: L524 - 659 / from 17890; L528 - 660 / from 17890
Make sure that:
The machine is in maintenance position 1.
The engine compartment hood is open.
The engine oil has been drained off.
A strap wrench and a suitable container are available.
Only use genuine LIEBHERR spare parts.

Procedure

Unscrewing the oil filter

Place a suitable container under the engine.
Release the filter cartridge 1 with a strap wrench and unscrew it.
Clean the seals on the filter bracket.
Lightly coat the rubber gaskets on the new oil filter cartridges with engine oil.
Screw on the new oil filter cartridge until the sealing ring touches the
filter bracket.
Tighten the oil filter cartridge by a half to three-quarter turn (do not use a tool).
Start the engine.
Check the oil pressure in the engine oil pressure display (see display unit).
Turn off the engine.
Check the seals on the oil filters and the oil level.
After 2 to 3 minutes, check the oil level on the dipstick.

Troubleshooting
Is the oil level between the min. and max. levels?
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Correct the oil level.

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Maintenance tasks

3.5.11 Changing the engine oil filterL538, L542

Valid for: L538 - 433 / from 17890; L542 - 435 / from 17890
Make sure that:
The machine is in maintenance position 1.
The engine compartment hood is open.
The engine oil has been drained off.
A strap wrench and a suitable container are available.
Only use genuine LIEBHERR spare parts.

Procedure

Note
Protect the V-ribbed-belt against emerging oil when changing the oil
filter cartridges.
After changing the oil filter, remove all traces of oil on the engine,
including behind the vibration damper, so that this is not diagnosed as a
leak in the radial shaft seal at a later stage.

Place a suitable container under the engine.

Release the filter cartridges 1 with a strap wrench and unscrew them.
Clean the seals on the filter bracket.
Lightly coat the rubber gaskets on the new oil filter cartridges with
engine oil.
Screw on the new oil filter cartridge until the sealing ring touches the filter
bracket.
Tighten the oil filter cartridge by a half to three-quarter turn. (Do not use a
LBH/Version 01/01.2008/en/lbhleh1/29.08.2014

tool for tightening).

Start the engine.
Check the oil pressure in the engine oil symbol field on the display unit.
Switch off the engine.
Check the seals on the oil filters and the oil level.
After 2 to 3 minutes, check the oil level on the dipstick.

Troubleshooting
Is the oil level between the min. and max. levels?
Correct the oil level.

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Maintenance tasks

3.5.12 Checking the V-ribbed belt L524, L528

Valid for: L524 - 659 / from 17890; L528 - 660 / from 17890
Access is from the right-hand side of the engine.
The V-ribbed belt drive has an automatic tensioning device.
The tensioning device cannot be repaired.
The tensioning device is designed so that the lever moves within the
tensioning limits 3 and the fixed limit stops 4.

Procedure for checking the V-ribbed belt

Make sure that:
The machine is in maintenance position 1.
The engine compartment hood is open.

V-ribbed belt tensioning device

Visually inspect the limit stops 4 and 5.
Check the V-ribbed belt for wear and damage.
If the tension limit stop 3 on the swivel arm touches the fixed stop 4,
check the brackets for the alternator, belt tensioner etc. and check the
belt tightness.
Replace the belt if necessary.

Procedure for replacing the V-ribbed belt

Make sure that:
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The machine is in maintenance position 1.

The engine compartment hood is open.
You have a new V-ribbed belt ready.
Take off the belt guard by removing the three screws 2.
Relax the tensioner and replace the belt.
Check the play between the tension stop 3 and the fixed stop 4.
If there is no play between the tension stop 3 and the fixed stop 4.
Check the length of the V-ribbed belt and the bearing of the
tensioning device.
Fit the belt guard again.

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Maintenance tasks

3.5.13 Checking the V-ribbed belt L538, L542

Valid for: L538 - 433 / from 17890; L542 - 435 / from 17890
Access is from the rear right side.
The V-ribbed belt drive has an automatic tensioning device.
The tensioning device cannot be repaired.
The tensioning device is designed so that the lever moves within the
tensioning limits.

1 Cover plate fixing screws 2 Deflector roller

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3 Automatic belt tensioner

Procedure for checking the V-ribbed belt

Check the V-ribbed belt for wear and damage.
If the tension limit stop on the swivel arm touches the fixed stop, check the
brackets for the alternator, belt tensioner etc. and check the belt tightness.
Replace the belt if necessary.

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Maintenance tasks

Procedure for replacing the V-ribbed belt

Make sure that:
The machine is in maintenance position 1.
The engine compartment hood is open.
You have a new V-ribbed belt ready.
Take off the belt guard by removing the three screws 1.
Push a DIN 3122 D 12.5 (1/2 ) ratchet into the square fitting of the
tensioning device.
Pull back the tensioning device against the spring force anticlockwise as
far as it will go and take off the belt.
Check that the tension roller and the pulleys are in perfect condition
(for example the tension roller bearings are in place and the pulleys are
not worn).
If any parts are damaged, replace them.
With the tensioning device swung back, put the new belt on the pulleys of
the crankshaft, air conditioning compressor, alternator and deflector
roller. Then return the tensioning device to the tensioning position.
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V-ribbed belt installation with tensioning device

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Maintenance tasks

3.5.14 Checking the valve play L524, L528

Valid for: L524 - 659 / from 17890; L528 - 660 / from 17890
Check the valve play with the engine cold.
Make sure that:
The machine is in maintenance position 1.
The engine compartment hood is open.
The special turning device (ID no. 0541887 which means there is no
need to remove the belt cover) or a 30 mm spanner is available.
You have the valve seals.
The engine is cold or has been allowed to cool for at least two hours.
Conventions on the cylinder numbering, direction of rotation and position of
the valves:
Cylinder 4 on flywheel side
Direction of rotation anticlockwise looking at the flywheel
Outlet valves on flywheel side

Valve play D504

Inlet valve 0.36 mm
Outlet valve 0.46 mm

Engine D 504
Cylinder
Overlap Adjust
4 1
2 3
1 4
3 2

Procedure

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Remove the intake line 2 from the manifold. Cover the opening of the
manifold to stop anything falling in.

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Maintenance tasks

Remove the injector cover and the wiring harness holder.

Remove the plug 1 from the valve cover and remove the hex nut below.
Carefully remove the valve cover to ensure that the seal rings of the
cover fixing screws are not lost and that the turbocharger oil return line
and the electrical connections for the injectors are not damaged.
Take off the belt guard (this is not required when using the special tool).

Cranking the engine

1 Belt 3 30 mm wrench
2 Water pump 4 Belt drive pulley
5 DIRECTION OF ROTATION
Using the belt pulley, 4 crank the engine with a 30 mm spanner or the
cranking tool (ID no. 0541887) in the direction of rotation 5 (anticlockwise
looking at the flywheel).
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Valve layout
S Flywheel end 2 Cylinder 2
A Outlet valve 3 Cylinder 3
E Inlet valve 4 Cylinder 4
1 Cylinder 1
Turn the crankshaft in the direction of rotation 5 until the valves of the
fourth cylinder overlap.
Adjust the valves of the first cylinder.

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Maintenance tasks

Adjusting the valves

Push a feeler gauge 5 between the valve 4 and the rocker arm 3 and
check the valve play.
If the valve play is not correct:
Loosen the counter nut 2 of the adjusting screw for the rocker arm 3
using a 17 mm ring spanner 6, and correct the setting using a 4 mm Allen
key 1. Tighten the counter nut 2 again.
Check the valve play again after you tighten the counter nut 2.
Check the other cylinders and adjust them as necessary by turning the
crankshaft until the valves overlap as shown in the table.
After checking and adjusting the valves, put on the valve cover with
new seals.
Put the belt guard and intake line back on.

3.5.15 Checking the valve play L538, L542

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Valid for: L538 - 433 / from 17890; L542 - 435 / from 17890
Make sure that:
The machine is in maintenance position 1.
The engine compartment hood is open.
You have the special cranking device, a feeler gauge and cylinder head
seals ready.
The engine is cold or has been allowed to cool for at least two hours.
Conventions on the cylinder numbering, direction of rotation and position of
the valves:
Cylinder 1 on flywheel side
Direction of rotation anticlockwise looking at the flywheel
Outlet valves on flywheel side

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Maintenance tasks

Valve play D 934 S

Inlet valve 0.30 mm
Outlet valve 0.40 mm

Engine D 934 S
Cylinder
Overlap Adjust
4 1
2 3
1 4
3 2

Procedure
Take off the cylinder head covers.
Attach the cranking device (ID no. 0524045) to the flywheel housing.
For reasons of space, use extensions on the cranking device to the rear
towards the ratchet.
Turn the crankshaft in the direction of rotation until the valves of the
cylinder to be adjusted. See the table for specifications.

Push a feeler gauge between the valve and the rocker arm and check the
valve play.

If the valve play is not correct:

Loosen the counter nut on the adjusting bolt for the rocker arm, adjust it
and tighten the nut again.
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Check the valve play again after you tighten the counter nut.
After checking and adjusting, put on the cylinder head covers with
new seals.

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Maintenance tasks

3.5.16 Checking the heating flange L524, L528

Valid for: L524 - 659 / from 17890; L528 - 660 / from 17890
Make sure that:
The machine is in maintenance position 1.
The engine compartment hood is open.
You have an ohmmeter or a multimeter ready.

Procedure

1 heating flange 2 Connection

Turn off the battery main switch.
Disconnect the electrical connection cable on the heating flange 1.
Connect the ohmmeter or multimeter to the terminal and check the
resistance (approx. 0.2 0.6 Ohm at 20 °C).
Disconnect the electric connection cable on the heating flange.
Turn on the battery main switch.

3.5.17 Checking the heating flange L538, L542

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Valid for: L538 - 433 / from 17890; L542 - 435 / from 17890
Make sure that:
The machine is in maintenance position 1.
The engine compartment hood is open.
You have an ohmmeter or a multimeter ready.

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Maintenance tasks

Procedure

Turn off the battery main switch.

Disconnect the electric connection cable 2 on the heating flange 1.
Connect the ohmmeter or multimeter to the terminal and check the
resistance (0.25 Ohm +/-10% at 20 °C).
Disconnect the electric connection cable on the heating flange.
Turn on the battery main switch.

3.5.18 Greasing the ring gear on the flywheel L538, L542

Valid for: L538 - 433 / from 17890; L542 - 435 / from 17890
Make sure that:
The machine is in maintenance position 1.
The engine compartment hood is open.

Procedure

Oil separator
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Unscrew the service cap 1 from the flywheel housing.

Check the starter gear ring 2 and lightly grease it.
Briefly run the engine and turn it off again. Apply more grease
if necessary.

Note
There may not be any grease on the sensor ring gear 3.

Screw the service cap 1 back on.

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Maintenance tasks

3.5.19 Changing the oil separator filter insert L538, L542

Valid for: L538 - 433 / from 17890; L542 - 435 / from 17890
The oil separator is on the flywheel side, on the right side of the engine.
Make sure that:
The machine is in maintenance position 1.
You have a genuine LIEBHERR oil separator filter insert ready.

Procedure

Oil separator
Carefully clean the oil separator and the area around it.
Unscrew the oil separator cap and take it off, using a screwdriver
if necessary.

3.5.20 Checking the bearings and condition of the engine

control units L524, L528
Valid for: L524 - 659 / from 17890; L528 - 660 / from 17890
Make sure that:
The machine is in maintenance position 1.
The engine compartment hood is open.

Procedure
Check that the bearings are properly seated and undamaged.
If you find any loose bearings:
Do not start the engine until you have tightened the screws.
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Maintenance tasks

3.5.21 Checking the bearings and condition of the engine control

units L538, L542
Valid for: L538 - 433 / from 17890; L542 - 435 / from 17890
Make sure that:
The machine is in maintenance position 1.
The engine compartment hood is open.

Procedure
Check that the bearings are properly seated and undamaged.
If you find any damaged bearings:
Do not start the engine until you have replaced all the bearings.

3.5.22 Checking the sensors and cable connections L524, L528

Valid for: L524 - 659 / from 17890; L528 - 660 / from 17890
Make sure that:
The machine is in maintenance position 1.
The engine compartment hood is open.
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Electrical engine components

1 Water temperature sensor 5 Crankshaft speed sensor
2 Rail pressure control valve 6 Rail pressure control valve
3 Rail pipe 7 Pump position sensor
4 Rail pressure sensor 8 Fuel temperature sensor

Procedure
Check that all the sensors and cable connections are properly seated and
in good condition.
Check that none of the cables and wiring harnesses are damaged, rub or
not properly fastened.
If you find any damaged cables, wiring harnesses or sensors:
Do not start the engine until you have replaced the defective parts.

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Maintenance tasks

3.5.23 Checking the sensors and cable connections L538, L542

Valid for: L538 - 433 / from 17890; L542 - 435 / from 17890
Make sure that:
The machine is in maintenance position 1.
The engine compartment hood is open.

Electrical engine components

1 Heating flange R701 6 Magnetic coupling M710 11 Oil pressure sensor B701
2 Starter M700 7 Alternator G700 12 Flywheel speed sensor B712
3 Thermostat B708 8 Engine electronics 13 Camshaft speed
4 Charge air pressure (LH-ECU) A700 sensor B713
sensor B703 9 Pump element magnetic 14 Flywheel speed sensor B711
5 Charge air temperature coil Y711 Y716
sensor B707 10 Water sensor B710

Procedure
Check that all the sensors and cable connections are properly seated and
in good condition.
Check that none of the cables and wiring harnesses are damaged, rub or
not properly fastened.
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If you find any damaged cables, wiring harnesses or sensors:

Do not start the engine until you have replaced the defective parts.

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Maintenance tasks

3.5.24 Changing the fuel pre-filter L524, L528

Valid for: L524 - 659 / from 17890; L528 - 660 / from 17890
Make sure that:
The machine is in maintenance position 1.
The engine compartment hood is open.
You have a suitable receptacle ready.
You have a LIEBHERR fuel pre-filter cartridge ready.

Procedure

DANGER
There is a risk of fire and explosions.
Do not smoke
Avoid naked flames.
Only work with the engine switched off and cooled down.

Place a receptacle under the fuel pre-filter.

Carefully clean the fuel pre-filter and the area around it.
Unplug the electrical connector 4.
Drain off the fuel. To do this, unscrew the bleeder screw 1 and drain plug 5.
Unscrew the retaining ring 2 anticlockwise and pull off the filter cartridge 3.
Unscrew the water separator container 6 from the filter cartridge 3.
Dispose of the old filter cartridge.
Wash the water separator container and dry it with compressed air.
Lightly lubricate the sealing ring of the water separator container.
Screw the water separator container onto the new filter cartridge.
Screw in the drain plug 5.
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Check the filter base, clean it and replace it if necessary.

Clean and oil the seals.
Fit a new filter cartridge 3 on the filter base.

Note
Make sure that the slots 7 in the filter base and the lugs 8 on the filter
cartridge are lined up.

Fit the snap ring and tighten it clockwise. The snap ring clicks into
the notch.
Plug in the electrical connector 4.
Close the bleeder screw 1.
Bleeding the fuel pre-filter:
See the section on bleeding the fuel system.

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Maintenance tasks

3.5.25 Changing the fuel pre-filter L538, L542

Valid for: L538 - 433 / from 17890; L542 - 435 / from 17890
On the right side of the diesel engine you can find:
The fuel pre-filter with water separator and depending on the engine
type fuel pre-heater (optional)
Water level probe
Integrated fuel hand pump
Bleeding the water of the fuel prefilter must be conducted after the water
level probe activates.
Make sure that:
The machine is in maintenance position 1.
The engine compartment hood is open.
You have a suitable receptacle ready.
Only use LIEBHERR spare parts.

Procedure

DANGER
There is a risk of fire and explosions.
Do not smoke
Avoid naked flames.
Only work with the engine switched off and cooled down.
Place a receptacle under the fuel pre-filter.
Carefully clean the fuel pre-filter and the area around it.

Fuel prefilter cartridge

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Disconnect the electrical connections of the water level probe 8 and the
fuel preheater 9 (optional).
Drain the fuel:
Unscrew the bleeder screw 6 and drain plug 5.
Release the filter cartridge 3 with a strap wrench or similar tools and
unscrew it.

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Maintenance tasks

Fuel water separator container

Unscrew the water separator container 4 from the filter cartridge 3.
Wash the water separator container and dry it with compressed air.
Lightly oil the O-ring 9 of the water separator container.
Screw the water separator container to the new filter cartridge until the O-
ring touches the filter cartridge.
Tighten the water separator container half a turn by hand.
Screw in the drain plug 5.
Check the filter head is clean and ensure that the thread adapter is firmly
in the filter head.
If the filter head is dirty:
Clean the filter head.
Lubricate the sealing ring 10 of the new filter cartridge with clean fuel.
Fill the filter cartridge via the holes on the outside and screw it on until the
sealing ring lies on the filter head.
Tighten the filter cartridge 3 half a turn by hand.
Disconnect the electrical connections of the water level probe 8 and the
fuel preheater 7 (optional).
Close the bleeder screw 6.
Bleeding the fuel pre-filter:
See the section on bleeding the fuel system.

3.5.26 Changing the fuel fine filter L524, L528

Valid for: L524 - 659 / from 17890; L528 - 660 / from 17890
LBH/Version 01/01.2008/en/lbhleh1/29.08.2014

Make sure that:

The machine is in maintenance position 1.
The engine compartment hood is open.
You have a suitable receptacle ready.
You have a LIEBHERR fuel pre-filter cartridge ready.

Procedure

DANGER
There is a risk of fire and explosions.
Do not smoke
Avoid naked flames.
Only work with the engine switched off and cooled down.

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Place a receptacle under the fuel fine filter.

Carefully clean the fuel fine filter and the area around it.
Open the drain screw 3 on the fuel fine filter by two or three turns.
Drain off the condensate into a suitable receptacle.
Turn the retaining ring 1 on the fine filter to the left, (possibly using a
strap wrench), take off the retaining ring and pull out the filter cartridge 2.
Clean the seal on the filter head.
Oil the seal on the new filter cartridge.
Fit a new filter cartridge 2 on the filter base. Make sure that the slot 4 in
the filter base and the lugs 5 on the filter element are lined up.
Fit the snap ring 1 and tighten it by 1/3 turn clockwise. The snap ring
clicks into the notch.
Bleeding the fuel fine filter
See the section on bleeding the fuel system.

3.5.27 Changing the fuel fine filter L538, L542

Valid for: L538 - 433 / from 17890; L542 - 435 / from 17890
Make sure that:
The machine is in maintenance position 1.
The engine compartment hood is open.
You have a suitable receptacle ready.
Only use LIEBHERR spare parts.

Procedure

DANGER
There is a risk of fire and explosions.
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Do not smoke
Avoid naked flames.
Only work with the engine switched off and cooled down otherwise
there is a risk of explosions.

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Place a receptacle under the fuel fine filter.

Carefully clean the fuel fine filter and the area around it.
Unscrew the fuel fine filter 1 (using a suitable strap wrench).
Check the filter base is clean and ensure that the thread adapter is firmly
in the filter base.
If the filter base is dirty:
Clean the filter base.
Lubricate the sealing ring 2 of the new filter cartridge with clean fuel.
Fill the filter cartridge and screw it on until the sealing ring lies on the
filter head.
Tighten the filter cartridge 1/2 a revolution by hand with a filter wrench.
Bleeding the fuel fine filter
See the section on bleeding the fuel system.

3.5.28 Draining off condensate from the fuel filter L524,L52

Valid for: L524 - 659 / from 17890; L528 - 660 / from 17890
After the integrated water level probe in the fuel prefilter is activated
(the service code is displayed), the water collector tank must be drained.

DANGER
There is a risk of fire and explosions.
Do not smoke
Avoid naked flames.
Only work with the engine switched off and cooled down.
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Draining the fuel pre-filter

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Make sure that:

The machine is in maintenance position 1.
The engine compartment hood is open.
You have a suitable receptacle ready.

Draining off condensate from the fuel pre-filter

Unscrew the bleeder screw 1 by 2 to 3 turns.
Open the drain plug 3 and drain the water until fuel emerges
without bubbles.
Tighten the drain plug 3.
Tighten the bleeder screw 1.
Bleeding the fuel pre-filter:
See the section on bleeding the fuel system.

Draining off condensate from the fuel fine filter

Unscrew the bleeder screw 6 by 2 to 3 turns.
Open the drain plug 4 and drain the water until fuel emerges
without bubbles.
Tighten the drain plug 4.
Tighten the bleeder screw 6.
Bleeding the fuel fine filter
See the section on bleeding the fuel system.

3.5.29 Draining off condensate from the fuel filter L538,L542

Valid for: L538 - 433 / from 17890; L542 - 435 / from 17890
After the integrated water level probe in the fuel prefilter is activated
(the service code is displayed), the water collector tank must be drained.

DANGER
There is a risk of fire and explosions.
Do not smoke
Avoid naked flames.
Only work with the engine switched off and cooled down.

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Draining the fuel pre-filter

Make sure that:
The machine is in maintenance position 1.
The engine compartment hood is open.
You have a suitable receptacle ready.

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Draining off condensate from the fuel

Place a receptacle under the fuel pre-filter and attach a drain hose if
necessary.
Open the drain plug, drain the water until fuel emerges without bubbles.
When fuel emerges:
Tighten the drain plug.
Bleeding the fuel system
See the section on bleeding the fuel system.

3.5.30 Bleeding the fuel system L524, L528

Valid for: L524 - 659 / from 17890; L528 - 660 / from 17890
Bleeding the fuel filter is necessary after:
Changing the fuel filter
Emptying the fuel tank
Make sure that:
The machine is in maintenance position 1.
The engine compartment hood is open.

DANGER
There is a risk of fire and explosions.
Do not smoke
Avoid naked flames.
Only work with the engine switched off and cooled down.
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Bleeding the fuel pre-filter

Unscrew the bleeder screw 1 on the fuel pre-filter 2 by 2 to 3 turns.
Push the hand pump 3 until bubble-free fuel comes out of the
bleeder screw.
Tighten the bleeder screw 1.
Continue to operate the hand pump until you feel strong resistance.

Bleeding the fuel fine filter

Unscrew the bleeder screw 5 on the fuel fine filter 4 by 2 to 3 turns.
Push the hand pump 3 until bubble-free fuel comes out of the
bleeder screw.
Tighten the bleeder screw 5.
Continue to operate the hand pump until you feel strong resistance.

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3.5.31 Bleeding the fuel system L538, L542

Valid for: L538 - 433 / from 17890; L542 - 435 / from 17890

DANGER
There is a risk of fire and explosions.
Do not smoke
Avoid naked flames.
Only work with the engine switched off and cooled down.

Bleeder screw on the head of the fuel prefilter

Make sure that:
The machine is in maintenance position 1.
The engine compartment hood is open.

Bleeding the fuel system

Unscrew the bleeder screw 1 on the top of the fuel prefilter by 2 to 3 turns.
Operate the hand pump 2.
When fuel flows out of the bleeder screw without bubbles:
Tighten the bleeder screw 1 (tightening torque 8 ±1 Nm).
Continue to operate the hand pump until you feel strong resistance.

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Bleeder screw on the head of the fuel fine filter

Unscrew the bleeder screw 1 on the top of the fuel fine filter by 2 to 3 turns.
Operate the hand pump 2.
When fuel flows out of the bleeder screw without bubbles:
Tighten the bleeder screw 1.
Continue to operate the hand pump until you feel strong resistance.

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Bleeder screw on the crankcase

Unscrew the bleeder screw 1 on the crankcase (if present) by 2 to
3 revolutions.
Operate the hand pump 2.
When fuel flows out of the bleeder screw without bubbles:
Tighten the bleeder screw 1.
Continue to operate the hand pump until you feel strong resistance.

Bleeding the fuel system with the bleeding function

It is necessary when the fuel tank has run completely empty and there is air
in the fuel system.
You can remove some of the air from the fuel system by bleeding the
fuel filter.
You can bleed the air between the injection pump and the injection nozzle by
activating engine bleeding mode.

DANGER
There is a risk of fire and explosions.
Do not smoke
Avoid naked flames.
Only work with the engine switched off and cooled down.
Bleed the fuel filter:
See the section on bleeding the fuel filter.
Activate the engine bleeding function.
Activation sequence:
Turn the ignition on
With the engine not running, press the button for 10 seconds.
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All 3 LEDs on the button light up when the engine bleeding function
is activated.
Turn the ignition key to position II and keep it in there until the
engine starts.
Do not hold the key in the starting position for more than
20 seconds at a time.
The ECU ends the engine bleeding function automatically as soon as the
engine starts again.
If the engine does not start:
Wait a minute and repeat the procedure. In the meantime, continue to
operate the hand pump until you feel strong resistance.

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3.5.32 Draining off condensate and sediment from the fuel tank
Make sure that the machine is in maintenance position 1.

Procedure

Remove the cover plate 1 by loosening the two 17 mm screws.

Unscrew the sealing cap on the drain valve 2 on the bottom of the fuel tank 3.
Screw the drain hose onto the drain valve 2.
Drain the condensation and sediment into a suitable receptacle until
clean fuel begins to flow.
Unscrew the drain hose, screw the sealing cap onto the drain valve 2 and
tighten it.
Screw on the cover plate with the two screws onto the fixing hole 3
(front and rear).

3.5.33 Cleaning the air filter service cap and dust extraction valve
Important: With the engine running at lower idle speed, you should clearly
feel air pulsating at the dust extraction valve.
If the valve is damaged, the dust extraction function is impaired and the
filters become clogged more quickly.
Make sure that:
The machine is in maintenance position 1.
The engine compartment hood is open.

Procedure for cleaning the dust extraction valve

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Air filter
1 Secondary element 4 Fixing clips
2 Primary element 5 Dust extraction valve
3 Service cap 6 Air filter housing
Press the rubber seal on the dust extraction valve 5 several times to
remove the dust from the service cap 3.
When working in dusty conditions, check and empty the dust extraction
valve 5 more often.
If the dust extraction valve is damaged or stays open:
Replace the dust extraction valve.

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Procedure for cleaning the service cap

Open the fixing clips 4 on the service cap 3 and take the cap off.
Clean the service cap.
Put the service cap back on the filter housing. The dust extraction valve 5
must face down.
Only when the lid completely covers the filter housing can you close the
fixing clips without excessive force.
Close the fixing clips 4.

3.5.34 Test the air filter vacuum switch

Make sure that:
The machine is in maintenance position 1.
You have a big enough plate available.

Procedure

Testing the vacuum switch

Take the rain cap 1 off the intake pipe 2.
Start the engine.
Slowly and carefully push the plate over the opening of the intake pipe 2.
At the same time, check whether the indicator lamp in the cab lights up or
the warning buzzer sounds.
If the intake pipe is just sealed and you do not hear a warning signal:
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Check the vacuum switch and wiring, and replace it if necessary.

3.5.35 Changing the air filter main element when indicated by the
vacuum switch
The primary element 2 should be replaced when the air filter contamination
symbol field on the display unit lights up.
If the air filter contamination symbol field remains lit after the primary element
2 has been serviced then the secondary element 1 must also be replaced.
Make sure that:
The machine is in maintenance position 1.
The engine compartment hood is open.

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Procedure

Air filter
1 Secondary element 4 Fixing clips
2 Primary element 5 Dust extraction valve
3 Service cap 6 Air filter housing
Open the fixing clips 4 on the service cap 3 and take the cap off.
Remove the primary element 2 and the secondary element 1. To do this
pull or turn the elements gently upwards, downwards or to the side in
order to release the seal.
Ensure that all dirt is removed from the filter housing before inserting a
new filter cartridge.
The secondary element 1 should be replaced every third time the primary
element 2 is replaced.
Lightly oil the seal surfaces before installing the filter cartridges (for the
primary element 2 this is on the inside, for the secondary element 1 on
the outside). Re-insert filter elements 1 and 2 and make sure that they
are correctly fitted.
Clean the service cap 3 and put it on the filter housing with the dust
extraction valve 5 facing down.
Only when the lid completely covers the filter housing can you close the
fixing clips without excessive force.
Close the fixing clips 4.

3.5.36 Changing the air filter secondary element

If the air filter contamination symbol field remains lit after the primary
element 2 has been serviced then the secondary element 1 must also be
replaced.
After replacing the primary element three times or at the latest after one
year, the secondary element must be replaced.
Make sure that:
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The machine is in maintenance position 1

The engine compartment hood is open
The battery main switch is switched off and the main switch key
is removed.

Procedure

Air filter

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1 Secondary element 4 Fixing clips

2 Primary element 5 Dust extraction valve
3 Service cap 6 Air filter housing
Open the fixing clips 4 on the service cap 3 and take the cap off.
Remove the secondary element 1. To loosen the seal, pull or twist the
element slightly up, down or sideways.
Ensure that all dirt is removed from the filter housing before inserting a
new or cleaned filter element.
Before installing the filter element, lightly oil the seal surface. On the
secondary element 1 this is the outside.
Re-insert the secondary element 1 and make sure that it is correctly fitted.
Clean the service cap 3 and put it on the filter housing with the dust
extraction valve 5 facing down.
Only when the lid completely covers the filter housing can you close the
fixing clips without excessive force.
Close the fixing clips 4.

3.5.37 Checking the air suction hoses for leaks and tight fitting
Make sure that:
The machine is in maintenance position 1.
The engine compartment hood is open.

Procedure
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Checking the air suction hoses for leaks and tight fitting
Check the following hoses and clips for looseness, damage and cracks:
The intake hose 4 between the air intake pipe 2 and the filter housing 5.
Check the turbo hose 7 between the filter housing 5 and the
turbocharger.
Check that the hose clips 3 and 6 on these hoses are tight.

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3.5.38 Checking the exhaust lines for leaks and tight fitting
Make sure that:
The machine is in maintenance position 1.
The engine compartment hood is open.

Procedure

Check that the clip 5, nuts 4 and seal 6 on the exhaust pipe between the
turbocharger and the silencer are tightly fastened and do not leak.
Check that the clip 2, tailpipe bolts 1 and silencer bolts 3 are tight.
Check that the alignment B of the flex pipe (aligned along both axes) and
the length compensation A of the flex pipe are correct.
The effective length of the flex pipe must be between the maximum and
minimum possible length of the flexible section.

3.5.39 Checking the coolant antifreeze and corrosion inhibitor

concentration
All year round, the coolant must contain at least 50% by volume of
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concentrated antifreeze, but not more than 60% by volume.

This protects against freezing down to around - 37 °C.
Make sure that:
The machine is in maintenance position 1.
The engine compartment hood is open.
You have the optical density tester kit or antifreeze tester ready.

Procedure for checking the antifreeze concentration

CAUTION
There is a danger of scalding due to coolant escaping under pressure.
Only open the cap on the filler neck once the engine has cooled down.
Check the coolant temperature.

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Open the sealing cap on the filler neck 1.

Take a sample of the coolant and check the antifreeze concentration
using the test tool.
If the antifreeze concentration is too low:
See the procedure for correcting the antifreeze concentration.

Procedure for correcting the antifreeze concentration

L524, L528 engine drain plug

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L538, L542 engine drain plug

Drain off the coolant and top up with pure antifreeze according to the
following diagram.

CAUTION
There is a risk of damage to the engine.
Too much antifreeze and corrosion protection agent impairs the cooling effect.
This eventually causes damage to the diesel engine.
Never use more than 60% antifreeze and corrosion inhibitor.

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Selection for antifreeze concentration

1 Amount of pure antifreeze to be 3 Example -15 °C 5 Total capacity of cooling system
added in litres 4 Measured coolant freezing point in litres
2 Guidelines in °C
Procedure for the example -15 °C:
If the total filling quantity is 25 litres and a temperature of -15 °C is measured
in the cooling system:
Follow the guideline 3 (starting from the measured temperature) to the
left down to the vertical line indicating the total filling quantity for the
cooling system 5 and from this point horizontally to the left edge.
This gives you the topping up quantity of pure antifreeze and corrosion
protection agent 1 to be added in order to achieve protection down to -37° C.
To restore the correct mixing ratio, you must drain off at least the
previously calculated quantity from the cooling system.

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Top up with the correct quantity of pure antifreeze and corrosion

protection agent.
The coolant previously drained off can be used if necessary to restore the
required coolant level.

Using anti-corrosion agent without antifreeze

In exceptional cases and when outside temperatures never fall below
freezing, such as tropical zones, where it is demonstrable that no approved
antifreeze and corrosion protection agent is available, corrosion inhibitors
may be used.
The coolant must be changed once a year.
The mixing ratio must consist of 7.5% corrosion inhibitor and 92.5% water.
The GEFO 2710 refractometer is recommended for testing.
See the section on coolant for diesel engines under lubricants and fuels.

Procedure for checking the coolant antifreeze concentration

CAUTION
There is a danger of scalding due to coolant escaping under pressure.
Only open the cap on the filler neck once the engine has cooled down.
Check the coolant temperature.

Carefully open the sealing cap on the filler neck.

Check the antifreeze concentration with a 2710 refractometer from GEFO.

GEFO refractometer no. 2710

Set the focus by turning the eyepiece.
Test procedure
Clean the cover and the prism carefully.
Place 1 or 2 drops of test fluid on the prism. The fluid is distributed by
closing the prism.
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Look through the eyepiece against a light background and focus the scale.
Read off the values on the blue line.

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Conversion table from Brix to corrosion inhibitor concentration (%vol)

Convert the value using the conversion diagram to find the actual
corrosion inhibitor conventration.
If the concentrations are not correct:
Refill with corrosion inhibitor until the required value is attained.

3.5.40 Cleaning the cooling system

Clean the coolers whenever necessary in order to ensure proper cooling. In
dusty environments, check the coolers every day and clean it if necessary.
Dirty cooler units result in overheating. The consequence is an audible and
visual warning with simultaneous power reduction of the travel drive.
Dust and other contaminants can be removed from the cooling fins with
water jets, steam or compressed air. Compressed air is preferable.
Make sure that:
The machine is in maintenance position 1.
The cooling system grille has been removed.
The air conditioning condenser (optional) is pulled forward.

Procedure

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NOTICE
Risk of damage to the cooling system
Careless handling can damage the cooler fins.
Do not use hard objects or excessive water pressure for cleaning.

Clean the cooler units 2 with compressed air, steam or water.

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3.5.41 Changing the coolant L524, L528

Valid for: L524 - 659 / from 17890; L528 - 660 / from 17890
Use clean, fresh water with a pH value between 6.5 and 8.5 and a low
sulphate / chlorine content for preparing the coolant.
The coolant must be prepared outside the cooling system.
Always dispose of any coolant which you have drained off but no longer
need according to the applicable regulations.
Make sure that:
The machine is in maintenance position 1.
The engine compartment hood is open.
You have a suitable receptacle and drain hose (on-board tools) ready.

Procedure

CAUTION
There is a danger of scalding due to coolant escaping under pressure.
Only open the cap on the filler neck once the engine has cooled down.
Check the coolant temperature.

Open the sealing cover 1 on the filler neck 2.

Open the sealing cap 4, screw on the drain hose and let the coolant flow
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into the receptacle.

If the coolant is very dirty or corrosive, flush out the cooling system
several times.
Close the cap 4 again.
Top up the coolant in the equalising reservoir 3 until you can see the
coolant in the filler neck 2.
Close the cover 1.
Start the engine and let it run at low idling speed.
Set the heater to warm.
Turn off the engine and check the coolant level again.

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3.5.42 Changing the coolant L538, L542

Valid for: L538 - 433 / from 17890; L542 - 435 / from 17890
Use clean, fresh water with a pH value between 6.5 and 8.5 and a low
sulphate / chlorine content for preparing the coolant.
The coolant must be prepared outside the cooling system.
Always dispose of any coolant which you have drained off but no longer
need according to the applicable regulations.
Make sure that:
The machine is in maintenance position 1.
The engine compartment hood is open.
You have a suitable receptacle and drain hose (on-board tools) ready.

Procedure

CAUTION
There is a danger of scalding due to coolant escaping under pressure.
Only open the cap on the filler neck once the engine has cooled down.
Check the coolant temperature.

Open the sealing cover 1 on the filler neck 2.

Open the cap 4, screw on the drain hose and let the coolant flow into
the receptacle.
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If the coolant is very dirty or corrosive, flush out the cooling system
several times.
Close the cap 4 again.
Top up the coolant in the equalising reservoir 3 until you can see the
coolant in the filler neck 2.
Close the cover 1.
Start the engine and let it run at low idling speed.
Set the heater to warm.
Turn off the engine and check the coolant level again.

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3.5.43 Checking the oil level in the hydraulic tank

Hydraulic tank
Make sure that:
The machine is cold.
The machine is in maintenance position 1.
The cooling system flap is open.

Procedure for checking the hydraulic oil level

The MIN MAX marking shows the correct oil level.
Check the oil level in the sight glass 1.
If the oil level is too low:
Top up with hydraulic oil.

Procedure for topping up with hydraulic oil

Release the tank pre-pressure: Unscrew the bleeder filter 1 on the

hydraulic tank.
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The hydraulic oil may only be poured in through the return strainer.
Open the cover 2 of the return strainer.
Top up the hydraulic oil to the correct level.
Put the cover 2 on the housing with the spring and tighten it up.
Screw on the bleeder filter.

3.5.44 Draining off condensate and sediment from the

hydraulic tank
Make sure that:
The machine has not been used for at least 3 hours.
The machine is in maintenance position 1.
The engine compartment hood is open.
You have a receptacle ready for water and oil.

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Procedure

Unscrew the cap 1 from the drain valve.

Connect the drain hose and let the water and sediment flow into the
receptacle.
Take off the drain hose and screw the cap onto the drain valve 1.

3.5.45 Changing the oil in the hydraulic tank

Make sure that:
The machine is at operating temperature.
The machine is in maintenance position 1.
The engine compartment hood is open.
You have a receptacle of around 100 l capacity for the used oil.

Procedure for draining hydraulic oil

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Release the tank pre-pressure: Unscrew the bleeder filter 1.

Unscrew the cap 3 from the drain valve.
Connect the drain hose and let the oil flow into the receptacle.
Take off the drain hose and screw the cap onto the drain valve 3.

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Procedure for filling hydraulic oil

Release the tank pre-pressure: Unscrew the bleeder filter 1.

The hydraulic oil may only be poured in through the return strainer.
Open the cover 2 of the return strainer.
Top up the hydraulic oil to the correct level.
Put the cover 2 on the housing and tighten it up.
Screw in the bleeder filter 1.

Special function – hydraulic oil adjustment

The type of hydraulic oil used is stored in the master controller (UEC3). This
setting is also required for the quick-filling phase of the gear switch coupling.
The travel range down button can be used to activate this mode. With the
ignition turned on, press the button until the segment display shows P7 X Hyd .
The display unit brightness control button can be used to change the
hydraulic oil.
The following conditions are possible, and will be shown in the segment
Travel range selection Brightness display P7 of the display unit:
control
1 Hydraulic oil - Liebherr Hydraulic Basic 68 (ISO VG 68)
2 Hydraulic oil - Liebherr Hydraulic HVI, Plus, Panolin (ISO VG 46)
3 Hydraulic oil - Liebherr Motoroil SAE 10W-40
4 Hydraulic oil - Liebherr Hydraulic Basic 100 (ISO VG 100)
Segment display P7 5 Hydraulic oil - Liebherr Hydraulik Arctic Plus (VG 15 - 46)
You can also set the type of hydraulic oil using the Sculi diagnostic software:
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3.5.46 Checking and cleaning the magnetic rod on the

hydraulic tank
Make sure that:
The machine is in maintenance position 1.
The cooling system flap is open.

Procedure

Release the tank pre-pressure: Undo the bleeder filter 1 by two turns.
Open the lid with the magnetic rod 2 and carefully lift it off.

Troubleshooting
Serious contamination or large metal fragments on the magnetic rod may
indicate damage to the hydraulic system.
In this event, locate the problem and rectify it.

Carefully clean the magnetic rod.

Put the cover with the magnetic rod 2 on the housing and tighten it.
Screw in the bleeder filter 1.

3.5.47 Changing the hydraulic tank return suction filter

Make sure that:
The machine is in maintenance position 1.
The cooling system flap is open.
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Procedure

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Release the tank pre-pressure: Undo the bleeder filter 1 by two turns.
Open the lid with the magnetic rod and carefully lift it off.

Troubleshooting
Serious contamination or large metal fragments on the magnetic rod may
indicate damage to the hydraulic system.
In this event, locate the problem and rectify it.

Let the filter element 2 drip dry and take it out.

Put in a new filter element.
Carefully clean the magnetic rod.
Put the cover on the housing with the magnetic rod and tighten it up.
Screw in the bleeder filter 1.

3.5.48 Changing the hydraulic tank bleeder filter

Make sure that:
The machine is in maintenance position 1.
The cooling system flap is open.

Procedure

You cannot clean the bleeder filter. The bleeder filter 1 and its plastic
housing must be changed at the intervals in the maintenance schedule.
Unscrew the old bleeder filter.
Screw on the new bleeder filter.
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3.5.49 Lubricating the pilot control device solenoids, universal

joints and tappets
Make sure that the machine is in maintenance position 1.

Procedure
Take the rubber sleeve 5 of the control lever off the retaining plate 4.
Move the control lever in the appropriate direction for better access.
Clean the retaining solenoids 1 with a brush.
Lubricate the universal joints 2 and the discs 3 with a brush.
Start the machine and check the retaining function of the solenoids.
Fit the rubber sleeve of the control lever on the retaining plate.

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3.5.50 Testing the steering

Make sure that:
The working attachment is in the transport position
There is enough space to test the steering

Procedure

CAUTION
Beware of accidents
Do not allow anyone into the danger area while the test is
being conducted.
Perform the test on level ground with no obstacles.

Start the engine.

Without moving the machine, turn the steering in both directions and
check that it is functioning properly.

3.5.51 Lubricating the bearing points on the steering cylinders

Make sure that:
The machine is in maintenance position 1.
The articulation lock is engaged if possible.

Procedure

Lubricating the bearing points on the steering cylinders.

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3.5.52 Testing the service brake and parking brake

Procedure for checking the service brake
Make sure that there is enough room to check the service brake.

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WARNING
Beware of running over bystanders or obstacles.
Do not allow anyone into the danger area while these tests are
being conducted.
Perform the test on level ground with no obstacles.

Start the machine, and drive it forwards at around 8 km/h.

While moving, push the inch/brake pedal 1 all the way down. The
machine must come to an abrupt stop.

Troubleshooting
If the braking effect is too slight or entirely absent:
Locate the fault and repair the rectify with the brake system.

Procedure for checking the parking brake

Make sure that there is enough room to check the parking brake.
Start the machine and drive it forwards at around 5 km/h.
Press the parking brake button while travelling.
The machine must come to an abrupt halt.
The symbol field for the parking brake lights up.

Troubleshooting
If the braking effect is too slight or entirely absent:
Locate the fault and repair the rectify with the brake system.

3.5.53 Checking the service brake discs for wear

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Valid for: L524 - 659 from 17890; L528 - 660 from 7890;
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3.5.54 Checking the gap and wear on the parking brake linings
Wear on the brake pads 8 can increase the gap between them and the brake
disc. If the gap is too wide, it must be adjusted.
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Make sure that:

The machine is in maintenance position 2.
Wedges are in place to secure the machine against rolling away.

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Procedure for checking the wear on the brake linings

Visually check the thickness of the lining on both pads 8.
If the linings are less than 1 mm thick:
Replace the brake pads as follows.
Start the engine and press the parking brake button (the brake is open,
under oil pressure).
Unscrew the cap 7, loosen the nut 5 and unscrew the adjusting screw 6.
Take out the cotter pin 4 and unscrew the castle nut 3.
Remove the guide pin 1 and swing out the entire brake caliper.
Replace the worn brake pads 2 with new ones.
Fit the brake caliper and the guide pin 1 in the reverse order.
Adjust the brake pad gap as described below.

Procedure for checking the brake pad gap

Start the engine and press the parking brake button (the brake is open,
under oil pressure).
Check the gap X with a feeler gauge (it should be 1 ±0.5 mm).
If the gap is not correct:
Adjust the gap to the minimum of 0.5 mm.
Unscrew the cap 7 and loosen the lock nut 5.
Tighten the adjusting screw 6 until the gap X is 0.5 mm.
Tighten the lock nut 5.
Engage the parking brake several times and check the gap again.
Screw on the cap 7 and tighten it.
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3.5.55 Checking the indicator lamps and lighting

Make sure that the machine is in maintenance position 1.

Procedure
When you switch on the ignition, the lamps on the display unit are tested. All
symbol fields light up for three seconds.
Switch on the ignition.
Check that the symbol fields on the display unit light up.
Check that all lights are working.

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3.5.56 Checking the batteries, fluid level and terminals

The batteries are housed in the right ballast weight and can be accessed by
opening the engine hood.
The batteries must always be in perfect condition in order for the machine to
work reliably.
Make sure that:
The machine is in maintenance position 1.
The battery main switch is switched off and the main switch key is
taken out.

WARNING
Batteries give off explosive gases. Battery acid is highly corrosive.
Do not smoke. Avoid naked flames when handling, servicing or
recharging batteries.

CAUTION
Beware of sparks and explosions!
Use a special terminal brush.

Wipe the battery with a clean cloth.

Clean the terminals and the connectors.
To guarantee a good connection, check that the connectors are tight on
the terminals, and tighten them if necessary.
Smear the terminals and connectors with acid-proof grease such
as vaseline.
At very high temperatures, the acid level in the individual cells can drop due
to different rates of evaporation.
Open the plugs on each cell and check the acid level.
Check the charge using an acid density tester.
If the charge is too low (acid density below 1.26 kg/l):
Recharge the batteries.
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If there is a risk of frost, it is important that the batteries are not discharged.
Otherwise the electrolyte can freeze and irreparably damage the battery.
If the acid level is too low:
Top up with distilled water to around 10 mm above the plates.

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3.5.57 Replacing the travel direction switch control lever rocker

and the pushbutton cover (optional)

Replace the travel direction switch rocker:

Set the ignition to OFF.

Insert a small screwdriver below the centre axis between the rocker and
the travel direction switch and lift out the rocker (see figure 1).

CAUTION
The travel direction switch can damage the seal (see figure 2/1)!
A damaged seal can affect the function of the travel direction switch.
Insert the screwdriver by a maximum of 5 mm.

Figure 1: Rocker
Check the seal for damage (see figure 2/1).
If the seal is damaged:
Replace the travel direction switch.
Place new rocker on the travel direction switch.

Figure 2: The travel direction switch seal

Replace the pushbutton cover (optional):

Unscrew both (2) Torx screws (size 8) (see figure 3/1).
Remove the pushbutton cover (see figure 3/2).

NOTE
To be able to disassemble the pushbutton cover more easily, press both LH
control lever grip plates together.
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Figure 3: Pushbutton cover

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Place buttons in the new pushbutton cover (see figure 4).

NOTE
Pay attention to the different sizes of the buttons!
Figure 4: Buttons

Place the pushbutton cover on the LH control lever. Pay attention to the
anti-twist lock (see figure 5)!

Figure 5: Anti-twist lock

NOTE
To keep the buttons from falling out of the pushbutton cover during
assembly:
Secure the three buttons by pressing them lightly from the outside to the in-
side (see figure 6).

Tighten the 2 TORX screws to a torque of 50 Ncm (see figure 6/1).

Figure 6: Pushbutton cover
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3.5.58 Checking the transfer gear oil level

Procedure

CAUTION
Do not open the filling, drain and level plugs when the transfer gear is hot, as
pressurised oil can cause scalding.
Slowly unscrew the filling plug 2 to allow any excess pressure to subside.

Remove the filling plug 2 on the axle transfer gear.

The oil level must be visible in the opening.
If you cannot see the oil level in the transfer gear or if it is much lower
than the opening:
Top up with gear oil using the same opening.
If the oil level is too high:
Drain the oil to the correct level and rectify the cause.

3.5.59 Changing the transmission oil

Make sure that:
The machine is in maintenance position 2.
The oil prescribed in the section on lubricants and fuels is available.
The oil in the gearbox is warm.
You have a suitable oil receptacle ready for disposal.
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Procedure

CAUTION
Do not open the filling, drain and level plugs when the transfer gear is hot, as
pressurised oil can cause scalding.
Slowly unscrew the filling plug 2 to allow any excess pressure to subside.

Remove the filling plug 2 on the axle transfer gear.

Open the drain plug 1 on the gearbox and drain the oil into a
suitable receptacle.
After completely draining, screw the drain plug 1 back in.

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Using a suitable hand pump or filling hose with a funnel, top up oil via the
filler opening 2 until the level is correct or oil comes out of the opening.
Screw in the filling plug 2 on the axle transfer gear.
Dispose of the used oil properly.

3.5.60 Checking the wheel tightness

Make sure that:
The machine is in maintenance position 1.
A 30 mm torque wrench with a measuring range of over 650 Nm is
available.

Procedure
Check that the nuts on all four wheels have been tightened with the
required torque of 650 Nm.

Note
This one-off maintenance tasks scheduled for 50, 100 and 250 service hours
must be performed every time the wheels are changed.
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3.5.61 Checking the axle oil levels

Make sure that the machine is in maintenance position 2.

Procedure for checking the oil level in the differential

CAUTION
Do not open the filling, drain and level plugs when the transfer gear is hot, as
pressurised oil can cause scalding.
Slowly unscrew the filling plug 2 to allow any excess pressure to subside.

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Open the filling plugs 1 and check the oil level.

If you cannot see the oil level in the differential or if it is much lower than
the opening:
Top up with gear oil using the same opening.
If the oil level is too high:
Drain the oil to the correct level and rectify the cause.
Close the filling plugs 1.

Procedure for checking the oil level in the wheel hub

CAUTION
Do not open the filling, drain and level plugs when the transfer gear is hot, as
pressurised oil can cause scalding.
Slowly unscrew the filling plug 2 to allow any excess pressure to subside.

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Turn the wheel hubs until the filling plug 1 is horizontal.

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Open the filling plug 1 on the wheel hub and check the oil level.
If you cannot see the oil level in the wheel hub or if it is much lower than
the opening:
Top up with gear oil using the same opening.
If the oil level is too high:
Drain the oil to the correct level and rectify the cause.

3.5.62 Changing the axle oil

Make sure that:
The machine is in maintenance position 2.
The oil prescribed in the section on lubricants and fuels is available.
The oil in the axles is warm.
You have a suitable oil receptacle ready for disposal.

Procedure for changing the oil in the differential

Open the filling plug 1.

Remove the drain plug 2 and catch the oil in a suitable receptacle.
After completely draining, screw the drain plug 2 back in.
Top up the oil on the differential up to the filling inlet 1.
Check the oil level after a few minutes and top up if necessary.
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Screw in the filling plug 1.

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Procedure for changing the oil in the differential

Turn the wheel hub until the drain plug 1 is right at the bottom.
Slowly unscrew the filling plug 1 to let off any pressure.
Open the plug 2 and and drain the oil into a receptacle.
After completely draining, close the drain plug 2.
Top up oil to the filling plug 1 (marked) on the filling inlet.
Screw in the filling plug 1.

3.5.63 Checking the tightening torque of the front axle fastening

bolts
Make sure that:
The machine is in maintenance position 2.
You have a torque wrench ready.

Procedure LBH/Version 01/01.2008/en/lbhleh1/29.08.2014

Front axle fastening bolts

Check the tightening torque of 850 Nm on all fastening bolts 1 (spanner
size 36 mm) on the front axle.

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3.5.64 Checking the tyre pressure

The air pressure in the tyres has a significant influence on the overall
operating performance of the machine.
The tyre pressure depends on the following factors:
The tyres used
The purpose the machine is used for
The attachment installed
For special uses where heavier loads may be expected, a higher tyre
pressure is recommended.
However, the tyre pressure may not be greater than the maximum
permitted by the tyre manufacturer s specifications.
Make sure that:
The machine is in maintenance position 1.
The correct tyre pressures are available.
The tyre pressures stated refer to cold tyres.

Procedure

WARNING
Exploding tyres can cause serious injury.
If the tyre inflation equipment is incorrectly or carelessly used or if the tyre
pressure is too high, the tyres may burst or the rims may come off, causing
severe, or possibly even fatal injuries.
Use a sufficiently long hose with a self-locking adapter for pumping
the tyres.
Always keep outside the danger zone when tyres are being pumped up.

Check the air pressure in all the tyres and adjust if necessary.

3.5.65 Lubricating the articulation bearing and rear oscillating

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bearing
Make sure that:
The machine is in maintenance position 1.
The articulation lock is engaged.

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Procedure

Lubricating the articulation bearing and rear oscillating bearing

Lubricate the front oscillating bearing (lubrication points 1).
Lubricate the rear oscillating bearing (lubrication points 2).

3.5.66 Lubricating the elongated hole on the accelerator pedal and

checking the bearing
Make sure that the machine is in maintenance position 1.

Accelerator pedal

1 Flight pin 3 Linkage

2 Elongated hole 4 Bearing

Clean the accelerator pedal.

Clean the bearing 4.
Clean the flight pin 1 and the elongated hole 2.
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Lubricate the flight pin and the elongated hole.

Check that the bearing 4 moves easily.
If the bearing is stiff: Replace the accelerator pedal.
Check that the bearing is not loose.
If the bearing has too much play, the tolerance range of the angle sensor on
the accelerator pedal is exceeded. This triggers service codes that are
saved in the Analyzer.
If you notice any play:
Connect the Sculi diagnostic software to the machine.
Use the Analyzer to check whether it contains any service codes
indicating a fault with the accelerator pedal.
If service codes indicating a fault with the accelerator pedal have been
stored:
Replace the accelerator pedal.

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3.5.67 Greasing the cab door hinges

Make sure that the machine is in maintenance position 1.

Procedure
Lubricate the door hinges with a grease gun.
For grease specifications, see the section on lubricants and fuels.

3.5.68 Checking / topping up the windscreen washer reservoir

Make sure that the machine is in maintenance position 1.

Procedure
Open the washer reservoir 3 and put in the washer additive.
Correct the antifreeze concentration.
Activate the washer system and switch on the wipers.
Check the spray pattern of the nozzles and test the front and rear wipers
1 and 2.
If necessary, adjust the nozzles and replace the wiper blades.

3.5.69 Cleaning the fresh air and recirculated air filter

Make sure that the machine is in maintenance position 1.

Procedure for cleaning the fresh air filter

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Open the door 1.

Take out the lint filter 2 and clean it (blow it out) or replace it.
Unscrew the fresh air filter 3 at the bottom on the front lug and clean it
(blow it out or wash it).
Insert the clean filter, making sure it is correctly fitted (the arrows
moulded on the filter frame point towards the air taken in).
Close the door again.

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Procedure for cleaning the recirculated air filter

Remove the pin 2.

Open the door 1.
Clean the recirculated air filter 3 (blow it out or wash it).
Put in a clean or new filter.
Close the door again.

3.5.70 Changing the fresh air and recirculated air filter

Make sure that the machine is in maintenance position 1.

Procedure for changing the fresh air filter

Open the door 1.

Take out the lint filter 2 and clean it (blow it out) or replace it.
Unscrew the fresh air filter 3 at the bottom on the front lug and change it.
Insert the new fresh air filter 3, making sure it is correctly fitted
(the arrows moulded on the filter frame point towards the air taken in).
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Close the door again.

Procedure for changing the recirculated air filter

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Remove the pin 2.

Open the door 1.
Take out the recirculated air filter 3 and change it.
Put in a new filter.
Close the door again.

3.5.71 Checking the indicator and filling level beads in the dryer-
collector unit (optional) of the air conditioner
The dryer-collector unit is located on the right under the cooling
system hood.

Procedure

Sight glass in the dryer-collector unit

Check the orange bead 2 (moisture indicator).
If the orange bead 2 has turned transparent:
There is moisture in the refrigerant circuit. You must replace the dryer-
collector and the compressor oil and refill the system.
The white bead 1 shows the filling level of R134a refrigerant in the circuit
and acts as an indicator during initial filling.
When the air conditioning is switched on and the ambient temperature is
above 20 °C, the white bead 1 should start to float.
The filling level can vary due to temperature fluctuations. It also sinks in time
due to natural leakage. This does not impair operation.
If the cooling performance deteriorates, one of the causes can be a low
refrigerant level.
In normal circumstances, one filling lasts for three to five years.
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3.5.72 Lubricating the lift arms and attachment (Z kinematics)

Make sure that the machine is in maintenance position 2.

Procedure

Bearings and lubricating points on the lift arms (Z kinematics)

Move the lift arms and the bucket to the position shown.
Secure the machine against rolling away with wheel wedges.
Grease all the bearing and lubrication points on the lift arms at the
specified intervals.
For grease specifications, see the section on lubricants and fuels.
If fitted, grease the lubrication points on the attachment.
The lower bucket bearings should be lubricated daily if necessary.
If fitted, lubricate the optional quick-change device. See the section on
lubricating the quick-change device.

3.5.73 Lubricating the lift arms and attachment (P kinematics)

Make sure that the machine is in maintenance position 2.

Procedure

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Bearings and lubricating points on the lift arms (P kinematics)

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Move the lift arms and the bucket to the position shown.
Secure the machine against rolling away with wheel wedges.
Grease all the bearing and lubrication points on the lift arms at the
specified intervals.
For grease specifications, see the section on lubricants and fuels.
If fitted, grease the lubrication points on the attachment.
The lower bucket bearings should be lubricated daily if necessary.
If fitted, lubricate the optional quick-change device. See the section on
lubricating the quick-change device.

3.5.74 Checking the lift arm bearing bushings

Dirt or insufficient lubrication can cause wear on the bearing bushings.
The increased play between the pin and bearing bushing causes noises.
Replace the bearing bushings in good time to prevent damage to the
material of the bucket arm.

Procedure for lift arms with Z kinematics

Checking the bearing bushings

Move the lift arms and the bucket to the position shown.
Gently and rapidly tilt the bucket in and out, and check the bearing points
for noise and play.
If there is significant play at the bearing points or loud noise:
Replace the bearing bushings.
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Procedure for lift arms with P kinematics

Checking the bearing bushings

Move the lift arms and the bucket to the position shown.
Gently and rapidly tilt the bucket in and out, and check the bearing points
for noise and play.
If there is significant play at the bearing points or loud noise:
Replace the bearing bushings.

3.5.75 Checking the lift arm bucket stops (Z kinematics)

Check the buckets stops for wear.
Make sure that the machine is in maintenance position 2.
If the sequence is correct, there is play at stop 1 and no play at stop 2.
The stop sequence is the same for lift arms with and without a quick-
change device.

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Lift arms with Z kinematics

a Lift arms without b Lift arms with 1 Bucket stop
quick-change device: quick-change device: 2 Linkage stop
Start the machine and raise the lift arms to about half way.
Retract the tilt cylinder so that there is no play at the stop 2 on
the linkage.
Turn off the engine.
Check that the gap 1 at the bucket stop is correct.

Designation Value Unit

Gap 5 ±3 mm

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3.5.76 Lubricating and testing the quick-change device

Procedure for lubricating the quick-change device

Make sure that the machine is in maintenance position 2.
If the lubricating points near the bucket coupling are poorly accessible:
The working attachment is disconnected

Quick-change device lubrication points

Lubricate the quick-change device.
For grease specifications, see the section on lubricants and fuels.

Procedure for testing the quick-change device

Make sure that:
The lift arms have been lowered.
The working attachment is tilted in.

The operation of the quick-change device can vary according to the version
or the type of machine.

WARNING
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Failure to use the quick-change device properly can cause accidents.

Follow the safety instructions.

To check that it is working properly:

Unlock the quick-change device and lock it again. This prevents the
locking pins from jamming and preventing the quick-change device from
being released.
For safety reasons, check that the quick-change device is properly
locked again.

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Maintenance tasks

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 Service manual Maintenance
Testing and adjustment tasks

3.6 Testing and adjustment tasks

3.6.1 Preparing for testing and adjustment
During the warranty period, only trained and authorised specialist staff may
carry out adjustments on the machine.
Make sure that:
The machine is in maintenance position 2.
The machine is at operating temperature (except when testing the
air conditioning).
The adjustment data for the machine is available or known.
Seals and safety caps are at hand.
The following special tools are available.

Special tools
Number Description ID no.
1 USB dongle for SCULI 1033 3608
1 Data lead for SCULI 1003 5410
2 Manometer, 0 - 40 bar class 1.0 7361 288
2 Manometer, 0 - 600 bar class 1.0 5002 866
2 4000 mm test leads 7009 134
2 1500 mm test leads 7002 475

Safety precautions for testing and adjustment

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

Visual contact
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Maintenance Service manual
Testing and adjustment tasks

3.6.2 Bringing the machine up to operating temperature

During testing and adjustment, the machine must be at an operating
temperature of 58±5 °C. The temperature is measured by the hydraulic oil
sensor and can be seen in SCULI.

Procedure
Unlock the cooler unit 3 using the lever 2 and open it.
Place a piece of cardboard between the hydraulic cooler 1 (the area
outlined in white) and the cooler unit 3, then lock it again.
Connect your laptop, start the engine and run the SCULI program.
In the variables editor in the group structure, select the Adjustment
Block Curve folder.
The Hydraulic Oil - Calculated Temperature variable shows the
hydraulic oil temperature during the adjustment.

58.1

Bring the machine up to operating temperature as follows:

Run the engine at around 2000 min-1.
Activate the tilt-in function as far as it will go and hold the control lever in
this position.
At the same time, lower the lift arms and hold the control lever in the
float position function.
Operate the travel hydraulics in travel range 1.
Bring the machine up to operating temperature until the hydraulic oil
±5
temperature is 58 °C.
When working on the hydraulic system, the hydraulic oil temperature must
be within the prescribed range.
After finishing the adjustment, take the piece of card out of the oil cooler
and lock the cooler unit.

3.6.3 Checking the fan motor and fan control pressure

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relief valve
Make the following checks on the fan motor:
Check the fan control (with the hydraulic oil temperature sensor
1 disconnected).
Test the pressure relief valve 7 on the fan motor 5 (with the plug on the
proportional valve disconnected).

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 Service manual Maintenance
Testing and adjustment tasks

Fan drive components

1 Hydraulic oil 3 Test connection 6 Proportional solenoid
temperature sensor 4 Fan gear pump 7 Pressure relief valve with
2 Temperature sensor 5 Proportional protective cap
connector solenoid connector
You can check the fan using the system pressure, measured at the test
connection 3 on the gear pump 4.

Checking the fan control

Connect a manometer (250 bar) to the test connection 3 on the gear
pump 4.
Disconnect the hydraulic oil temperature sensor 1.
Start the engine and bring it to top idle speed.
Check whether the pressure is correct at top engine idle speed.
Valid for: L524 - 659 / from 17890; L528 - 660 / from 17890
Description Value Unit
±10
Fan pressure 75 bar
Fan speed 1600 min-1

Valid for: L538 - 433 / from 17890; L542 - 435 / from 17890
Description Value Unit
±10
Fan pressure 120 bar
Fan speed 1700 min-1
If it is not correct:
Check the fan motor pressure relief valve
LBH/Version 01/01.2008/en/lbhleh1/29.08.2014

Checking the fan motor pressure relief valve

Connect a manometer (250 bar) to the test connection 3 on the gear
pump 4.
Pull out the plug 5 on the proportional solenoid 6.
Start the engine and bring it to top idle speed.
Check whether the pressure is correct at top engine idle speed.
If it is not correct:
Adjust the pressure relief valve 7 on the proportional solenoid 6 (using
the adjusting screw and a 5 mm open-end spanner the lock nut is a
round nut).
Turn clockwise to increase the pressure and anticlockwise to reduce it.
Remove the cap on the pressure relief valve 7.
±10
Adjust the screw on the proportional valve: 175

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Maintenance Service manual
Testing and adjustment tasks

3.6.4 Calibrating the Inch pedal

The Inch pedal can only be calibrated using the SCULI software.
During calibration, the MIN and MAX positions of the Inch pedal are stored in
the electronic controller.

Procedure
Connect your laptop, turn on the start switch and run the SCULI program.
In the variables editor in the group structure, select the Adjustment
Pedals folder.
Set Inch pedal - start adjustment to 1.
Push the inch pedal all the way down.
The MIN and MAX positions of the inch pedal are stored. After 15
seconds the value automatically returns to 0 and calibration is finished.
Check that Inch pedal - guide value is 100% when the pedal is not
pressed and 0% when the pedal is pressed all the way down.

100,0

3.6.5 Checking the engine speed

You can see the engine speed in the RPM segment display in the
display unit.
The engine speed cannot be mechanically adjusted; it is determined directly
by the engine control unit.
Cab display unit
Procedure
Start up the engine.
Check that the top and bottom engine speeds are correct.
If it is not correct:
Calibrate the gas pedal using the SCULI program and service the engine.
Check the top and bottom idle speeds again.
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 Service manual Maintenance
Testing and adjustment tasks

Valid for: L524 - 659 / from 17890; L528 - 660 / from 17890
Description Value Unit
Lower idle speed 850 10
min-1
20 -1
Upper idle speed 2550 min

Valid for: L538 - 433 / from 17890; L542 - 435 / from 17890
Description Value Unit
Lower idle speed 900±10 min-1
±20 -1
Upper idle speed 2060 min

3.6.6 Checking the replenishing pressure of the variable

displacement pump L524, L528
Valid for: L524 - 659 / from 17890; L528 - 660 / from 17890

Procedure
Measure the replenishing pressure at the test connection G.
Connect a manometer (40 bar) to the test connection G.
Start the machine and let the engine run at top idling speed.
Check that the replenishing pressure is correct.
If it is not correct:
Turn the adjusting screw on the replenishing pressure relief valve 1 until
the replenishing pressure is correct.

Description Value Unit

Replenishing pressure 34±1 bar

3.6.7 Checking the replenishing pressure of the variable

displacement pump L538, L542
Valid for: L538 - 433 / from 17890; L542 - 435 / from 17890

Procedure
Measure the replenishing pressure at the test connection G.
Connect a manometer (40 bar) to the test connection G.
Start the machine and let the engine run at top idling speed.
Check that the replenishing pressure is correct.
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If it is not correct:
Turn the adjusting screw on the replenishing pressure relief valve 1 until
the replenishing pressure is correct.

Description Value Unit

±1
Replenishing pressure 34 bar

3.6.8 Checking the pressure relief and replenishing valve of the

variable displacement pump
The pressure relief and replenishing valves protect the variable displacement
pump from pressure peaks. These can occur when braking the machine.
When a pressure peak occurs, oil flows from the high pressure side via
the pressure relief and replenishing valve to the low pressure side in a
closed circuit.

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Maintenance Service manual
Testing and adjustment tasks

Procedure
To attain the set value for the pressure relief and replenishing valves, the
pressure cut-off must be set to a higher value.
Screw in the adjusting screw 1 on the pressure cut-off by one turn.
Connect a manometer (600 bar) to the test connections MA and MB.
Use SCULI to set the Inch pedal - function OFF variable to 1 the
inching function is disabled.
Check the pressure relief and replenishing valve 2 for forward travel on the
manometer MA.
Check the pressure relief and replenishing valve 3 for reverse travel on the
manometer MB.
Select forward or reverse travel, and hold the machine in the blocked
condition using the service brake.

NOTICE
Heat is quickly generated when you test the pressure relief and
replenishing valves.
Excessive heat can irreparably damage the pump.
Only test the pressure relief and replenishing valves for a short time.
In the blocked condition, increase the engine speed to the maximum.
Check that the high pressure at the two pressure relief and replenishing
valves is correct.
If it is not correct:
Turn the adjusting screw on the pressure relief and replenishing valve
until the high pressure is correct.
Loosen the adjusting screw 1 on the pressure cut-off by one turn and
check the pressure cut-off.
Use SCULI to set the Inch pedal - function OFF variable back
to 0 the inching function is enabled.
Description Value Unit
10
High pressure 470 bar

3.6.9 Checking the pressure cut-off of the variable

displacement pump L524, L528
Valid for: L524 - 659 / from 17890; L528 - 660 / from 17890
The pressure cut-off limits the maximum pressure of the variable
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displacement pump.
When this pressure is reached, the pump flow is automatically reduced in
order to maintain the maximum permitted pressure.

Procedure
Connect a manometer (600 bar) to the test connection MA.
Use SCULI to set the Inch pedal - function OFF variable to 1 the
inching function is disabled.
Select forward travel and hold the machine in the blocked condition using
the service brake.
In the blocked condition, increase the engine speed to the maximum.
Check that the high pressure on the manometer MA is correct.
Check that the engine suppression is below the threshold.

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 Service manual Maintenance
Testing and adjustment tasks

If it is not correct:
Turn the adjusting screw 1 on the pressure cut-off 1 until the manometer
MA reaches the correct value.
Use SCULI to set the Inch pedal - function OFF variable back to 0
the inching function is enabled.

Description Value Unit

5
High pressure 440 bar
-1
Maximum engine suppression at top 50 min
idle speed

3.6.10 Checking the pressure cut-off of the variable

displacement pump L538, L542
Valid for: L538 - 433 / from 17890; L542 - 435 / from 17890
The pressure cut-off limits the maximum pressure of the variable displace-
ment pump.
When this pressure is reached, the pump flow is automatically reduced in
order to maintain the maximum permitted pressure.

Procedure
Connect a manometer (600 bar) to the test connection MA.
Use SCULI to set the Inch pedal - function OFF variable to 1 the
inching function is disabled.
Select forward travel and hold the machine in the blocked condition using
the service brake.
In the blocked condition, increase the engine speed to the maximum.
Check that the high pressure on the manometer MA is correct.
Check that the engine suppression is below the threshold.
If it is not correct:
Turn the adjusting screw 1 on the pressure cut-off until the manometer
MA reaches the correct value.
Use SCULI to set the Inch pedal - function OFF variable back to 0
the inching function is enabled.

Description Value Unit

5
High pressure 440 bar
-1
Maximum engine suppression at top idle 30 min
speed
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Maintenance Service manual
Testing and adjustment tasks

3.6.11 Calibrating the block curve L524, L528

Valid for: L524 - 659 / from 17890; L528 - 660 / from 17890
The block curve can only be calibrated using the SCULI software.
During calibration, the current to the proportional valve on the variable
displacement pump is adjusted so that the pump reaches a set pressure at a
set engine speed.

Procedure
Connect a manometer (600 bar) to the test connection MA.
Connect your laptop, start the engine and run the SCULI program.
In the variables editor in the group structure, select the Adjustment
Block Curve 524/528 folder.
Set the Inch pedal - function OFF variable to 1 the inching function is
disabled.
Set the Travel pump - diesel restriction to block curve support point
-1
variable to 1 the engine speed is restricted to 930 min .
-1 -1 -1
Note: 0 = no restriction, 1 = 930 min , 2 = 1300 min , 3 = 1600 min ,
-1 -1
4 = 2000 min , 5 = 2200 min .
Select forward travel and hold the machine in the blocked condition using
the service brake.
Depress the gas pedal and check the high pressure.
If it is not correct:
Adjust the Travel pump – current at 930, 1300, 1600, 2000, 2200 rpm
(JD) variables until the set value is reached.
Set the Inch pedal - function OFF variable back to 0 the inching
function is enabled.

932
58.1
1

1
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Description Value Unit

-1 10
High pressure at 930 min engine speed 50 bar
-1 10
High pressure at 1300 min engine speed 180 bar
-1 10
High pressure at 1600 min engine speed 260 bar
-1 10
High pressure at 2000 min engine speed 350 bar
-1 10
High pressure at 2200 min engine speed 435 bar

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 Service manual Maintenance
Testing and adjustment tasks

3.6.12 Calibrating the block curve L538, L542

Valid for: L538 - 433 / from 17890; L542 - 435 / from 17890
The block curve can only be calibrated using the SCULI software.
During calibration, the current to the proportional valve on the variable
displacement pump is adjusted so that the pump reaches a set pressure at a
set engine speed.

Procedure
Connect a manometer (600 bar) to the test connection MA.
Connect your laptop, start the engine and run the SCULI program.
In the variables editor in the group structure, select the Adjustment
Block Curve 538/542 folder.
Set the Inch pedal - function OFF variable to 1 the inching function
is disabled.
Set the Travel pump - diesel restriction to block curve support point
-1
variable to 1 the engine speed is restricted to 930 min .
Note: 0 = no restriction, 1 = 930 min , 2 = 1200 min , 3 = 1300 min-1,
-1 -1

4 = 1700 min-1.
Select forward travel and hold the machine in the blocked condition using
the service brake.
Depress the gas pedal and check the high pressure.
If it is not correct:
Adjust the Travel pump – current at 930, 1200, 1400, 1700 rpm (LH)
variables until the set value is reached.
Set the Inch pedal - function OFF variable back to 0 the inching
function is enabled.

932
58.4
LBH/Version 01/01.2008/en/lbhleh1/29.08.2014

Description Value Unit

-1 10
High pressure at 930 min engine speed 50 bar
-1 10
High pressure at 1200 min engine speed 180 bar
-1 10
High pressure at 1400 min engine speed 260 bar
-1 10
High pressure at 1700 min engine speed 350 bar

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Maintenance Service manual
Testing and adjustment tasks

3.6.13 Checking the start of regulation for variable

displacement motor 1 L524, L528
Valid for: L524 - 659 / from 17890; L528 - 660 / from 17890
Perform this check in the blocked condition.

Procedure
Connect a manometer (600 bar) to the test connection MA on the
variable displacement pump.
Connect a manometer (600 bar) to the test connection M1 on the variable
displacement motor 1.
In the variables editor in the group structure, select the Adjustment
Block Curve 524/528 folder.
Set the Inch pedal - function OFF variable to 1 the inching function
is disabled.
Start the engine and select forward travel.
In the blocked condition, slowly increase the engine speed until the
manometer MA shows approximately 300 bar.
Slowly reduce the engine speed until the servo pressure at the test
connection M1 is 50 bar.
Check that the high pressure at the test connection MA is correct.
If the high pressure in the control range is too high:
Tighten the adjusting screw 1.
If the high pressure in the control range is too low:
Loosen the adjusting screw 1.
Set the Inch pedal - function OFF variable back to 0 the inching
function is enabled.

Description Value Unit

±10
Variable displacement pump 250 bar
high pressure at MA
Variable displacement motor 1 50±10 bar
servo pressure at M1

3.6.14 Checking the start of regulation for variable

displacement motor 1 L538, L542
Valid for: L538 - 433 / from 17890; L542 - 435 / from 17890
Perform this check in the blocked condition.
LBH/Version 01/01.2008/en/lbhleh1/29.08.2014

Procedure
Connect a manometer (600 bar) to the test connection MA on the
variable displacement pump.
Connect a manometer (600 bar) to the test connection M1 on the variable
displacement motor 1.
In the variables editor in the group structure, select the Adjustment
Block Curve 538/542 folder.
Set the Inch pedal - function OFF variable to 1 the inching function
is disabled.
Start the engine and select forward travel.
In the blocked condition, slowly increase the engine speed until the
manometer MA shows approximately 300 bar.
Slowly reduce the engine speed until the servo pressure at the test
connection M1 is 50 bar.

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 Service manual Maintenance
Testing and adjustment tasks

Check that the high pressure at the test connection MA is correct.

If the high pressure in the control range is too high:
Tighten the adjusting screw 1.
If the high pressure in the control range is too low:
Loosen the adjusting screw 1.
Set the Inch pedal - function OFF variable back to 0 the inching
function is enabled.
Description Value Unit
Variable displacement pump high 250 ±10 bar
pressure at MA
Variable displacement motor 1 servo 50 ±10 bar
pressure at M1

3.6.15 Calibrating variable displacement motor 2

The variable displacement motor 2 is automatically calibrated by the master
electronics (UEC-3).

Procedure
Connect your laptop, start the engine and run the SCULI program.
In the variables editor in the group structure, select the Adjustment
travel motors folder.
Set the Travel motor 2 - start adjustment to 1.
The engine speed is automatically increased at the maximum and minimum
swivel angles. After this, variable adjustment motor 2 is calibrated across the
entire speed range.
After calibration, the Travel motor 2 - start adjustment variable returns to 0.

58.4

4125
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Note: Once the automatic calibration of variable adjustment motor 2 is

complete, a service code appears in the display.
This can happen if the variable displacement motor 2 current is too high or
low. In this case, the variable displacement motor 2 must be adjusted using
the adjusting screw 1.
Service codes:
E503A Maximum current too low (< 560 mA) Loosen the adjusting screw
E503B Maximum current too high (> 680 mA) Tighten the adjusting screw
E503C Minimum current too high (> 290 mA) Tighten the adjusting screw
E503D Minimum current too low (< 160 mA) Loosen the adjusting screw

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Maintenance Service manual
Testing and adjustment tasks

3.6.16 Checking the engine output

Before you check the power of the engine, you must carry out the
following tasks:
Tasks in maintenance schedule (air filter, fuel filter etc.).
Check the operating pressures according to the adjustment checklist.
The machine must be at operating temperature.
The engine test takes place at a speed of 3 km/h. It is regulated using
variable displacement motor 1.
Engine at around rated speed: good engine output
Engine below threshold level (lower tolerance): poor engine output
If the engine output is poor, the engine speed falls below the set value.

Procedure
Connect a manometer (600 bar) to the test connection MA.
In the variables editor in the group structure, select the Check diesel
engine folder.
Set the Inch pedal - function OFF variable to 1 the inching function
is disabled.
Start the machine and select forward or reverse travel direction.
Hold the machine with the service brake and run it at full throttle.
Slowly release the service brake until the machine moves at 3 km/h.
Check that the set values are reached.
If they are not correct:
Troubleshoot the engine: air filter, fuel filter etc.
Troubleshoot the travel hydraulics: check the operating pressure etc.

3.1

LBH/Version 01/01.2008/en/lbhleh1/29.08.2014

Set the Inch pedal - function OFF variable back to 0 the inching
function is enabled.
Valid for: L524 - 659 / from 17890; L528 - 660 / from 17890
Description Value Unit
High pressure 240±10 bar
+50 -1
Diesel engine speed 2300 -170 min

Valid for: L538 - 433 / from 17890; L542 - 435 / from 17890
Description Value Unit
High pressure 240±10 bar
1900 -150 min-1
+30
Diesel engine speed

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 Service manual Maintenance
Testing and adjustment tasks

3.6.17 Checking the secondary pressure relief valves on the

control block L524, L528
Valid for: L524 - 659 / from 17890; L528 - 660 / from 17890

Procedure
Connect a manometer (600 bar) to the test connection P on the working
hydraulics pump.
Loosen the adjusting screws on the secondary pressure relief valves 2,
3 and 4 on the control block by half a turn. Note: only unscrew 4 on Z
lift arms.
Start the machine and let the engine run at lower idling speed.
Raise the lift arms, tilt out the bucket, tilt in the bucket and operate the
additional equipment, each to the limit.
Check that the pressure at each secondary pressure relief valve is correct.
If it is not correct:
Turn the adjusting screw on the secondary pressure relief valve until it
is correct.
After testing, tighten the secondary pressure relief valves 2, 3 and 4 by
half a turn. Note: only screw in 4 on Z lift arms.

Description Value Unit

±5
Lifting function (2) 250 bar
±5
Tilt-in function (3) 220 bar
±5
Tilt-out function (4) Z kinematics 220 bar
±5
Tilt-out function (4) P kinematics 150 bar
±5
Additional equipment function (1 + 5) 250 bar
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Maintenance Service manual
Testing and adjustment tasks

3.6.18 Checking the secondary pressure relief valves on the

control block L538, L542
Valid for: L538 - 433 / from 17890; L542 - 435 / from 17890

Procedure
Connect a manometer (600 bar) to the test connection P on the working
hydraulics pump.
Loosen the adjusting screws on the secondary pressure relief valves 2,
3 and 4 on the control block by half a turn. Note: only unscrew 4 on Z
lift arms.
Start the machine and let the engine run at lower idling speed.
Raise the lift arms, tilt out the bucket, tilt in the bucket and operate the
additional equipment, each to the limit.
Check that the pressure at each secondary pressure relief valve is correct.
If it is not correct:
Turn the adjusting screw on the secondary pressure relief valve until it
is correct.
After testing, tighten the secondary pressure relief valves 2, 3 and 4 by
half a turn. Note: only screw in 4 on Z lift arms.
Description Value Unit
±5
Lifting function (2) 250 bar
±5
Tilt-in function (3) 220 bar
±5
Tilt-out function (4) Z kinematics 220 bar
±5
Tilt-out function (4) P kinematics 150 bar
±5
Additional equipment function (1 + 5) 250 bar

3.6.19 Checking the LS pressure cut-off on the

control block L524, L528
Valid for: L524 - 659 / from 17890; L528 - 660 / from 17890

Procedure
The LS pressure cut-off 1 for the working hydraulics and the LS pressure
cut-off 2 for the steering are valves screwed into the control block.
Connect a manometer (600 bar) to the test connection P on the working
hydraulics pump.
Start the machine and let the engine run at lower idling speed.
Raise the lift arms to the limit.
LBH/Version 01/01.2008/en/lbhleh1/29.08.2014

Check that the pressure is correct.

If it is not correct:
Turn the adjusting screw on the LS pressure cut-off 1
(working hydraulics) until the pressure is correct.
Turn the steering as far as it will go and continue moving the
steering wheel.
Check that the pressure is correct.
If it is not correct:
Turn the adjusting screw on the LS pressure cut-off 2 (steering) until the
pressure is correct.

Description Value Unit

±5
LS working hydraulics pressure cut-off (1) 315 bar
±5
LS steering pressure cut-off (2) 250 bar

3.6-14 of 22 Copyright L524 - 659 / from 17890

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 Service manual Maintenance
Testing and adjustment tasks

3.6.20 Checking the LS pressure cut-off on the control block L538, L542
Valid for: L538 - 433 / from 17890; L542 - 435 / from 17890

Procedure
The LS pressure cut-off 1 for the working hydraulics and the LS pressure
cut-off 2 for the steering are valves screwed into the control block.
Connect a manometer (600 bar) to the test connection P on the working
hydraulics pump.
Start the machine and let the engine run at lower idling speed.
Raise the lift arms to the limit.
Check that the pressure is correct.
If it is not correct:
Turn the adjusting screw on the LS pressure cut-off 1 (working
hydraulics) until the pressure is correct.
Turn the steering as far as it will go and continue moving the steering wheel.
Check that the pressure is correct.
If it is not correct:
Turn the adjusting screw on the LS pressure cut-off 2 (steering) until the
pressure is correct.

Description Value Unit

±5
LS working hydraulics pressure cut-off (1) 330 bar
±5
LS steering pressure cut-off (2) 250 bar

3.6.21 Checking the flow controller of the working

hydraulics pump L524, L528
Valid for: L524 - 659 / from 17890; L528 - 660 / from 17890
Measure the standby pressure at the test connections P with the working
hydraulics not actuated.

Procedure
Connect a 40 bar manometer to the test connection P.
Start the engine and let it run at low idling speed.
Check that the standby pressure at the test connection P is correct.
If it is not correct:
Turn the adjusting screw on the flow controller 1 until the standby
pressure is correct.
LBH/Version 01/01.2008/en/lbhleh1/29.08.2014

Description Value Unit

Flow controller standby pressure 32±2 bar

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Maintenance Service manual
Testing and adjustment tasks

3.6.22 Checking the flow controller of the working

hydraulics pumpL538, L542
Valid for: L538 - 433 / from 17890; L542 - 435 / from 17890
Measure the standby pressure at the test connections P with the working
hydraulics not actuated.

Procedure
Connect a 40 bar manometer to the test connection P.
Start the engine and let it run at low idling speed.
Check that the standby pressure at the test connection P is correct.
If it is not correct:
Turn the adjusting screw on the flow controller 1 until the standby
pressure is correct.

Description Value Unit

Flow controller standby pressure 32±2 bar

3.6.23 Depressurising ride control and the hydro accumulators

You must depressurise the system before checking and filling the hydro
accumulator or making repairs to the ride control system.
This is how to depressurise the ride control system:

Procedure
Note: Perform the following actions in the correct sequence.
Put the machine and the lift arms in maintenance position 2.
The working attachment and lift arms must lie on the ground under their
own weight.
Turn off the engine.
Connect a manometer (40 bar) to the test connection M4 on the
front axle.
Connect the same test line to the test connection MX.
The pressure can then be relieved through this line to the tank. This takes
around 5 minutes.
After 5 minutes, take the test line off test connection M4 and drain the
remaining fluid into a suitable receptacle.
Leave the test line connected during the testing and repair work.
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After servicing, remove the test line from test connection MX.

3.6.24 Checking the cut-off pressure in the stabilisation module

The cut-off function limits the pressure in the hydro accumulator when ride
control is deactivated. This is how to check the cut-off pressure:
The cut-off pressure is fixed by the spring force. This means the cut-off
pressure cannot be adjusted.

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 Service manual Maintenance
Testing and adjustment tasks

Procedure
Connect a manometer (600 bar) to the test connection MX on the
stabilisation module.
Start the diesel engine (with ride control deactivated).
With the engine idling, raise the lift arms to their full height to build up
pressure.
Check that the high pressure on the manometer is correct (reading the
highest value).
If it is not correct:
Find the cause and rectify the fault.

Description Value Unit

High pressure 120±20 bar

3.6.25 Checking the nitrogen in the ride control hydro accumulator

Make sure that you have a charging and testing device with a
nitrogen bottle.
The hydro accumulator can only be tested or filled when it is depressurised.
Note: The nitrogen chamber of the hydro accumulator has around 350 cm³
of oil in it to protect the membrane.

Procedure
Depressurise the ride control system as described in the section on
depressurising ride control and the hydro accumulator.

Take off the cap and slightly loosen the plug 2 of the hydro accumulator
using a 6 mm allen key.
Connect the charging and testing device 4 to the hydro accumulator.
Open the valve 6 and check whether the nitrogen filling is correct.
If it is not correct:
Slowly open the valve 8 on the nitrogen bottle 9 until the pressure
is correct.
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You can reduce the pressure in the hydro accumulator using the relieve
valve 5. The nitrogen escapes to the open air.
When the nitrogen filling reaches the desired level, close valve 6 and
remove filling/testing unit 4.
Tighten plug 2 mit with Allen key SW6 to 20 Nm.
Note: If the plug 2 is overtightened, the seal may be damaged.
Check the leak tightness of plug 2 with a suitable leak detector spray and
refit the protective cap.

Description Value Unit

Hydro accumulator temperature 0 10 20 30 °C
±2 ±2 ±2 ±2
Nitrogen for filling the hydro accumulator 25 26 27 28 bar
±2 ±2 ±2 ±2
Minimum hydro accumulator nitrogen filling 23 24 25 26 bar

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Testing and adjustment tasks

3.6.26 Checking the opening and closing pressure of the compact

brake valve
The compact brake valve fills the brake accumulator until the shut-off
pressure is reached.
When you repeatedly press the inch-brake pedal, the pressure in the brake
accumulators falls until the opening pressure is reached. The brake
accumulator charging function then begins.

Procedure
You can check the cut-off pressure of the brake accumulator charging
function using the test connection M3 on the compact brake valve.
Connect a manometer (600 bar) with a short test line to the test
connection M3.
Start the engine and let it run at low idling speed.
Push the inch/brake pedal all the way down several times.
Look at the manometer M3 to check that the correct opening pressure
is reached.
When the opening pressure is reached, the pressure on the manometer
begins to rise. The pressure then increases to the closing pressure.
Check the manometer M3 to see if the cut-off pressure is correct.
If it is not correct:
Turn the adjusting screw 1 on the compact brake valve until the closing
pressure is correct.

Description Value Unit

±5
Opening pressure 130 bar
±5
Closing pressure 160 bar

3.6.27 Checking the brake pressure at the axles

You can check the brake pressure on the wet disc brakes in the wheel hubs
at the test connection M4 on the front axle and at the test connection M5 on
the rear axle.

Procedure

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Connect manometers (600 bar) to the test connections M4 on the front

axle 1 and M5 on the rear axle 2.
Start the engine and let it run at low idling speed.
Push the inch/brake pedal all the way down.
Check that the pressure on both manometers is correct.
If it is not correct:
Adjust the pedal stop screw 3 so that the brake pressure is correct when
the pedal is all the way down. Remove the seal 4, loosen the counter nut
and adjust the bottom screw.

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Testing and adjustment tasks

Description Value Unit

±5
Brake pressure with the pedal fully pressed 60 bar

3.6.28 Checking the capacity of the brake accumulators

Test the capacity of the brake accumulators 1 and 2 for the front and rear
axles respectively by pressing the inch/brake pedal nine times. Before the
test, the pressure in the brake accumulators must be 130 bar.
After pressing the inch/brake pedal nine times, the pressure should not be
below the correct level.

Procedure

Connect manometers (600 bar) to the test connections M4 on the front

axle 1 and M5 on the rear axle 2.
Connect a manometer (600 bar) to the test connection M3 on the
compact brake valve 3.
Push the inch/brake pedal all the way down several times to lower the
brake accumulator pressure to 130 bar.
Slowly press the inch/brake all the way down nine times, keeping it down
the final time.
Check that the correct pressure is reached on the manometers M4
and M5.
If the brake pressure on either manometer falls below the correct level:
Replace the brake accumulator if necessary.

Description Value Unit

Lower brake pressure tolerance 50 bar

3.6.29 Check the accumulator charge pressure

The pressure switch generates a warning if the brake accumulator pressure
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is too low. When the pressure in the brake accumulators is reached, the
symbol field 2 goes out and the brake system is ready for operation.

Procedure
You can check the switching point of the pressure switch 1 using the test
connection M3 on the compact brake valve and the symbol field 2 on the
display unit.
Connect a manometer (600 bar) with a short test line to the test
connection M3.
Turn on the starter switch.
Gently push the inch/brake pedal to slowly lower the pressure in the
brake accumulators.
Check that the symbol field 2 lights up when the correct pressure is
shown on the manometer M3.

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Testing and adjustment tasks

If it is not correct:
Replace the brake accumulator pressure switch 1.

Description Value Unit

±5
Pressure switch activation point 90 bar

3.6.30 Check the brake light pressure switch and brake lights
This check tests the brake lights.

Procedure
Turn on the starter switch.
Slowly and gently press the inch/brake pedal and watch the brake lights
light up.
If the brake lights do not light up:
Check the brake lights; replace the brake light pressure switch 1
if necessary.

3.6.31 Transmission - setting the rapid draining time

If the clutch plates are worn or if the transmission has been replaced, the
shifting behaviour may be negatively affected.
Poor shifting may also be caused by incorrect hydraulic oil settings
(see 3.5.45).
Using the TransModTuning variable, you can set the duration (ms) of rapid
draining.
Correctly set rapid draining time:
The required quantity of oil flows out of the clutch during rapid draining. The
clutch is positively connected immediately after modulation begins (oil flows
through the orifice).
Rapid draining time too short:
Not enough oil flows out of the clutch during rapid draining. During the
modulation phase it takes a long time until the clutch is positively connected.
The clutch slips and the discs become worn.
Rapid draining time too long:
The clutch is positively connected before rapid draining is finished. This
causes jolts when shifting.

Procedure
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Accelerate the wheel loader to 20 km/h.

Release the accelerator pedal to the idle position.
Between 12 and 8 km/h, push down the accelerator pedal to the full load
position and check the shifting behaviour from 3rd to 2nd travel range.
Select the TransModTuning variable in the Variable Editor (filter using
All variables , see figure).
Increase the value (ms = milliseconds) until you can feel hard shifting.
Then reduce the value until the shifting feels right.
If increasing the value does not result in hard switching behaviour check
the hose lines on solenoid valve Y61 (see illustration). Hose 1 must be
installed on connection A (not on connection P).
If resetting the value does not result in soft switching behaviour check
whether the orifice (0.8 mm) is installed on Solenoid valve Y61, connection
B.

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Testing and adjustment tasks

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 Service manual Maintenance
Lubricants and fuels

3.7 Lubricants and fuels

See the section on lubricants and fuels in the operating instructions!
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Lubricants and fuels

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 4 Diesel engine
4.0

Chapter contents
4 Diesel engine ...................................................................... 4.0-1

4.1 Diesel engine – L524, L528 2plus1 ................................................ 4.1-1

4.1.1 Common rail high pressure pump ........................................ 4.1-5
4.1.2 Rail pipe, lines and pressure sensor .................................... 4.1-6
4.1.3 Injector .................................................................................. 4.1-7

4.2 Electrical components of the diesel engine – L524, L528 2plus1 .. 4.2-1
4.2.1 Crankshaft speed sensor ..................................................... 4.2-2
4.2.2 Pump position speed sensor ................................................ 4.2-3
4.2.3 Coolant temperature sensor and fuel temperature .............. 4.2-4
4.2.4 Charge air temperature sensor ............................................ 4.2-4
4.2.5 Oil pressure sensor .............................................................. 4.2-5
4.2.6 Rail pressure sensor............................................................. 4.2-5
4.2.7 Pressure control valve .......................................................... 4.2-6

4.3 Fuel system – L524, L528 2plus1 ................................................... 4.3-1

4.3.1 Fuel tank ............................................................................... 4.3-2
4.3.2 Fuel level sensor .................................................................. 4.3-3
4.3.3 Fuel filter system .................................................................. 4.3-4
4.3.4 Fuel pre-filter ........................................................................ 4.3-5
4.3.5 Fuel fine filter ........................................................................ 4.3-6

4.4 Diesel engine – L538, L542 2plus1 ................................................ 4.4-1

4.5 Electrical components of the diesel engine – L538, L542 2plus1 .. 4.5-1
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4.5.1 Crankshaft flywheel speed sensors – B711/B712 ................ 4.5-2

4.5.2 Camshaft speed sensor – B713 ........................................... 4.5-3
4.5.3 Coolant temperature sensor – B708 Fuel temperature
sensor – B709 ...................................................................... 4.5-4
4.5.4 Charge air temperature sensor – B707 ................................ 4.5-5
4.5.5 Charge air pressure sensor – B703 ..................................... 4.5-6
4.5.6 Oil pressure sensor – B701 .................................................. 4.5-7

4.6 Fuel system – L538, L542 2plus1 ................................................... 4.6-1

4.6.1 Fuel tank ............................................................................... 4.6-2
4.6.2 Fuel level sensor .................................................................. 4.6-3
4.6.3 Fuel filter system .................................................................. 4.6-4
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4.6.4 Fuel pre-filter ........................................................................ 4.6-5

4.6.5 Fuel fine filter ....................................................................... 4.6-6

4.7 Air filter system............................................................................... 4.7-1

4.7.1 Air filter ................................................................................. 4.7-2
4.7.2 Vacuum switch ..................................................................... 4.7-3

4.8 Exhaust system .............................................................................. 4.8-1

4.8.1 Silencer ................................................................................ 4.8-2

4.9 Coupling ......................................................................................... 4.9-1

4.9.1 Coupling L524/L528............................................................. 4.9-1
4.9.2 Coupling (torsion absorber) L538/L542 ............................... 4.9-2

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 Service Manual Diesel engine
Fuel system – L524, L528 2plus1

4.1 Diesel engine – L524, L528 2plus1

(D504 ID. Nr. 9739323; CD4045 ID. Nr. 10678551)

Technical data
See section 2.1

Design
The diesel engine is a water-cooled, four-stroke in-line engine with direct
injection, turbocharger and charge air cooling.
The engine is fitted transversely in the rear section and elastically supported
on rubber elements. The flywheel end faces left.
Cylinder 1 is at the water pump end and cylinder 4 is at the flywheel end.

Diesel engine components / front left view

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1 Engine oil drain plug 6 3-phase alternator

2 Oil filter 7 Poly V belt tensioner
3 Dipstick 8 Gear pump auxiliary drive
4 Fuel with water separator 9 Cooler bypass
5 Fuel fine filter 10 Coolant drain valve
11 Oil pan
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Fuel system – L524, L528 2plus1

Diesel engine components / starter view (rear left)

1 Crankcase 10 Valve cover

2 Pump position sensor 11 ECU engine control unit
3 Control valve (measuring unit) 12 Cylinder head
4 High pressure pump 13 Turbo lubricating oil return line
5 Fuel temperature sensor 14 Rail pipe with lines
6 Thermostat 15 Starter
7 Exhaust manifold 16 Flywheel
8 Water pump outlet 17 Engine bearing fastening
9 Turbocharger
Design features of the diesel engine:
– Water-cooled four-stroke direct injection diesel engine
– Turbocharger
– Charge air cooling
– Maintenance-free gear drive of lubricant pump and auxiliary power take-
off for gear pump
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– Oil-cooled light alloy pistons

– Cast crankshaft on sliding bearing
– Forged connecting rods on sliding bearing
Cylinder 1 is at the water pump end and cylinder 4 is at the
flywheel end.

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 Service Manual Diesel engine
Fuel system – L524, L528 2plus1

Diesel engine components / right view (front right)

1 Cooling water temperature 5 Crankshaft speed sensor

sensor 6 Rail pressure control valve
2 Rail pressure control valve 7 High pressure pump
connector 8 Fuel temperature sensor
3 Rail pipe
4 Rail pressure sensor
LBH/Version 01/07.2007/en/Weissenbacher Andreas

Diesel engine components / left view (rear right)

(LBH)/05.02.2013

1 Type plate 5 Fuel pre-filter

2 Fuel fine filter 6 Alternator
3 Fuel preflow pump 7 Auxiliary drive cap
4 Fuel water sensor

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Fuel system – L524, L528 2plus1

Function description

Basic function
The diesel engine converts chemical energy in the fuel into mechanical
energy, which it provides to the flywheel via the torsion absorber of the travel
hydraulics and working hydraulics pump.
A small portion of the power is taken off at the accessory PTO side of the
engine to drive the hydraulic fan.
The common rail system consists of a number of modules. The following
components govern the injection characteristics of the system:
– Solenoid-controlled injectors screwed into the cylinder head
– Pressure accumulator (rail)
– High pressure pump
In addition, the following components are required for operating the system:
– An electronic controller
– Crankshaft speed sensor
– High pressure pump speed sensor
– Rail pressure sensor
– Rail pressure control valve
The pressure in the system is generated independently of injection.
The speed of the high pressure pump is linked to the engine speed at a
fixed ratio.
The injectors, which are connected to the rail via short lines, essentially
consist of an injection nozzle and a solenoid valve. The control unit
energises the solenoid valves correctly and thus controls the start and
duration of injection. The injected fuel quantity is proportional to the
activation time of the solenoid valve and therefore independent of the engine
or pump speed. The signals from the crankshaft and pump speed sensors
determine the start and duration of injection.

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 Service Manual Diesel engine
Fuel system – L524, L528 2plus1

4.1.1 Common rail high pressure pump

Design

1 High pressure pump 9 Pump housing

2 Leak oil connection 10 Pump holder with position
3 Leak oil distributor sensor
4 Fuel intake 11 High pressure pump gear
5 High pressure injection 12 Rail pipe
line connection 13 Fuel temperature sensor
6 High pressure pump connector
position sensor 14 Pump position sensor connector
7 High pressure housing output 15 Pressure control valve
8 High pressure connection to rail connector
Type: radial dual-piston pump
The high pressure pump 1 is located on the front right and is driven by a
bevel spur gear drive 11 via the main shaft.
The pump holder 10 contains the position sensor 6 for the high pressure
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pump. Note the adjustment mark on the spur gear 11, which can be seen
through the sight hole. It must be flush with cylinder 1 at injection UDC.

Function description
Sectional view of the The high pressure pump is supplied by the fuel pump.
high pressure pump
The high pressure pump piston applies pressure to the fuel.
(LBH)/05.02.2013

The fuel is pumped under high pressure via the rail pipe to the injectors.
The high pressure is generated via the pressure control valve 15 according
to the input values of the sensors and the ECU's calculations. The high
pressure pump is fuel-lubricated.

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Fuel system – L524, L528 2plus1

4.1.2 Rail pipe, lines and pressure sensor

Design

Rail pipe

1 Cylinder 1 high pressure line 5 Rail pipe 1 high pressure line

with flow restrictor 6 Low pressure fuel intake
2 Cylinder 2 high pressure line 7 Rail pipe 2 high pressure line
with flow restrictor 8 Rail pipe
3 Cylinder 3 high pressure line 9 Pressure restrictor valve
with flow restrictor 10 Fuel return safety valve
4 Cylinder 4 high pressure line (2000 bar)
with flow restrictor 11 Pressure sensor

Function description
The high pressure pump delivers fuel via two axial pistons and the pressure
lines 5 and 7 to the rail pipe 8. The rail pipe 8 acts as a pressure
accumulator and provides the necessary high pressure to the injectors via
the flow restrictor 9 and the high pressure lines 1-4.
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The pressure sensor 11 measures the high pressure and provides a signal
to the ECU for calculating the opening period and controlling the rail
pressure control valve. The rail pressure sensor also has a monitoring
function. Error codes are logged in the control unit.

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Fuel system – L524, L528 2plus1

4.1.3 Injector

Design

Injector

1 Plug fixing 5 Part number and classification

2 80 V plug connector 6 O-ring seal face
3 Solenoid 7 Cylinder seal
4 Fuel connection and leak 8 Perforated nozzle
oil port

Function description
The injectors are always supplied with high pressure via the rail pipe and the
restrictor valves. The ECU uses input values and characteristics to
determine the time and duration of injection. The injection quantity is
calculated using the signal from the pressure sensor and the opening time.
The terminals of the ECU apply 80 V at the solenoid 3 on the injector. The
magnetic coil lifts a sealing cone against the spring force so that the internal
hydraulics can raise the nozzle needle.
There are two injections per working cycle. These affect noise and exhaust
depending on the ECU characteristic.
A Shows the injector in the closed position: the pressure acts above the
cone on the closed solenoid valve and the hydraulic pressure forces the
LBH/Version 01/07.2007/en/Weissenbacher Andreas

Injector structure needle down.

B Shows the injector in the open, energised position: the solenoid valve
raises the cone. The pressure at the surface of the needle suddenly
decreases and the needle is raised by the existing pressure acting
underneath it on the ring face.
Due to manufacturing variations, needles must be divided into classes. This
code is stored in the control unit in order to meter the ideal injection quantity.
(LBH)/05.02.2013

(This ensures perfectly smooth running.)

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Fuel system – L524, L528 2plus1

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 Service Manual Diesel engine
Electrical engine components

4.2 Electrical components of the diesel

engine – L524, L528 2plus1
Design

Electrical engine components

1 Water temperature sensor 5 Crankshaft speed sensor

2 Rail pressure control valve 6 Rail pressure control valve
3 Rail pipe 7 High pressure pump
4 Rail pressure sensor 8 Fuel temperature sensor
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Diesel engine Service Manual
Electrical engine components

4.2.1 Crankshaft speed sensor

Design
The crankshaft position sensor is located in the right of the front cover.
The signal voltage, whose frequency is proportional to the speed, is
used for:
– Controlling the injection times
– Monitoring the rotary speed
– Power limiting control
– Overspeed protection
– Fault diagnosis
The speed sensor is an inductive sensor. Inductive sensors are electro-
magnetic components with a permanent magnet and a coil.
The distance between the sensor and the spur gear is fixed.

Function description

Speed sensor location Basic function

On the spur gear, there is a gear with 45 equally arranged, equally sized
teeth. Also, there is a gap of three teeth's width between the teeth.
According to the principle of induction, a sinusoidal voltage wave is
generated between each tooth and the gap. The control unit detects these
waves and converts them.
There is an interruption at the position with the three missing teeth; this is
used to detect the upper dead centre position for cylinder 1.

Note
Malfunction
! Malfunctions are indicated by service codes in display.

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 Service Manual Diesel engine
Electrical engine components

4.2.2 Pump position speed sensor

Design
The pump position speed sensor is installed in the holding plate for the high
pressure pump.
If the position sensor fails while the engine is running, the engine continues
turning.
When the engine is turned off and started again, its running is restricted.
The signal voltage, whose frequency is proportional to the speed, is used
for:
– Controlling the diesel engine
The speed sensor is an inductive sensor. Inductive sensors are electro-
magnetic components with a permanent magnet and a coil.
The distance between the sensor and the flywheel ring gear is fixed.

Function description

Speed sensor location Basic function

On the spur gear, there is a gear with 12 equally arranged, equally sized
teeth. There is also a ridge between the teeth.
According to the principle of induction, a sinusoidal voltage wave is
generated between each tooth and the gap. The control unit detects these
waves and converts them.
There is an interruption at the position with the raised tooth; this is used to
detect the upper dead centre position for cylinder 1.

Note
Malfunction
! Malfunctions are indicated by service codes in display.
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Diesel engine Service Manual
Electrical engine components

4.2.3 Coolant temperature sensor and fuel temperature

Design
The coolant temperature sensor is attached to the bottom of the thermostat
housing of the engine, while the fuel temperature sensor is fitted in the high
pressure fuel pump. Both have the task of signalling the temperature to the
engine control unit (ECU) in the form of an electrical resistance. The ECU
uses these signals for:
Coolant temperature:
– Indicating the coolant temperature in the cab
– Controlling the fan drive
– Preglow control
Fuel temperature:
– Controlling the fan drive
Coolant and fuel
temperature sensor – Engine power limiting control
The temperature sensor is a resistance thermometer which operates with an
NTC characteristic (semiconductor).

Function description
Basic function
The resistance in the sensor decreases as the temperature rises. The curve
is not a straight line. If the sensor is defective, a default temperature
is assumed.

4.2.4 Charge air temperature sensor

Design
The charge air temperature sensor is attached to the air intake pipe of the
engine and has the task of signalling the charge air temperature to the
engine control unit (ECU) in the form of an electrical resistance. The ECU
uses this signal for:
– Controlling the fan drive
– Preglow control
– Engine power limiting control
The temperature sensor is a resistance thermometer which operates with an
LBH/Version 01/07.2007/en/leh/05.02.2013

NTC characteristic (semiconductor).

Function description

Basic function
The resistance in the sensor decreases as the temperature rises. The curve
is not a straight line. If the sensor is defective, a default temperature is
Charge air temperature sensor assumed.

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Electrical engine components

4.2.5 Oil pressure sensor

Design
The oil pressure sensor is attached to the front right side of the crankcase,
just below the high pressure pump, and has the task of signalling the oil
pressure to the engine control unit (ECU) in the form of an electrical voltage.
The ECU uses this signal for:
– Indication in the cab
– Controlling the engine as a function of the safety curve

Function
The oil pressure sensor 4 has three pins. The ECU sends a reference
voltage via a line 1 as well as the engine earth 3. The built-in IC module
returns a pressure signal voltage via the signal line 2 to the ECU.

Pressure sensor function diagram

Note
Malfunction
! Malfunctions are indicated by service codes in display.

4.2.6 Rail pressure sensor

Design
The rail pressure sensor is fitted in the rail pipe.
It monitors the high pressure so that the injection times and quantities can
be calculated.
– Controlling the diesel engine
– Rail pressure restriction

Function
The rail pressure sensor 4 has three pins. The ECU sends a reference
voltage via a line 1 as well as the engine earth 3. The built-in IC module
Rail pressure sensor returns a pressure signal voltage via the signal line 2 to the ECU.
LBH/Version 01/07.2007/en/Weissenbacher Andreas

Function diagram
Function description

Basic function
The ECU receives the latest values from the sensor via the signal line. The
rail pressure is controlled using the pressure control valve, based on the
(LBH)/05.02.2013

characteristic stored in the computer and the values from the other sensors.
This signal is also used for diagnosing the injectors and the pump.

Note
Malfunction
! Malfunctions are indicated by service codes in display.

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4.2.7 Pressure control valve

Design

1 Pressure control valve

Function description
This pressure control valve is flange-mounted to the high pressure pump.
The anchor pushes the valve cone onto the seal face via a spring. This seals
the high pressure side from the low pressure side.
The force on the anchor is increased by an electromagnet when the valve is
actuated. Fuel flows all round the anchor. This is for lubrication and to
dissipate the heat generated when reducing the high pressure to ambient
pressure.
Functions:
Pressure control valve not activated: only the force of the spring acts on the
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anchor. This is designed so that the rail pressure settles at around 100 bar.
Pressure control valve activated: the force on the anchor can be increased
proportionally according to the current flowing through the electromagnet.
The valve remains closed until there is equilibrium between the high
pressure and magnetic force, and the spring force. Once equilibrium has
been reached, the valve remains open in a position which allows exactly the
specified rail pressure.

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Fuel system – L524, L528 2plus1

4.3 Fuel system – L524, L528 2plus1

Design
The fuel system consists of the fuel tank, fuel lines, the fuel pre-filter, the
supply pump, the fuel fine filter, the high pressure pump and the injectors.
(The parts on the high pressure side are described in the section on the
engine).

Function description
The pump draws fuel from the tank via the pre-filter and pumps it through the
fine filter to the injection pump.
The excess fuel at the injection pump can flow back to the tank via the pre-
tension valve.
The injection pump delivers the fuel via the high pressure lines to the
injection nozzles.
The injection nozzles spray aerosol fuel into the combustion chambers.
On the underside of the fuel tank there is a valve for draining water
(condensate) and sediment (fuel contamination).
Use the drain hose supplied with the tool kit.
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Fuel system – L524, L528 2plus1

4.3.1 Fuel tank

Technical data
See section 2.1

Design
The plastic fuel tank is located behind the right cab access.

Fuel tank

1 Tank 3 Tank sensor with connections

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2 Tank seal 4 Drain plug with valve

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4.3.2 Fuel level sensor

Design
The fuel level sensor is fitted vertically in the tank.
It is connected via a lead and plugs to the display unit.
The sensor tube contains two electrodes to transmit the fuel level in the tank.

Fuel level sensor

1 Sensor electronics 3 Electrodes

2 Fuel level sensor

Function description
The fuel level sensor tube 2 contains electrodes 3 which measure the fuel
level using a capacitive resistor.
The electronics in the head of the fuel level sensor 2 transmit a
corresponding voltage signal of 1 V – 4 V to the fuel level segment field on
the display unit.
LBH/Version 01/07.2007/en/Weissenbacher Andreas
(LBH)/05.02.2013

Fuel level bar display

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1 Fuel level sensor 4 Fuel tank

2 Warning lamp 5 Voltage
3 Fuel indicator 6 Quantity in litres

The diagram shows the voltages from the fuel level sensor 1 with reference
to the contents of the tank.
The lower the fuel level 6 the higher the voltage 5 and thus the level shown
on the fuel level segment field 2.
The first bar in the fuel level segment display 2 on the left flashes when the
fuel is at reserve level.

4.3.3 Fuel filter system

Design
The fuel filter system consists of a pre-filter 3 with a water separator, a
preflow pump 2 and a main fuel filter 1. The preflow filter 2 is fitted between
the fuel pre-filter and the main fuel filter. The filters must be replaced with
each service according to the schedule.

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Installing the fuel filter system

1 Fuel fine filter 3 Fuel pre-filter with water
2 Fuel pump separator and sensor
The fuel pre-filter is designed as a filter cartridge and has a transparent
housing in the lower part. The water sensor is attached in the transparent
housing.
The main fuel filter is also designed as a filter cartridge.

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Function description
The fuel pump sucks the fuel through the fuel pre-filter. Any foreign particles
are caught in the filter mesh. These can be seen through the transparent
housing, indicating the degree of contamination. The fuel is then pushed
through the main filter and cleaned again.
You can also observe the fuel flow. This is an advantage when servicing the
fuel system, for example when it needs bleeding.

4.3.4 Fuel pre-filter

Technical data
See section 2.1

Design
The filter has a snap fitting and can be serviced without any tools. The filter
and the water separator have a fixing ring and can be removed and replaced
by hand during a service.
The fuel filter is designed as a pre-filter and is fitted between the fuel tank
and the fuel pump.
The filter element is a cartridge fixed to the filter head with a snap ring. This is
a disposable filter cartridge which must be replaced each time it is serviced.
The fuel pre-filter has a water separator sight glass. There is a tap on the sight
glass to drain the water. The fuel water sensor is attached in the sight glass.
LBH/Version 01/07.2007/en/Weissenbacher Andreas
(LBH)/05.02.2013

Fuel pre-filter

1 Filter base 6 Drain valve

2 Filter intake 7 Water separator sight glass
3 Filter outlet 8 Filter insert
4 Filter housing snap ring 9 Bleeder screw
5 Water separator snap ring 10 For special functions

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Function description
The fuel fine filter protects the fuel system from contamination. Also, any
water which might be in the fuel system is caught in the water separator.
The water separator below it is coaxially connected to the fine filter.
The diesel fuel is pumped under pressure from the fuel pump through the
filter intake into the filter insert.
The pressure of the fuel pump forces the fuel through the filter membrane.
The filtered fuel then flows through the outlet in the filter head via the fuel
line to the fine filter.
The water in the fuel system is separated by the impregnation of the filter
insert, and then settles in the water separator sight glass.
The container can be emptied during maintenance by opening the drain valve.

4.3.5 Fuel fine filter

Technical data
See section 2.1

Design
The filter has a snap fitting and can be serviced without any tools. The filter
can be removed with the snap ring and replaced by hand during a service.
The fuel filter is a fine filter and is fitted between the fuel pump and H.
The filter element is a cartridge fixed to the filter head with a snap ring. This is
a disposable filter cartridge which must be replaced each time it is serviced.

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Fuel fine filter

1 Filter base 6 Filter insert snap ring

2 Filter intake 7 Bleeder screw
3 Filter outlet 8 For special functions
4 Drain valve
5 Filter insert

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Fuel system – L524, L528 2plus1

Function description
The fuel fine filter protects the fuel system from contamination. Also, any
water which might be in the fuel system is caught in the filter housing.
The diesel fuel is pumped under pressure from the fuel pump through the
filter intake 2 into the filter insert 5.
The pressure of the fuel pump forces the fuel through the filter membrane.
The filtered fuel then flows through the outlet in the filter head via the fuel
line to the injection pump.
The water in the fuel system is separated by the impregnation of the filter
insert, and then settles in the filter housing at the bottom.
The filter housing can be emptied during maintenance by opening the drain
valve.
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Diesel engine – L538, L542 2plus1

4.4 Diesel engine – L538, L542 2plus1

Technical data
See section 2.1

Design
The diesel engine is a water-cooled, four-stroke in-line engine with pump-
line-nozzle (PLD) direct injection, turbocharging and charge air cooling.
The engine is fitted lengthways in the rear section and elastically supported
on rubber elements. The flywheel end faces to the rear.

Diesel engine components / right view

1 Flywheel housing 12 Lube oil filler neck

2 Flywheel 13 Air intake pipe
3 Opening for cranking device 14 Flame glow plug
4 Auxiliary drives 15 Engine electronics (LH-ECU)
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5 Fuel pre-filter 16 Air conditioning compressor

6 Crankcase bleeder 17 Alternator
7 Bleeder filter with oil separator 18 Fuel line connections
8 Hand pump 19 Auxiliary drive
9 Cylinder head 20 Engine block
10 Fuel fine filter 21 Dipstick
11 Charge air pipe 22 Oil separator return line
23 Oil pan
24 Fuel pump

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Diesel engine – L538, L542 2plus1

Diesel engine components / left view

1 Water pump 9 Starter

2 Belt drive cover 10 Oil cooler
3 Thermostat housing 11 Cooling water supply to cooler
4 Oil filter 12 Cooling water return from cooler
5 Charge air pipe 13 Crankshaft / vibration damper
6 Housing bleeder
7 Turbocharger compressor
8 Turbocharger turbine
Design features of the diesel engine:
– Water-cooled four-stroke diesel engine with pump-line-nozzle (PLD) direct
injection
– Turbocharger and charge air cooling
– Maintenance-free gear drive for camshaft, fuel pump, lubricant pump on
flywheel end and coolant pump on motor end, as well as power take-off
for gear pumps
– Individual cylinder heads with cast integral vortex intake duct
– Replaceable wet bushings
– Small number of parts due to lubricant and coolant lines integrated in
crankcase
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– Oil spray-cooled three-ring piston made of light alloy (D934S)

– Engine oil cooler
– Double lube oil filter
– Large, tilt-proof oil pan
– 5-bearing (4-cylinder) steel crankshaft with forged counterweights and
diagonal “cracked” piston rods. Lead bronze triple composite bearings.
– Balance shafts

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Function description

Basic function
The diesel engine converts the chemical energy in the fuel into kinetic
energy, which it provides to the flywheel via the torsion absorber and the
pump distributor gear to the travel hydraulics, working hydraulics and
steering hydraulics pumps.
A small portion of the power is taken off at the accessory drive side of the
diesel engine to drive the gear pumps.
These are the single gear pump for the transmission shift pressure, and the
triple gear pump for the hydrostatically driven fan, the accumulator pressure
brake system and the leak oil scavenging in the variable displacement
motor.
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4.5 Electrical components of the

diesel engine – L538, L542 2plus1
Design

Electrical engine components

1 Heating flange – R701 7 Alternator – G700 12 Crankshaft 2 flywheel speed

2 Starter – M700 8 Engine electronics (LH-ECU) sensor – B712
3 Coolant temperature indicator – A700 13 Camshaft speed sensor – B713
+ thermostat – B708 9 Pump element magnetic coil 14 Crankshaft 1 flywheel speed
4 Charge air pressure sensor Y711 – Y716 sensor – B711
– B703 10 Water sensor on fuel pre-filter
5 Charge air temperature sensor – B710
– B707 11 Oil pressure sensor – B701
6 Air conditioning compressor
magnetic coupling – M710
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4.5.1 Crankshaft flywheel speed sensors – B711/B712

Design
For safety reasons, two identical speed sensors are used on the crankshaft.
The two speed sensors, B711 and B712, are attached to the engine flywheel
housing and their job is to record the speed and position of the crankshaft.
The first sensor (B711) is the working sensor; if it fails, the system
automatically switches to the second backup sensor (B712).
The signal voltage, whose frequency is proportional to the speed, is used
for:
– Controlling the fan drive
– Starting the emergency steering pump check
– Controlling the diesel engine
– Indicating the engine speed
– Power limiting control
– Overspeed protection
– 0-inching control
The speed sensors are Hall-effect sensors. Hall-effect sensors are
electromagnetic components with a permanent magnet and a Hall element
(Hall IC).
The distance between the sensor and the flywheel ring gear is fixed.
Distance “a” = 0.5 - 2 mm

Function description

Speed sensor location Basic function

If a Hall-effect sensor has voltage supplied and is put vertically into a
magnetic field, it provides an output voltage. This signal voltage modulates
proportionally to the speed of the ring gear on the flywheel and is provided to
the engine electronics as a frequency signal.

Note
Attempts to measure the resistance will irreparably damage the Hall-effect
sensor.
Never measure resistance on a Hall-effect sensor.
! Malfunctions are indicated by service codes in display.
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Plug assignment
1 Weight
2 Frequency signal (output voltage)
3 12 V power supply

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4.5.2 Camshaft speed sensor – B713

Design
The speed sensor B713 is attached to the crankshaft housing of the engine;
its job is to detect the phase of the engine while starting.
If the camshaft sensor fails while the engine is running, the engine continues
turning.
When the engine is turned off and started again, its running is restricted.
The signal voltage, whose frequency is proportional to the speed, is used
for:
– Controlling the diesel engine
The speed sensor is a Hall-effect sensor. Hall-effect sensors are
electromagnetic components with a permanent magnet and a Hall element
(Hall IC).
The distance between the sensor and the flywheel ring gear is fixed.
Distance “a” = 0.5 - 2 mm

Function description

Speed sensor location Basic function

If a Hall-effect sensor has voltage supplied and is put vertically into a
magnetic field, it provides an output voltage. This signal voltage modulates
proportionally to the speed of the ring gear on the flywheel and is provided to
the engine electronics as a frequency signal.

Note
Attempts to measure the resistance will irreparably damage the Hall-effect
sensor.
Never measure resistance on a Hall-effect sensor.
! Malfunctions are indicated by service codes in display.

Plug assignment
1 Weight
2 Frequency signal (output voltage)
3 12 V power supply
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4.5.3 Coolant temperature sensor – B708

Fuel temperature sensor – B709
Design
The coolant temperature sensor B708 is attached to the thermostat housing
of the engine, while the fuel temperature sensor B709 is fitted in the fuel
supply line. Both have the task of signalling the temperature to the engine
control unit (ECU) in the form of an electrical resistance. The ECU uses
these signals for:
– Indicating the coolant temperature in the cab
– Controlling the fan drive
– Preglow control
– Engine power limiting control

Coolant temperature [°C] -100 -15 100 101 120 150

Power reduction [%] 10 0 0 4 50 50

– Increasing the engine idling speed

Coolant temperature [°C] -100 -90 -40 -10 20

Idling speed increase [rpm] 0 200 200 100 0

– Controlling the fan drive

– Engine power limiting control

Fuel temperature [°C] -100 -5 0 75 80 85 100

Power reduction
10 3 0 0 3 10 30
[%]

The temperature sensor is a resistance thermometer which operates with an

NTC characteristic (semiconductor).

Function description
Basic function
The resistance in the sensor decreases as the temperature rises. The curve
is not a straight line. If the sensor is defective, a temperature of -100°C is
assumed.

Coolant and fuel Coolant resistance characteristic B708

temperature sensor Temperature (°C)
105
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100
95
90
85
80
75
70
65
60
55
50
45
40
35
30
25
20
15
10
5
0
0 0,3 0,6 0,9 1,2 1,5 1,8 2,1 2,4 2,7 3,0 3,3 3,6 3,9 4,2 4,5 4,8 5,1 5,4 5,7 6,0

Resistance (kOhm)

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4.5.4 Charge air temperature sensor – B707

Design
The charge air temperature sensor B707 is attached to the air intake pipe of
the engine and has the task of signalling the charge air temperature to the
engine control unit (ECU) in the form of an electrical resistance. The ECU
uses this signal for:
– Controlling the fan drive
– Preglow control
– Engine power limiting control
Charge air temperature
-100 -15 75 80 85 100
[°C]
Power reduction [%] 10 0 0 0 10 30

The temperature sensor is a resistance thermometer which operates with an

NTC characteristic (semiconductor).

Function description

Basic function
The resistance in the sensor decreases as the temperature rises. The curve
is not a straight line. If the sensor is defective, a temperature of -100°C is
Charge air temperature sensor assumed.

Widerstandskennlinie Ladeluft B707

105
100
95
90
85
80
75
70
65
60
55
50
45
40
35
30
25
20
15
10
5
0
0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100

Widerstand in k
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4.5.5 Charge air pressure sensor – B703

Design
The charge air pressure sensor B703 is attached to the air intake pipe of the
engine and has the task of signalling the charge air pressure to the engine
control unit (ECU) in the form of an electrical voltage. The ECU uses this
signal for:
– Engine power limiting control

Power reduction (%) Speed (rpm)

1000 1300 1600 1900 2100

Atmospheric 550 23.1 24.1 24.4 24.4 23.3

pressure 4850*
(mbar)
Height above 620 19.5 19.6 19.1 19.1 18.0
sea level* 3950*
(m)
690 14.2 14.8 13.9 13.6 12.6
3100*

770 10.0 10.1 8.9 8.4 7.2

2250*

840 0.0 0.0 0.0 0.0 0.0

1550*

The charge air pressure sensor is an absolute pressure sensor with a

membrane and an evaluation circuit. At atmospheric pressure, an absolute
pressure sensor is subject to approximately 1 bar (at sea level 1030 mbar).
1 Electrical connections
2 Evaluation circuit
3 Membrane with sensor element
4 Pressure port
5 Fixing thread

Function description

Basic function
Cross section of the
pressure sensor The electrical resistance varies on the layers applied to the membrane as
they change shape. This deformation due to the accumulating system
pressure alters the electrical resistance and causes a change in the voltage
of the resistance bridge, which has a 5 V supply.
This voltage is in the range of 0 to 70 mV (depending on the pressure) and is
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amplified in the evaluation circuit to between 0.5 and 4.5 V.

Note
Attempts to measure the resistance will irreparably damage the pressure
sensor.
Never measure resistance on a pressure sensor.
! Malfunctions are indicated by service codes in display.

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4.5.6 Oil pressure sensor – B701

Design
The oil pressure sensor B701 is attached to the crankcase of the engine and
has the task of signalling the oil pressure to the engine control unit (ECU) in
the form of an electrical voltage. The ECU uses this signal for:
– Indication in the cab
– Controlling the engine as a function of the safety curve

Engine speed [rpm] 300 1000 1400 1800 2100

Oil pressure [bar] 0 1.5 2.5 3.0 3.0

The oil pressure sensor is a relative pressure sensor with a membrane and
an evaluation circuit. At atmospheric pressure, a relative pressure sensor is
subject to 0 bar.
1 Electrical connections
2 Evaluation circuit
3 Membrane with sensor element
4 Pressure port
5 Fixing thread

Function description

Basic function
Cross section of the
pressure sensor The electrical resistance varies on the layers applied to the membrane as
they change shape. This deformation due to the accumulating system
pressure alters the electrical resistance and causes a change in the voltage
of the resistance bridge, which has a 5 V supply.
This voltage is in the range of 0 to 70 mV (depending on the pressure) and is
amplified in the evaluation circuit to between 0.5 and 4.5 V.

Note
Attempts to measure the resistance will irreparably damage the pressure
sensor.
Never measure resistance on a pressure sensor.
! Malfunctions are indicated by service codes in display.
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 Service Manual Diesel engine
Fuel system – L538, L542 2plus1

4.6 Fuel system – L538, L542 2plus1

Design
The fuel system consists of the fuel tank, the fuel lines, the fuel pre-filter, the supply
pump, the fuel fine filter, the injection pump and the injection nozzles.

Fuel system

1 Fuel tank 6 Refuelling pump seal screw 10 Fuel pre-filter

2 Filler strainer 7 Auxiliary heating seal screw 11 Fuel fine filter
3 Tank cap 8 Intake line 12 Fuel pump
4 Fuel level sensor seal 9 Return line 13 Injection pump
5 Fuel level sensor 14 Drain valve

Function description

The pump draws fuel from the tank via the pre-filter and pumps it through the
fine filter to the injection pump.
The excess fuel at the injection pump can flow back to the tank via the pre-
tension valve.
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The injection pump delivers the fuel via the high pressure lines to the
injection nozzles.
The injection nozzles spray aerosol fuel into the combustion chambers.
On the underside of the fuel tank there is a valve for draining water
(condensate) and sediment (fuel contamination).
Use the drain hose supplied with the tool kit.

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4.6.1 Fuel tank

Technical data
See section 2.1

Design
The plastic fuel tank is located behind the right cab access.

Fuel tank

1 Tank 7 Auxiliary heater plug

2 Filler strainer 8 Supply
3 Tank cap 9 Return
4 Fuel level sensor seal 10 Drain valve
5 Fuel level sensor
6 Filler pump plug
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4.6.2 Fuel level sensor

Design
The fuel level sensor is fitted vertically in the tank.
It is connected via a lead and plugs to the display unit.
The sensor tube contains two electrodes to transmit the fuel level in the tank.

Fuel level sensor

1 Sensor electronics 3 Electrodes

2 Fuel level sensor

Function description
The fuel level sensor tube 2 contains electrodes 3 which measure the fuel
level using a capacitive resistor.
The electronics in the head of the fuel level sensor 2 transmit a
corresponding voltage signal of 1 V – 4 V to the fuel level segment field on
the display unit.
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Fuel level bar display

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Diesel engine Service Manual
Fuel system – L538, L542 2plus1

1 Fuel level sensor 4 Fuel tank

2 Warning lamp 5 Voltage
3 Display unit 6 Quantity in litres

The diagram shows the voltages from the fuel level sensor 1 with reference
to the contents of the tank.
The lower the fuel level 6 the higher the voltage 5 and thus the level shown
on the fuel level segment field 2.
The first bar in the fuel level segment display 2 on the left shows that the fuel
is a reserve level.

4.6.3 Fuel filter system

Design
The fuel filter system consists of a pre-filter 3 with a water separator, a
preflow pump 2 and a main fuel filter 1. The preflow filter 2 is fitted between
the fuel pre-filter and the main fuel filter. The filters must be replaced with
each service according to the schedule.

The fuel pre-filter is designed as a filter cartridge and has a transparent

housing in the lower part. The water sensor is attached in the transparent
housing.
The main fuel filter is also designed as a filter cartridge.

Function description
The fuel pump sucks the fuel through the fuel pre-filter. Any foreign particles
are caught in the filter mesh. These can be seen through the transparent
housing, indicating the degree of contamination. The fuel is then pushed
through the main filter and cleaned again.
You can also observe the fuel flow. This is an advantage when servicing the
fuel system, for example when it needs bleeding.

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Fuel system – L538, L542 2plus1

4.6.4 Fuel pre-filter

Technical data
See section 2.1

Design
The filter has a snap fitting and can be serviced without any tools. The filter
and the water separator have a fixing ring and can be removed and replaced
by hand during a service.
The fuel filter is designed as a pre-filter and is fitted between the fuel tank
and the fuel pump.
The filter element is a cartridge fixed to the filter head with a snap ring. This is
a disposable filter cartridge which must be replaced each time it is serviced.
The fuel pre-filter has a water separator sight glass. There is a tap on the
sight glass to drain the water. The fuel water sensor is attached in the sight
glass.

Fuel pre-filter
1 Filter base 6 Drain valve
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2 Filter intake 7 Water separator sight glass

3 Filter outlet 8 Filter insert
4 Filter housing snap ring 9 Bleeder screw
5 Water separator snap ring 10 For special functions

Function description
The fuel fine filter protects the fuel system from contamination. Also, any
water which might be in the fuel system is caught in the water separator.
The water separator below it is coaxially connected to the fine filter.
The diesel fuel is pumped under pressure from the fuel pump through the
filter intake into the filter insert.

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Fuel system – L538, L542 2plus1

The pressure of the fuel pump forces the fuel through the filter membrane.
The filtered fuel then flows through the outlet in the filter head via the fuel
line to the fine filter.
The water in the fuel system is separated by the impregnation of the filter
insert, and then settles in the water separator sight glass.
The container can be emptied during maintenance by opening the drain
valve.

4.6.5 Fuel fine filter

Technical data
See section 2.1

Design
The filter has a snap fitting and can be serviced without any tools. The filter
can be removed with the snap ring and replaced by hand during a service.
The fuel filter is a fine filter and is fitted between the fuel pump and injection
pump.
The filter element is a cartridge fixed to the filter head with a snap ring. This
is a disposable filter cartridge which must be replaced each time it is
serviced.

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Fuel fine filter

1 Filter base 6 Filter insert snap ring

2 Filter intake 7 Bleeder screw
3 Filter outlet 8 For special functions
4 Drain valve
5 Filter insert

Function description
The fuel fine filter protects the fuel system from contamination. Also, any
water which might be in the fuel system is caught in the filter housing.

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 Service Manual Diesel engine
Fuel system – L538, L542 2plus1

The diesel fuel is pumped under pressure from the fuel pump through the
filter intake 2 into the filter insert 5.
The pressure of the fuel pump forces the fuel through the filter membrane.
The filtered fuel then flows through the outlet in the filter head via the fuel
line to the injection pump.
The water in the fuel system is separated by the impregnation of the filter
insert, and then settles in the filter housing at the bottom.
The filter housing can be emptied during maintenance by opening the drain
valve.
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Fuel system – L538, L542 2plus1

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 Service Manual Diesel engine
Air filter system

4.7 Air filter system

Design

Air filter system

1 Rain cap 6 Bracket

2 Air intake pipe 7 Rear section
3 Air hose clips 8 Air filter
4 Unfiltered air intake hose 9 Filtered air intake manifold
5 Air filter clips 10 Vacuum switch

Function description
The engine takes in fresh air via the rain cap 1, the air hoses and the air
filter 8.
The filtered air is provided to the engine via the turbocharger.
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Air filter system

4.7.1 Air filter

Technical data
See section 2.1

Design

Air filter arrangement

1 Secondary element 4 Fixing clips
2 Primary element 5 Dust extraction valve
3 Service cap 6 Filter housing

Function description
The primary element 2 and the secondary element 1 of the dry air filter are
designed to ensure maximum protection for the engine at very long service
intervals.
The primary element 2 with radial sealing at the filtered air connection in the
filter housing 6 is subject to scheduled and non-scheduled maintenance.
The secondary element 1 acts as a back-up if the primary element 1 is
damaged.
The secondary element 1 is not a service filter. It must be replaced if
necessary.
The dust extraction valve 5 automatically removes dust from the service
cap 3.
The tangential arrangement of the intake port sets the air into quick rotation,
so that large dust particles are thrown by centrifugal force against the
housing and accumulate in the service cap 3 due to the air flow.
At idle speed, the accumulated dust particles in the service cap 3 are carried
outside via the dust extraction valve 5 by the vibrations in the intake air.
The service cap 3 must be fitted so that the dust extraction valve 5 faces
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down.
With the engine running at lower idle speed, you should clearly feel air
pulsating at the dust extraction valve 5.

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Air filter system

4.7.2 Vacuum switch

Technical data
See section 2.1

Design

Vacuum switch arrangement

1 Vacuum switch 2 Air filter

Function description
The vacuum switch 1 monitors the pressure ratio between the turbocharger
and the air filter 2.
If the filters are dirty (excessive vacuum) it activates the air contamination
symbol field on the display unit.
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Air filter system

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 Service Manual Diesel engine
Exhaust system

4.8 Exhaust system

Design

Exhaust system layout

1 Tail pipe 5 Seals

2 Heat shield 6 Exhaust pipe
3 Silencer 7 Flexible section of exhaust pipe
4 Turbocharger 8 Cooler support

Function description
The exhaust gas passes from the turbocharger 4 through the exhaust pipe 6,
the silencer 3 and the tail pipe 1 to the open air.
The silencer 3 is fitted in the cooler support 8 and bolted to it.
Movement between the turbocharger 4 on the engine and the silencer 3 is
compensated by the flexible section of the exhaust pipe 7.
The exhaust pipe 6 must be set so that the flexible section 7 is flush along
both axes and is extended roughly half way.
There are seals 5 between the turbocharger 4, exhaust pipe 6 and
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silencer 3.
To keep radiated heat away from the cab, the tail pipe 1 is fitted with a heat
shield 2.

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Exhaust system

4.8.1 Silencer

Design
The silencer is fitted in the cooler support and bolted to it.

Silencer
1 Fastening plate 4 Fastening point
2 Silencer outlet 5 Silencer intake
3 Housing

Function description
The job of the silencer is to absorb sound energy.
The silencer is a combined absorption/reflection silencer.

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 Service Manual Diesel engine
Coupling

4.9 Coupling
4.9.1 Coupling L524/L528

Technical data
See section 2.1

Design
The coupling connects the flywheel on the diesel engine to the tandem pump.

Position of the coupling

1 Flywheel 5 Hub star shoulder

2 Fixing screw 6 Fixing screws
3 Elastic element 7 Elastic element
4 Hub star
Installation position and instructions
– The elastic element 3 is fitted with its ribs facing the flywheel. The smooth
side can be seen from the outside.
– The hub star 4 is fitted with its shoulder 5 facing the travel hydraulics
pump.
– All screws are glued with LOCTITE 241.
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Function description
The coupling is an elastic connection between the diesel engine and the
tandem pump.

Power transmission
The following components transmit the engine torque to the tandem pump:
– Flywheel 1
– Fixing screws 6
– Elastic element 3
– Hub star 4
– Hub

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Diesel engine Service Manual
Coupling

4.9.2 Coupling (torsion absorber) L538/L542

Technical data
See section 2.1

Design
The coupling is an elastic torsion and vibration absorber between the
flywheel on the engine and the splitter box.

Position of the coupling

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1 Torsion absorber 2 Flywheel

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 Service Manual Diesel engine
Coupling

Main components of the torsion absorber

1 Torsion absorber assembly 5 Disc
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2 Hub 6 Fixing screw

3 Pressure springs 7 Flywheel housing
4 Disc 8 Flywheel
The disc 5 is bolted to the flywheel 8 of the engine. The hub 2 is axially guided
by circular discs riveted to the hub. The hub 2 can move radially on the disc 4.
The springs 3 are arranged in a ring and form an elastic connection which
transfers the torque between the disc 5 and the hub 2. The drive shaft of the
splitter box is connected to the hub 2 by a spline shaft gearing.

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Coupling

Function description

Basic function
The coupling is an elastic connection which also absorbs torque peaks
between the engine and the driven splitter box.
The coupling transmits the engine torque to the splitter box.

Power transmission
The following components transmit the engine torque to the splitter box:
– Flywheel 8
– Fixing screws 6
– Discs 4 and 5
– Pressure springs 3
– Hub 2

Damping
The springs 3 absorb load fluctuations and torque peaks on the engine
crankshaft. The vibrations of the crankshaft are greatly reduced as torque is
transmitted to the splitter box.

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 5 Cooling system
5.0

Chapter contents
5 Cooling system.................................................................... 5.0-1

5.1 Cooling system ............................................................................... 5.1-1

5.1.1 Hydraulic cooling system ...................................................... 5.1-2
5.1.2 Electric fan speed control ..................................................... 5.1-6
5.1.3 Engine coolant cooling system L524, L528 .......................... 5.1-7
5.1.4 Engine coolant cooling system L538/L542 ........................... 5.1-8
5.1.5 Engine intake air cooling system (charge air) ...................... 5.1-9

5.2 Gear pump ...................................................................................... 5.2-1

5.3 Gear motor ...................................................................................... 5.3-1

5.4 Temperature sensors ...................................................................... 5.4-1

5.4.1 Hydraulic oil temperature sensor .......................................... 5.4-1
5.4.2 Coolant temperature sensor ................................................. 5.4-1
5.4.3 Charge air temperature sensor ............................................ 5.4-2
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Cooling system Service Manual

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 Service Manual Cooling system
Gear motor

5.1 Cooling system

Design
The cooling system is fitted on the rear section between the diesel engine
and the driver's cab.

Cooler unit components

1 Cooler unit 4 Cooler for engine coolant 8 Fan blade

2 Air conditioning condenser 5 Engine charge air cooler 9 Grille
3 Air conditioning condenser 6 Hydraulic oil cooler 10 Fan motor
bearing 7 Air scoop

Function description

Basic function
The fan takes in air from the outside of the cooler unit, and blows it over the
fins of the cooler unit, through the engine and out again.
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The speed of the hydrostatically driven fan depends on the following factors:
– Engine speed
– Coolant temperature
– Hydraulic oil temperature
– Charge air temperature
– Air conditioning system
The cooler system cools:
– The engine coolant
– The hydraulic oil
– The engine charge air
– The coolant in the air conditioning system (optional)

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5.1.1 Hydraulic cooling system

Hydraulic cooling system components

1 Hydraulic system oil cooler 6 Housing cross-flushing 10 Travel motor 2

2 Fan gear motor pre-tension valve 11 Hydraulic tank intake port
3 Fan gear pump 7 Travel pump return line 12 Cooler unit housing
4 Oil cooler collector pipe 8 Travel motor flushing valve 13 Suction and return filter
5 Gear motor 200 µ line filter return line return line
9 Travel motor 1 14 Return strainer return line
15 Thermo valve
Cooling by the hydraulic system oil cooler 1
The following lines from the tank pass through the oil cooler:
– Cooling system return line
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– Travel pump return line

– Travel motor return line
– Flushing valve return line
The leak oil of these components is pumped to the oil cooler collector pipe 4.
The following conditions are possible:
Hydraulic oil < 45 °C
– Hydraulic oil can flow directly from the collector pipe 4 via the thermo
valve 15 and the suction and return filter 13 to the hydraulic tank 12.
Hydraulic oil > 45 °C
– Hydraulic oil must flow from the collector pipe 4 via the hydraulic oil cooler
1 and the suction and return filter 13 to the hydraulic tank 12.
The safety valve 6 (2.5 bar) ensures that any pressure peaks for the oil
cooler 1 are reduced.

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 Service Manual Cooling system
Gear motor

Hydraulic fan control

Hydraulic plan of fan drive

1 Collector pipe 7 Proportional valve 14 Return strainer

2 Hydraulic oil cooler 8 Pressure relief valve 15 Return suction filter
3 Oil cooler pressure peak 9 Fan gear pump 16 Hydraulic oil temperature
safety valve 10 45 °C temperature valve sensor B8
4 Fan blade 11 Travel pump housing 17 Hydraulic tank intake port
5 Gear motor for fan with pressure safety valve 18 Travel pump
proportional pressure relief valve 12 Hydraulic tank 19 Travel motor 2
6 Cooling circuit in-line filter 13 Hydraulic tank bleeder filter 20 Travel motor 1
The fan pump 9 draws oil from the hydraulic tank 12 and pumps it through
the in-line filter 6 to the gear motor 5.
To protect the proportional pressure relief valves 7 and 8 from dirt, a 200 µ
in-line filter 6 is fitted at the motor intake.
The proportional valve 7 continuously regulates the integrated pressure relief
valve 8 of the gear motor 5.
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At low temperatures, the opening pressure of the pressure relief valve 8 is

also low. Most of the oil flows through the pressure relief valve 8 to the tank.
The fan turns at low speed (minimum speed = dragging speed).
As the temperature increases the current to the proportional valve 7
reduces, and the opening pressure of the pressure release valve 8 thus
continuously increases. The fan turns faster.
If the current fails at the proportional valve 7, the opening pressure increases
to the mechanically set level and the fan motor 5 turns at maximum speed,
regardless of the engine speed (failsafe function).

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Fan speed characteristics

1 Fan speed 5 Fan speed full power with
2 Current to proportional valve proportional valve deenergised
(mA) 6 Fan speed at low temperature
3 Engine speed (minimum speed)
4 Rated speed and current
control limit

Valid for: L524 - 659; L528 - 660

Fan control at upper engine speed System pressure Current Fan speed
Hydraulic oil up to 57 °C
Coolant up to 87 °C 20±10 bar 1,300 mA 450 ±50
min-1
Charge air temperature up to 50 °C
Hydraulic oil > 57 – 75 °C
Coolant up to 87 – 92 °C 20 - 75 bar 1,300 - 910 mA 450 - 1,600±50 min-1
Charge air temperature up to 50 - 70 °C
Hydraulic oil above 75 °C ±10 ±50 -1
75 bar 910 mA 1,600 min
Coolant above 92 °C
Hydraulic oil above 95 °C
Coolant above 110°C Warning lamp + buzzer + power reduction
Charge air temperature above 90 °C
Pressure relief valve adjustment:
175±10 bar 0 mA 2,150 min-1
Proportional solenoid deenergised
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Table of values for fan control

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 Service Manual Cooling system
Gear motor

Fan speed characteristics

1 Fan speed 5 Fan speed full power with
2 Current to proportional valve proportional valve deenergised
(mA) 6 Fan speed at low temperature
3 Engine speed (minimum speed)
4 Rated speed and current
control limit

Valid for: L538 - 433; L542 - 435

Fan control at upper engine speed System pressure Current Fan speed
Hydraulic oil up to 57 °C
Coolant up to 87 °C 20±10 bar 1,300 mA 410±50 min-1
Charge air temperature up to 50 °C
Hydraulic oil 57 - 75 °C
±50 -1
Coolant 87 - 92 °C 20 - 120 bar 1,300 - 650 mA 450 - 1,640 min
Charge air temperature up to 50 - 70 °C
Hydraulic oil above 95 °C
120 bar±10bar 650 mA 1,700±50 min-1
Coolant above 110 °C
Hydraulic oil above 95 °C
Coolant above 110 °C Warning lamp + buzzer + power reduction + error code
Charge air temperature above 90 °C
Pressure relief valve adjustment: ±10 ±50 -1
175 bar 0 mA 2,110 min
Proportional solenoid deenergised
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Table of values for fan control

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Gear motor

5.1.2 Electric fan speed control

Electric control takes place using sensors and the control unit. The UEC3
uses input signals and a characteristic to regulate the proportional solenoid
via an output. (See table.)
The UEC3 controller (Universal Earth Mover Controller 3) is fitted under the
cover on the rear wall of the cab behind the driver's seat.
The UEC3 is fitted with a plug connector to communicate with the various
components.

Design

UEC3 (Universal Earth Mover Controller 3)

1 Plug X3 4 Plug X4
2 UEC3 Housing 5 Screws for fixing control
3 Housing ventilation valve board to cooler
(Goretex)
Controlling the fan system The fan system is regulated automatically, depending on the temperatures
sent to the UEC3 by the temperature sensors for the hydraulic oil, coolant
and charge air.
The air conditioning also affects the fan regulation.
(See the detailed description in chapter 10 on the electrical system.)
The UEC3 controller uses the readings from the temperature sensors for
the hydraulic oil, coolant, charge air and engine speed to calculate an
output current.
This current controls the proportional pressure relief valve on the fan motor
M1 and therefore the fan speed.
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If the fluid is hot, the resistance on the temperature sensor changes and thus
reduces the current to the proportional pressure relief valve Y13.
If the hydraulic oil temperature exceeds a set level the following
actions are taken:
– The hydraulic oil overheating symbol field lights up on the display.
– After one minute, the power is restricted until the temperature is reduced.
If the coolant oil temperature exceeds a set value (see the table of fan
control values), the following actions are taken:
– The current is reduced to a minimum level. The fan motor M1 turns at
maximum speed.
– The hydraulic oil overheating symbol field flashes on the display.
– After one minute, the power is restricted until the temperature is reduced.
– An interval tone sounds (1 sec. on / 10 sec. off). Warning buzzer B9

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 Service Manual Cooling system
Gear motor

5.1.3 Engine coolant cooling system L524, L528

Valid for: L524 - 659/17890-; L528 - 660/17890-

Cooling circuit for coolant

1 Equalising reservoir 4 Engine 7 Cooler

2 Reservoir cap 5 Coolant hose from cooler to 8 Coolant hose from cooler to
3 Coolant hose from engine to engine equalizing reservoir
cooler 6 Connecting hose from cooling 9 Reservoir overflow pipe
circuit to reservoir
Depending on the temperature and controlled by the thermostat, the engine
coolant is either cooled internally or pumped through the cooler 7.
The coolant is pumped from the thermostat housing through the hose 3 from
the engine to the cooler.
The coolant flows through the cooler fins.
It passes through the hose 3 back to the engine 4.
The oil returning to the engine 4 flows around the coolant temperature
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sensor. The coolant temperature sensor T04 reports the current temperature
to the UEC3 controller A6, which regulates the fan speed.
The coolant returns to the coolant circuit via the hose 6 connecting the
coolant circuit and the equalising reservoir.
The coolant circuit can be bled using the cooler bleeder line 8.

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5.1.4 Engine coolant cooling system L538/L542

Valid for: L538 - 433/17890-; L542 - 435/17890-

Cooling circuit for coolant

1 Equalising reservoir 5 Equalising reservoir return line 9 Hose from cooler to engine
2 Reservoir cap 6 Engine 10 Hose from engine to cooler
3 Equalising reservoir 7 Thermostat housing 11 Coolant cooler
overflow pipe 8 Connecting hose from cooling 12 Cooler bleeder line
4 Engine bleeder line circuit to reservoir
Depending on the temperature and controlled by the thermostat, the engine
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coolant is either cooled internally or pumped through the cooler 11.

The coolant is pumped from the thermostat housing through the hose 10
from the engine to the cooler.
The coolant flows through the cooler fins.
It passes through the hose 9 back to the engine 6.
The oil returning to the engine 6 flows around the coolant temperature
sensor B708. The coolant temperature sensor B708 reports the current
temperature to the UEC3 controller A6, which regulates the fan speed.
The coolant returns to the coolant circuit via the hose 12 connecting the
coolant circuit and the equalising reservoir.
The coolant circuit can be bled using the engine and cooler bleeder lines
4 and 12.

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 Service Manual Cooling system
Gear motor

5.1.5 Engine intake air cooling system (charge air)

Valid for: L524 - 659/17890-; L528 - 660/17890-

Charge air cooling circuit

1 Charge air cooler 4 Engine

2 Charge air hose from cooler 5 Charge air hose from engine
to engine to cooler
3 Air intake pipe port 6 Hose connector
The air drawn in by the turbocharger and heater due to compression is
pumped through the hose 5 from the engine to the charge air cooler 1.
The charge air cooler 1 cools down the air and returns it via the hose 2 to
the engine.
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Gear motor

Valid for: L538 - 659/17890-; L542 - 660/17890-

Charge air cooling circuit

1 Charge air cooler 4 Turbocharger outlet

2 Charge air hose from cooler 5 Charge air hose from engine
to engine to cooler
3 Engine 6 Hose connector
The air drawn in by the turbocharger and heater due to compression is
pumped through the hose 5 from the engine to the charge air cooler 1.
The charge air cooler 1 cools down the air and returns it via the hose 2 to
the engine.

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 Service Manual Cooling system
Gear motor

5.2 Gear pump

Design

Gear pump arrangement (left: L538/L542; right: L524/L528)

1 Brake 5 Brake
gear pump intake hose
2 Fan gear pump 6 Fan motor pressure hose
3 Fan drive intake hose 7 Fan test connection
4 Brake
return hose
The fan gear pump 2 is fitted on the auxiliary drive of the engine and is
driven by the engine at a specific transmission ratio via a spur gear.
The fan pump 2 draws oil from the hydraulic tank and pumps it through the
in-line filter to the gear motor.

Function description

Basic function
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Gear pump components

1 Gear fixing nut 7 Feather key

2 Snap ring 8 Gears
3 Shaft seal ring 9 Housing
4 Flange 10 Housing cover
5 Seals 11 Screw
6 Bearing bushings

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Cooling system Service Manual
Gear motor

The gear pump consists of two intermeshing gears 8 enclosed in a

housing 9. One of the two gears 8 is driven via the outgoing shaft (driving
gear), and the other driven by the gear teeth (driven gear).
The fluid taken in is injected into the gaps between the teeth and pumped
outside along the housing 9 from the intake port to the pressure port.

Pressure cut-off
The cooling system gear pump pressure cut-off is performed by the pressure
relief valve on the gear motor.

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 Service Manual Cooling system
Gear motor

5.3 Gear motor

The gear motor 1 is attached to the fan grille. The gear motor 1 drives the
fan blades via the fan drive shaft 2.
The proportional pressure relief valve 3 attached to the gear motor 1 controls
the fan speed.

Design

Gear motor with proportional pressure relief valve

1 Gear motor 3 Proportional pressure
2 Fan drive shaft relief valve
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Gear motor with proportional pressure relief valve

1 Bearing cover 7 Seal set 10 O-ring
2 Seal set 8 Proportional pressure relief valve 11 O-ring
3 Bearing bushings connecting housing 12 Shaft
4 Gears 9 Proportional pressure relief valve 13 Roller bearing
5 Bearing bushings 14 Shaft seal ring
6 Motor housing 15 Bearing cover

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Cooling system Service Manual
Gear motor

Proportional pressure relief valve

1 Pressure relief adjusting screw 5 Electromagnet connection 10 Housing
2 Counter nut 6 Secondary spring 11 Primary spring
3 Cap 7 Housing 12 Main piston
4 Electromagnet 8 Secondary piston 13 Primary restrictor
9 Secondary restrictor

Function description

Basic function
The gear motor 1 is powered by the current from the gear pump.
The gear motor 1 has a proportional pressure relief valve 3, which controls
the speed of the gear motor and therefore the fan speed.

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1 Gear motor P Pump intake

2 Proportional pressure T1 Return to tank
relief valve assembly T2 Relief seal (return to tank)
3 Proportional pressure
relief valve

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 Service Manual Cooling system
Gear motor

Pressure regulation by the proportional pressure relief valve

How the proportional pressure relief valve works

When the solenoid 1 is not energised, the proportional pressure relief valve
acts like a pilot-controlled pressure relief valve.
The pressure acting at “P” passes through the primary restrictor 8 to the
spring chamber of the main piston 7 and acts via the secondary restrictor 5
on the secondary piston 4. The pressure equalisation on the main piston 7
causes the primary spring 6 to close it.
If the pressure on the secondary piston 4 becomes so high that the set force
of the secondary spring 2 is exceeded, the secondary piston 4 opens,
allowing oil to flow into the tank chamber. This gives rise to a difference in
pressure in front of and behind the main piston 7, causing it to open.
If the solenoid 1 is energised, a magnetic force is generated depending on
the current.
The magnetic force acts on the iron core 3, pulling it back according to the
current strength.
This magnetic force reduces the set spring force of the secondary spring
2 accordingly. This causes the proportional valve to open at a lower
system pressure.

Fan speed regulation

The proportional pressure relief valve acts as a bypass on the gear motor.
At low temperature the bypass is almost fully open. Most of the pump flow
goes through the bypass valve to the tank. The fan turns at low speed
(minimum speed = dragging speed).
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As the temperature rises, the bypass valve closes proportionally. The gear
motor turns the fan faster.

Failsafe function
The failsafe function is as follows: if the power supply to the proportionally
controlled pressure relief valve fails, the bypass closes. The full flow of the
gear pump drives the gear motor. The fan turns at maximum speed.

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Cooling system Service Manual
Gear motor

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 Service Manual Cooling system
Temperature sensors

5.4 Temperature sensors

5.4.1 Hydraulic oil temperature sensor
(ID 10043264)

Technical data
The temperature sensor is used for measuring the temperature of the
coolant and the hydraulic oil.

Design
The sensor element of the temperature sensor consists of a thin-layer nickel
resistor encapsulated in epoxy resin.

Function description

Temperature measurement

Temperature/resistance curve
The resistance in the sensor rises along with the temperature.
The resistance curve of the temperature sensor is almost linear.

5.4.2 Coolant temperature sensor

Design
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The coolant temperature sensor is attached to the bottom of the thermostat

housing of the engine, while the fuel temperature sensor is fitted in the high
pressure fuel pump. Both have the task of signalling the temperature to the
engine control unit (ECU) in the form of an electrical resistance. The ECU
uses these signals for:
Coolant temperature:
– Indicating the coolant temperature in the cab
– Controlling the fan drive
– Preglow control
– Engine power limiting control
Fuel temperature:
– Controlling the fan drive
– Engine power limiting control

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Cooling system Service Manual
Temperature sensors

The temperature sensor is a resistance thermometer which operates with an

NTC characteristic (semiconductor).

Function description
Basic function
The resistance in the sensor decreases as the temperature rises. The curve
is not a straight line. If the sensor is defective, a default temperature
is assumed.

Coolant and fuel

temperature sensor

5.4.3 Charge air temperature sensor

Design
The charge air temperature sensor is attached to the air intake pipe of the
engine and has the task of signalling the charge air temperature to the
engine control unit (ECU) in the form of an electrical resistance. The ECU
uses this signal for:
– Controlling the fan drive
Charge air temperature sensor – Preglow control
– Engine power limiting control
The temperature sensor is a resistance thermometer which operates with an
NTC characteristic (semiconductor).

Function description

Basic function
The resistance in the sensor decreases as the temperature rises. The curve
is not a straight line. If the sensor is defective, a default temperature
is assumed.

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 6 Travel hydraulics
6.0

Chapter contents
6 Travel hydraulics ................................................................. 6.0-1

6.1 Travel hydraulics ............................................................................. 6.1-3

6.2 Variable displacement pump .......................................................... 6.2-1

6.2.1 Variable displacement pump to Ser. No. .............................. 6.2-1
6.2.2 Variable displacement pump from Ser. No.. ...................... 6.2-11

6.3 Variable displacement motors ........................................................ 6.3-1

6.3.1 Variable displacement motor 1 ............................................. 6.3-3
6.3.2 Variable displacement motor 2 ............................................. 6.3-9
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 Service manual Travel hydraulics

6.1 Travel hydraulics

Layout
Valid for: L524 - 659 / from 17890; L528 - 660 / from 17890

Main components of the travel hydraulics

1 Oil cooler 3 Fan motor 5 Variable displacement motor 2

2 Hydraulic tank 4 Variable displacement pump 6 Variable displacement motor 1
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Travel hydraulics Service manual

Valid for: L538 - 433 / from 17890; L542 - 435 / from 17890

Main components of the travel hydraulics

1 Oil cooler 3 Fan motor 5 Variable displacement motor 2

2 Hydraulic tank 4 Variable displacement pump 6 Variable displacement motor 1

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 Service manual Travel hydraulics

Function description

Basic function
Valid for: L524 - 659 / 17890 - 25488; L528 - 660 / 17890 - 25488;
L538 - 433 / 17890 - 22951; L542 - 435 / 17890 - 22951;
LBH/Version 01/01.2008/en/dw/07.02.2013

Diagram of the travel hydraulics

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Valid for: L524 - 659 / from 25489; L528 - 660 / from 25489;
L538 - 433 / from 22952; L542 - 435 / from 22952;

LBH/Version 01/01.2008/en/dw/07.02.2013

Diagram of the travel hydraulics

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 Service manual Travel hydraulics

1 Hydraulic tank 25 Pressure relief and 46 Swivel restrictor

2 Bleeder filter replenishing valve B 47 Restrictor 1.5 mm
3 Return strainer 26 Pressure relief and 48 Restrictor 1.5 mm
4 Bypass valve replenishing valve A 50 Fan motor assembly
5 Return suction filter 27 Replenishing pressure 51 Main piston
6 Pre-tension valve relief valve 52 Pressure relief and
7 Replenishing valve with strainer 28 Pressure cut-off replenishing valve
8 Check valve 29 Control pressure 53 Gear motor
9 Servostat tank connection proportional valve 54 Fan blade
10 Working hydraulics pump leak oil 30 Replenishing pump 55 Oil cooler
11 2plus1 transmission solenoid 31 Working hydraulics pilot control 56 Collector pipe
valve tank connection 33 Variable displacement 57 Check valve
12 Compact brake block motor 2 assembly 58 Fan gear pump
tank connection 34 Axial piston rotary group 59 Brake system gear pump
13 Pilot control device 35 Check valves
tank connection 36 Proportional valve Y57 and Test connections:
14 Control block return oil control piston PST Variable displacement pump
15 Working hydraulics pump 37 Servo piston control pressure
intake connection 38 Discharge valve G Replenishing pressure
16 Hydraulic oil temperature sensor 39 Pressure relief valve with orifice MA Forward travel direction high
17 Emergency steering pump 40 Variable displacement pressure
intake connection motor 1 assembly MB Reverse travel direction high
18 Temperature valve 41 Axial piston rotary group pressure
20 Variable displacement 42 Check valves M1 Variable displacement motor 1
pump assembly 43 Travel direction solenoid valve servo pressure
21 Axial piston pump Y26 M2 Variable displacement motor 2
22 Travel direction valve 44 Servo piston servo pressure
23 Servo cylinder 45 Control piston with travel range 1 P Fan high pressure
24 Inlet restrictor 1.8 mm solenoid valve Y58

The hydrostatic travel drive operates in a closed circuit. The variable

displacement pump 20 pumps oil directly to the variable displacement
motors 33 and 40. The oil returning from the motors is pumped back to the
l intake side of pump.
Travel range 1: When the travel range 1 solenoid valve is activated, it holds varia-
ble displacement motor 1 at the maximum swivel angle (25°). The fully energised
proportional valve also holds variable displacement motor 2 at the maximum
swivel angle (25°). This achieves a maximum speed of around 5 km/h.
Travel range 2: Both variable displacement motors move to a certain swivel
angle, depending on the speed. Variable displacement motor 1 is controlled
according to the high pressure (HA). Variable displacement motor 2 is controlled
by the proportional valve (EP). The maximum speed is around 18 km/h.
Travel range 3: At 15 km/h variable displacement motor 2 is moved to 0° swivel
angle and decoupled. As the speed increases, variable displacement motor 1
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moves to a narrower swivel angle according to the high pressure (HA). The
maximum speed of around 40 km/h is achieved at a swivel angle of 15°.

Variable displacement pump

The variable displacement pump operates in a closed circuit. It pumps the oil
directly to the variable displacement motors. The oil flowing back from the
motors is fed back to the intake side of the pump.
The variable displacement pump is controlled by the master controller
(UEC-3). The master controller regulates the control pressure proportional
valve 1, depending on the situation. The proportional valve controls the
control pressure and therefore the pump flow.

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L524 - 659 / 17890 - 25488; L524 - 659 / from 25489;

L528 - 660 / 17890 - 25488; L528 - 660 / from 25489;

L538 - 433 / 17890 - 22951; L538 - 433 / from 22952;

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The return force of the high pressure reduces the pump flow at high load.
The travel direction valve 2 determines the pump flow and therefore the
travel direction of the machine.
The pressure cut-off 4 limits the maximum operating pressure in the
closed circuit.
The pressure relief valves 3 and 5 for forward and reverse travel protect the
travel drive from excessive pressure peaks.
See the detailed description in the section on the variable displace-
ment pump.

Regulation of the variable displacement pump

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The variable displacement pump is controlled by the master controller (UEC-3).

The following parameters affect the regulation of the variable displace-
ment pump.
– Gas pedal position
– Engine speed
– Inching function
– Excessive hydraulic oil temperature
– Excessive engine speed or road speed

Gas pedal position When the gas pedal is depressed, the current to the control pressure pro-
portional valve is increased and the variable displacement pump pivots out.

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 Service manual Travel hydraulics

The control pressure proportional valve is only energised when the engine
speeds exceeds 900 rpm. The current is then increased to the set value
according to the engine speed.
Inching function When the inch/brake pedal is depressed, the master controller (UEC-3)
reduces the current to the control pressure proportional valve and
hydrostatic braking takes place.
When the engine speed is too high (2450 rpm for LH, 2600 rpm for John
Deere), the inching function is gradually reduced, until it is deactivated at the
threshold engine speed (2600 rpm for LH, 2800 rpm for John Deere). This
prevents engine overspeed when travelling downhill.
If the inching angle sensor fails, the inching function is gradually deactivated
within 20 seconds.
Overheating If the hydraulic oil overheats (90 – 95 °C), the master controller (UEC-3)
reduces the current to the control pressure proportional valve. The current is
gradually reduced to 40% of the maximum level.
The control pressure proportional valve is energised normally again when
the temperature falls back below the threshold.
Excessive engine Above a certain speed in each gear, the master controller (UEC-3) starts
speed or road speed gradually reducing the current to the control pressure proportional valve
to 200 mA.
Variable displacement motors
The variable displacement motors drive the transmission. A higher or
lower torque is transferred to the transmission, depending on the swivel
angle and pressure.
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The flow from the displacement pump reaches the variable displacement
motor via pressure port A or B. In the process, pressure acts on the
regulating pistons which move along the cylinder of the rotary group. The
resulting force turns the drive shaft and generates a certain torque.
Variable displacement motor 1 is controlled according to the high pressure
(HA). When the high pressure reaches a certain level, variable displacement
motor 1 moves to a wider swivel angle. The travel direction solenoid valve
prevents engine overspeed when travelling downhill.
Variable displacement motor 2 is regulated by the master controller (UEC-3).
The proportional valve 5 on the variable displacement motor 2 is activated,

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depending on the situation. This adjusts the pivot angle and displacement to
the current operating condition.
The discharge valve 6 in the variable displacement motor 2 is employed in
the closed circuit to prevent heat build-up. Oil is discharged from the low
pressure side of the closed circuit and fed to the hydraulic tank. The
replenishing pump replaces this oil with cooled oil.

Regulation of variable displacement motor 2

Variable displacement motor 2 is controlled by the master controller (UEC-3).
The following parameters affect the regulation:
– Road speed
– Variable displacement motor power limiting control
(excessive engine suppression)
– Inching function
– Excessive engine speed or road speed

Road speed The proportional valve on variable displacement motor 2 is energised

according to the road speed.
The lower the current at the proportional valve of variable displacement
motor 2, the smaller the swivel angle and the displacement of the motor 2.
Variable displacement motor Power limiting control comes into effect when the engine is excessively
power limiting control suppressed due to load. This can occur while driving and simultaneously
operating the working hydraulics.
The master controller (UEC-3) increases the current to the proportional valve
of variable displacement motor 2 until the engine speed is back in the normal
range. Variable displacement motor 2 then pivots out again.
Excessive engine If the engine exceeds a critical speed when driving downhill, variable
speed or road speed displacement motor 2 pivots in. The hydrostatic braking effect is reduced
and the machine accelerates. The driver must brake the machine.

Hydraulic tank
The hydraulic tank 1 provides filtered oil for the replenishing pump of the
travel hydraulics. The replenishing pump draws up oil from the hydraulic tank
via the connection 7.
A pre-tension valve in the return suction filter 4 preloads the suction side of
the replenishing pump with a pressure of 0.5 bar. The replenishing pump is
better able to draw up the oil for cold starts. This means that the pressure in
the hydrostatic control circuit increases more quickly and driving perfor-
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mance is improved.
The oil returning from the travel hydraulics is directed through the collector
pipe 6 to the oil cooler 5. The oil is then pumped through the return suction
filter 4 back to the hydraulic tank.
The bleeder filter 4 compensates for pressure differences inside the
hydraulic tank by providing appropriate ventilation.
See the detailed description in the section on the hydraulic tank.

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 Service manual Travel hydraulics
Variable displacement pump

6.2 Variable displacement pump

6.2.1 Variable displacement pump to Ser. No.
Valid for: L524 - 659 / 17890 - 25488; L528 - 660 / 17890 - 25488;
L538 - 433 / 17890 - 22951; L542 - 435 / 17890 - 22951;

Technical data
See section 2.1

Layout

L524, L528 Main components of the variable displacement pump L538, L542

1 Servo cylinder 3 Travel direction valve 5 Replenishing pump

2 Control pressure proportional valve 4 Connection housing 6 Pump housing
The variable displacement pump is flange-mounted on the flywheel housing
of the engine.
The variable displacement pump is an axial piston pump with a swash plate
design. The pump contains proportional valves for the control pressure and
pressure cut-off, as well as a replenishing pressure valve, pressure relief
and replenishing valve, and a replenishing pump.
The following diagrams illustrate the design of the variable displacement pump:
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Variable displacement pump

Components of the variable displacement pump, side view

1 Drive shaft 12 Coupling hub 24 Piston

2 Shaft seal ring 13 Bearing bushing 25 Return ball
3 Snap ring 14 Internal gear 26 Return plate
4 Pump housing 15 External gear 27 Glide shoe
5 Servo piston 16 Bearing bushing 28 Cup springs
6 Travel direction valve 17 Bearing bushing 29 Swash plate
7 Control pressure 18 Bushing 30 Guide pin
proportional valve 19 Control lens 31 Pin
8 Pressure cut-off 20 Snap ring 32 Swash plate bearing
9 Connection housing 21 Pressure spring 33 Roller bearing
10 Disc 22 Bushing 34 Snap ring
11 Replenishing pump housing 23 Cylinder
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 Service manual Travel hydraulics
Variable displacement pump

Components of the variable displacement pump, servo cylinder and servo valve view

1 Servo piston 9 Pressure cut-off 16 Solenoid

2 Pump housing 10 Travel direction valve 17 Receptacle ring
3 Spring cup 11 Control pressure proportional valve 18 Adjusting screw for the
4 Pressure spring 12 Connection housing pump zero position
5 Pressure spring 13 Pressure relief and 19 Counter nut
6 Turcon-Glyd seal replenishing valve 20 Spring cup
7 Guide ring 14 Replenishing pressure relief valve 21 Snap ring
8 Solenoid 15 Twist screw 22 Cover
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Variable displacement pump

Components of the variable displacement pump, front view

1 Pressure cut-off 4 Restrictor 7 Pressure relief and

2 Connection housing 5 Plug replenishing valve
3 Pressure relief and 6 Replenishing pressure
replenishing valve relief valve

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 Service manual Travel hydraulics
Variable displacement pump

Function description

Basic function

Hydraulic plan of the variable displacement pump

1 Variable displacement pump 9 Control pressure

2 Servo cylinder proportional valve
3 Travel direction valve 10 Replenishing pump
4 Restrictor 11 Replenishing pump intake
5 Pressure relief and connection
replenishing valve A 12 To working hydraulics
6 Pressure relief and pilot control
replenishing valve B 13 To variable displacement motor
7 Replenishing pressure bearing lubrication
relief valve 14 To oil cooler
8 Pressure cut-off 15 To bypass valve and
return strainer
The variable displacement pump is designed for hydrostatic drives in a
closed circuit. The pump delivers directly to the variable displacement
motors. The oil flowing back from the motors is fed back to the opposite side
of the pump.
The variable displacement pump is regulated by the master controller (UEC-3).
LBH/Version 01/01.2008/en/dw/07.02.2013

The control pressure proportional valve 9 is activated by the master controller

according to the situation. The proportional valve regulates the control pressure
and therefore the pump flow.
At high load, the pump flow is reduced by the reaction forces from the
high pressure.
The travel direction valve determines the pump flow and therefore the travel
direction of the machine.
The pressure relief and replenishing valves A and B protect the travel drive
from excessive pressure peaks. At the same time, the valves act as
replenishing valves for the closed circuit.
The pressure cut-off limits the maximum operating pressure within the
closed circuit.

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Variable displacement pump

Regulation of the pump

The variable displacement pump is regulated by the master controller (UEC-3).
The control pressure proportional valve is activated by the master controller
according to the situation. The proportional valve regulates the control pressure
and therefore the pump flow.
The following parameters affect the control of the pump:
– Gas pedal position
– Engine speed
– Inching function
– Excessive hydraulic oil temperature
– Excessive engine speed or road speed

Control pressure proportional valve

The master controller activates the control pressure proportional valve
according to the situation. The valve reduces the pressure in the duct PST in
proportion to the solenoid current. It operates largely independently of the
replenishing pressure PSP.

In the de-energised state, the control pressure duct PST is connected to the
tank T. The more the current increases, the higher the control pressure. The
maximum level is limited by the replenishing pressure.
Depending on the current to the proportional valve 3, the control piston 2 is
moved closer to or further from the regulating springs 1. This adjusts the
pressure in the duct PST.

Servo piston and swash plate

The servo piston 3 turns the swash plate 2 mounted on roller bearings and
thus alters the pump flow.
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Servo piston and swash plate

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 Service manual Travel hydraulics
Variable displacement pump

1 Swash plate bearing 3 Servo piston

2 Swash plate 4 Cylinder with piston
As the swivel angle increases, the pump flow is increased. The drive torque
is increased.
When the swivel angle is reduced, the flow rate of the pump is also reduced.
The drive torque is reduced.
In the zero position, the pump delivers no oil. The strong spring centring in
the servo cylinder keeps the swash plate in the zero position if no control
signals are present. The zero position can be mechanically adjusted.

Sectional view of the servo cylinder

1 Pump housing 5 Reverse travel direction servo

2 Pressure spring oil supply
3 Servo cylinder 6 Pressure spring
4 Forward travel direction servo 7 Zero position adjusting screw
oil supply
When the zero position is passed, the flow direction of the hydraulic oil is
smoothly reversed.

Travel direction valve

The travel direction valve determines the direction in which the pump
swivels out.
The travel direction valve directs the control pressure into one of the two
servo chambers in the servo cylinder. The opposite chamber remains
connected to the drain.
LBH/Version 01/01.2008/en/dw/20.01.2014

Sectional view of the travel direction valve

1 Forward travel 4 Forward travel direction

direction solenoid Y2 servo oil supply
2 Servo oil supply 5 Reverse travel direction
3 Reverse travel servo oil supply
direction solenoid Y3 6 Servo piston
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Variable displacement pump

Replenishing pump
The replenishing pump is an internal gear pump. The replenishing pump
draws up oil from the hydraulic tank. The delivery volume of the pump is
proportional to the drive speed.

Front view of the replenishing pump

1 Internal gear pump 2 Suction side of the

replenishing pump
The replenishing pump supplies the closed circuit with fresh, cooled oil. The
replenishing pump also provides oil for the control circuit (control pressure).
The maximum replenishing pressure is limited by the replenishing pressure
relief valve.

Replenishing pressure relief valve

This directly actuated pressure relief valve protects the replenishing pump
from excess pressure.

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Cross section of the replenishing pressure relief valve

1 Tank outlet 4 Oil to the pressure relief and
2 Oil from the replenishing pump replenishing valve
3 Adjusting screw 5 Valve piston
Excess oil that is not fed into the closed circuit flows via the replenishing
pressure relief valve to the pump housing. At the same time, this oil cools
the rotary group of the variable displacement pump.

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 Service manual Travel hydraulics
Variable displacement pump

Pressure cut-off
The pressure cut-off valve limits the operating pressure in the closed circuit.
When the maximum operating pressure is reached, the flow of the variable
displacement pump is reduced so that the maximum operating pressure is
just maintained.

Hydraulic diagram of active/inactive pressure cut-off

1 Variable displacement pump 4 Pressure cut-off

2 Travel direction valve 5 Nozzle
3 Control pressure 6 Replenishing pump
proportional valve
Pressure cut-off active: when the maximum operating pressure is reached in
the closed circuit, the pressure cut-off is activated. Control oil flows into the
tank duct.
Not enough oil can now flow from the replenishing pump 6 through the
nozzle 5. Up to the nozzle 5 the replenishing pressure acts; behind it, only
the reduced control pressure.
Pressure cut-off inactive: the control pressure acts in the duct up to the
control pressure proportional valve 3 and the pressure cut-off 4.
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Sectional view of the pressure cut-off

1 Pressure spring 5 Tank outlet 8 Check valve

2 Valve piston 6 Tappet 9 Bore hole
3 Servo oil supply 7 Low pressure / closed circuit 10 High pressure / closed circuit
4 Control edge
The operating pressure controls the valve. When the maximum operating
pressure has been reached, the tappet 6 and the valve piston 2 are pushed
against the pressure spring 1. The control pressure duct 3 is linked to the tank
outlet 5, and servo oil drains off. The control pressure drops and the variable
displacement pump swivels to a smaller flow rate. The variable displacement
pump then delivers just enough oil to attain the maximum pressure.

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Variable displacement pump

Pressure relief and replenishing valve

The pilot-controlled pressure relief and replenishing valves prevent excess
pressure from forming in the closed circuit.
The high pressure from the system acts via the nozzle 6 on the pilot control
piston 2. It the set value is exceeded, the pilot control piston opens. The rear
piston chamber 3 is opened via the relief duct 8 to the low pressure side.
The main piston 4 then opens and the high pressure oil can flow to the low
pressure side 5.

Pressure relief and replenishing valve at high pressure

1 Pressure spring 5 Low pressure side

2 Pilot control piston 6 Nozzle
3 Rear piston chamber 7 High pressure
4 Main piston 8 Relief duct
At the same time, the valves act as replenishing valves for the closed circuit.
Oil leaks in the closed circuit reduce the pressure on the low pressure side.
This opens the main piston and oil from the replenishing pump can flow into
the closed circuit.

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Pressure relief and replenishing valve during replenishment

1 Main piston 4 Replenishing oil intake
2 Pressure spring 5 Closed circuit replenishment
3 Main piston control edge

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Variable displacement pump

6.2.2 Variable displacement pump from Ser. No..

Valid for: L524 - 659 / from 25489; L528 - 660 / from 25489;
L538 - 433 / from 22952; L542 - 435 / from 22952;

Technical data
See section 2.1

Layout

L524, L528 Main components of the variable displacement pump L538, L542

1 Servo cylinder 3 Travel direction valve 5 Replenishing pump

2 Control pressure proportional valve 4 Connection housing 6 Pump housing
The variable displacement pump is flange-mounted on the flywheel housing
of the engine.
The variable displacement pump is an axial piston pump with a swash plate
design. The pump contains proportional valves for the control pressure and
pressure cut-off, as well as a replenishing pressure valve, pressure relief
and replenishing valve, and a replenishing pump.
The following diagrams illustrate the design of the variable displacement pump:
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Variable displacement pump

Components of the variable displacement pump, side view

1 Drive shaft 12 Bearing bushing 23 Piston

2 Shaft seal ring 13 Internal gear 24 Return ball
3 Snap ring 14 External gear 25 Return plate
4 Pump housing 15 Bearing bushing 26 Glide shoe
5 Servo piston 16 Bearing bushing 27 Cup springs
6 Travel direction valve 17 Bushing 28 Swash plate
7 Pressure cut-off 18 Control lens 29 Guide pin
8 Connection housing 19 Snap ring 30 Pin
9 Disc 20 Pressure spring 31 Swash plate bearing
10 Replenishing pump housing 21 Bushing 32 Roller bearing
11 Coupling hub 22 Cylinder 33 Snap ring

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 Service manual Travel hydraulics
Variable displacement pump

Components of the variable displacement pump, servo cylinder and servo valve view

1 Servo piston 9 Pressure cut-off 16 Receptacle ring

2 Pump housing 10 Travel direction valve 17 Adjusting screw for the
3 Spring cup 11 Connection housing pump zero position
4 Pressure spring 12 Pressure relief and 18 Counter nut
5 Pressure spring replenishing valve 19 Spring cup
6 Turcon-Glyd seal 13 Control pressure proportional valve 20 Snap ring
7 Guide ring 14 Twist screw 21 Cover
8 Solenoid 15 Solenoid
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Variable displacement pump

Components of the variable displacement pump, front view

1 Pressure cut-off 4 Restrictor 7 Pressure relief and

2 Connection housing 5 Control pressure proportional valve replenishing valve
3 Pressure relief and 6 Replenishing pressure relief valve
replenishing valve

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 Service manual Travel hydraulics
Variable displacement pump

Function description

Basic function

Hydraulic plan of the variable displacement pump

1 Variable displacement pump 9 Control pressure

2 Servo cylinder proportional valve
3 Travel direction valve 10 Replenishing pump
4 Restrictor 11 Replenishing pump intake
5 Pressure relief and connection
replenishing valve A 12 To working hydraulics
6 Pressure relief and pilot control
replenishing valve B 13 To variable displacement motor
7 Replenishing pressure bearing lubrication
relief valve 14 To oil cooler
8 Pressure cut-off 15 To bypass valve and
return strainer
The variable displacement pump is designed for hydrostatic drives in a
closed circuit. The pump delivers directly to the variable displacement
motors. The oil flowing back from the motors is fed back to the opposite side
of the pump.
The variable displacement pump is regulated by the master controller (UEC-3).
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The control pressure proportional valve 9 is activated by the master controller

according to the situation. The proportional valve regulates the control pressure
and therefore the pump flow.
At high load, the pump flow is reduced by the reaction forces from the
high pressure.
The travel direction valve determines the pump flow and therefore the travel
direction of the machine.
The pressure relief and replenishing valves A and B protect the travel drive
from excessive pressure peaks. At the same time, the valves act as
replenishing valves for the closed circuit.
The pressure cut-off limits the maximum operating pressure within the
closed circuit.

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Variable displacement pump

Regulation of the pump

The variable displacement pump is regulated by the master controller (UEC-3).
The control pressure proportional valve is activated by the master controller
according to the situation. The proportional valve regulates the control pressure
and therefore the pump flow.
The following parameters affect the control of the pump:
– Gas pedal position
– Engine speed
– Inching function
– Excessive hydraulic oil temperature
– Excessive engine speed or road speed

Control pressure proportional valve

The master controller activates the control pressure proportional valve
according to the situation. The valve reduces the pressure in the duct PST in
proportion to the solenoid current. It operates largely independently of the
replenishing pressure PSP.

In the de-energised state, the control pressure duct PST is connected to the
tank T. The more the current increases, the higher the control pressure. The
maximum level is limited by the replenishing pressure.
Depending on the current to the proportional valve 3, the control piston 2 is
moved closer to or further from the regulating springs 1. This adjusts the
pressure in the duct PST.

Servo piston and swash plate

The servo piston 3 turns the swash plate 2 mounted on roller bearings and
thus alters the pump flow.
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Servo piston and swash plate

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Variable displacement pump

1 Swash plate bearing 3 Servo piston

2 Swash plate 4 Cylinder with piston
As the swivel angle increases, the pump flow is increased. The drive torque
is increased.
When the swivel angle is reduced, the flow rate of the pump is also reduced.
The drive torque is reduced.
In the zero position, the pump delivers no oil. The strong spring centring in
the servo cylinder keeps the swash plate in the zero position if no control
signals are present. The zero position can be mechanically adjusted.

Sectional view of the servo cylinder

1 Pump housing 5 Reverse travel direction servo

2 Pressure spring oil supply
3 Servo cylinder 6 Pressure spring
4 Forward travel direction servo 7 Zero position adjusting screw
oil supply
When the zero position is passed, the flow direction of the hydraulic oil is
smoothly reversed.

Travel direction valve

The travel direction valve determines the direction in which the pump
swivels out.
The travel direction valve directs the control pressure into one of the two
servo chambers in the servo cylinder. The opposite chamber remains
connected to the drain.
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Sectional view of the travel direction valve

1 Forward travel 4 Forward travel direction

direction solenoid Y2 servo oil supply
2 Servo oil supply 5 Reverse travel direction
3 Reverse travel servo oil supply
direction solenoid Y3 6 Servo piston
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Variable displacement pump

Replenishing pump
The replenishing pump is an internal gear pump. The replenishing pump
draws up oil from the hydraulic tank. The delivery volume of the pump is
proportional to the drive speed.

Front view of the replenishing pump

1 Control pressure 3 Suction side of the replenishing

proportional valve pump
2 Internal gear pump
The replenishing pump supplies the closed circuit with fresh, cooled oil. The
replenishing pump also provides oil for the control circuit (control pressure).
The maximum replenishing pressure is limited by the replenishing pressure
relief valve.

Replenishing pressure relief valve

This directly actuated pressure relief valve protects the replenishing pump
from excess pressure.

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Cross section of the replenishing pressure relief valve

1 Tank outlet 4 Oil to the pressure relief and
2 Oil from the replenishing pump replenishing valve
3 Adjusting screw 5 Valve piston
Excess oil that is not fed into the closed circuit flows via the replenishing
pressure relief valve to the pump housing. At the same time, this oil cools
the rotary group of the variable displacement pump.

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Variable displacement pump

Pressure cut-off
The pressure cut-off valve limits the operating pressure in the closed circuit.
When the maximum operating pressure is reached, the flow of the variable
displacement pump is reduced so that the maximum operating pressure is
just maintained.

Sectional view of the pressure cut-off

1 Pressure spring r 5 Tank outlet 8 Check valve
2 Valve piston 6 Tappet 9 Bore hole
3 Servo oil supply 7 Low pressure / closed circuit 10 High pressure / closed circuit
4 Control edge
The operating pressure controls the valve. When the maximum operating
pressure has been reached, the tappet 6 and the valve piston 2 are pushed
against the pressure spring 1. The control pressure duct 3 is linked to the tank
outlet 5, and servo oil drains off. The control pressure drops and the variable
displacement pump swivels to a smaller flow rate. The variable displacement
pump then delivers just enough oil to attain the maximum pressure.

Pressure relief and replenishing valve

The pilot-controlled pressure relief and replenishing valves prevent excess
pressure from forming in the closed circuit.
The high pressure from the system acts via the nozzle 6 on the pilot control
piston 2. It the set value is exceeded, the pilot control piston opens. The rear
piston chamber 3 is opened via the relief duct 8 to the low pressure side.
The main piston 4 then opens and the high pressure oil can flow to the low
pressure side 5.
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Pressure relief and replenishing valve at high pressure

1 Pressure spring 5 Low pressure side

2 Pilot control piston 6 Nozzle
3 Rear piston chamber 7 High pressure
4 Main piston 8 Relief duct
At the same time, the valves act as replenishing valves for the closed circuit.

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Variable displacement pump

Oil leaks in the closed circuit reduce the pressure on the low pressure side.
This opens the main piston and oil from the replenishing pump can flow into
the closed circuit.

Pressure relief and replenishing valve during replenishment

1 Main piston 4 Replenishing oil intake
2 Pressure spring 5 Closed circuit replenishment
3 Main piston control edge

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Variable displacement motors

6.3 Variable displacement motors

Function description

Basic function

Variable displacement motor arrangement

1 Variable displacement motor 1 4 Travel direction solenoid valve

2 Variable displacement motor 2 Y26
3 Travel range 1 solenoid valve 5 Proportional valve Y57
Y58 6 Discharge valve
The variable displacement motors drive the transmission. A higher or lower
torque is transferred to the transmission, depending on the pivot angle
and pressure.

Regulation of variable displacement motor 1

The variable displacement motor is controlled according to the high pressure
(HA). When the high pressure reaches a certain level, the motor moves to a
wider swivel angle. HA regulation can be set using the adjusting screw 1.
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The travel direction solenoid valve 2 prevents engine overspeed when

travelling downhill.
The travel range 1 solenoid valve 3 is activated in travel range 1. The
variable displacement motor is held at the maximum swivel angle by
hydraulic force.

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Variable displacement motors

Regulation of variable displacement motor 2

Variable displacement motor 2 is regulated by the master controller (UEC-3).
The proportional valve 1 is activated according to the situation. This adjusts
the swivel angle and displacement to the current operating condition.
The discharge valve 2 on the variable displacement motor is employed in the
closed circuit to prevent heat build-up. Oil is discharged from the low
pressure side of the closed circuit and fed to the hydraulic tank. The
replenishing pump replaces this oil with cooled oil.

Variable displacement motor bearing flushing

During bearing flushing, fresh, cooled oil is directed to the tapered roller
bearings and into the housing of the variable displacement motors. The hot
oil is pumped out.
Oil from the replenishing pump 4 is pumped to the connection U of the
motors. The orifices on the connection U ensure that the oil flows in
controlled quantities to the motors.
The return oil from the fan motor 7 is pumped to the connection T1 of
variable displacement motor 1. Oil flows through the connection T2 to the
connection T1 of variable displacement motor 2. The hot oil is directed from
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the connection T2 (variable displacement motor 2) through the collector pipe

5 to the oil cooler 6.

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Variable displacement motors

6.3.1 Variable displacement motor 1

Technical data
See section 2.1

Layout

Main components of the variable displacement motor

1 Regulation unit 5 Housing

2 Travel direction solenoid valve Y26 6 Control unit
3 Travel range 1 solenoid valve Y58 7 Cover
4 Drive shaft
The variable displacement unit is flange-mounted on the transmission. The
variable displacement motor is an inclined axial tapered piston rotary group
and includes the control and regulation unit.
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Variable displacement motors

Components of the variable displacement motor

1 Drive shaft 11 Control bushing 20 Servo piston

2 Snap ring 12 Adjusting pin 21 Servo piston seal
3 Shaft seal ring 13 Control piston 22 Hex socket screw
4 Drive shaft bearing 14 Regulating spring 23 Cover
5 Centre pin 15 Spring cup 24 Q min. adjusting screw
6 Pressure spring 16 Pressure spring 25 Control lens
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7 Spacer 17 Connecting plate 26 Cylinder

8 Q max. adjusting screw 18 Control pin 27 Piston
9 Travel range 1 solenoid valve 19 Threaded pin 28 Motor housing
10 HA control adjustment screw

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Variable displacement motors

Components of the variable displacement motor

1 Cover 4 Valve insert 7 Piston with pressure spring
2 Swivel restrictor 5 Control piston 8 Travel range 1 solenoid valve Y58
3 Check valve 6 Control bushing 9 Travel direction solenoid valve Y26
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Variable displacement motors

Function description

Basic function

Hydraulic diagram of the variable displacement motor

1 Variable displacement motor 7 Oil from fan motor

2 Check valves 8 Oil to variable displacement
3 Travel direction solenoid valve motor 2
4 Servo piston 9 Oil for bearing lubrication with
5 Swivel restrictor orifice
6 Control piston with travel M1 Servo pressure test connection
range 1 solenoid valve
The oil from the pump reaches the motor via pressure port A or B. In the
process, pressure acts on the tapered pistons which move along the cylinder
of the rotary group. The resulting force turns the drive shaft and generates a
certain torque. The torque of the drive shaft depends on the swivel angle
and the operating pressure of the motor. The speed of the drive shaft
depends on the quantity of oil supplied and the swivel angle of the motor.
– When the swivel angle is decreased, the engine speed increases and the
torque is reduced.
– When the swivel angle is increased, the torque increases and the engine
speed is restricted.
The regulation and control unit contained in the closing plate adjusts the
angle of the motor. The angle of the motor is determined by the high
pressure in the closed circuit.
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Variable displacement motors

High pressure hydraulic control (HA)

The regulation and control unit moves the motor to the required angle.
The variable displacement motor is controlled according to the high pressure
(HA). When the high pressure reaches a certain level, the motor moves to a
wider swivel angle (Q max).
The high pressure in the closed circuit acts on the ring face 10. If the set
value (250 bar) is exceeded, the servo piston 7 is pushed down against the
return spring 6. This allows hydraulic oil to flow to the large servo piston
face 1. The motor moves to a wider angle until the high pressure falls back
below the set level.

HA regulation on the variable displacement motor

1 Large servo piston face 7 Control piston

2 Small servo piston face 8 Travel range 1 solenoid valve
3 Servo piston 9 Adjusting screw for start
4 Control lens of regulation
5 Control pin 10 Ring face
6 Regulating spring
The regulating spring 6 is set using the adjusting screw 9. The adjustment
has the following effect:
– Tighten the adjusting screw to bring forward the start of regulation (the
high pressure level is lower)
– Loosen the adjusting screw to delay the start of regulation (the high
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pressure level is higher)

The travel range 1 solenoid valve 8 is activated in travel range 1. The
variable displacement motor is held at the maximum swivel angle by
hydraulic force.
Travel range 1 solenoid valve activated: the solenoid pushes the control
piston 7 down against the regulating spring 6. This allows hydraulic oil to
flow to the large servo piston face 1. The motor pivots out (Q max).

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Variable displacement motors

Swivel time restriction

The swivel restrictor 1 ensures smooth regulation of the variable
displacement motor. The swivel restrictor 1 prevents the motor from moving
from a narrow angle (Q min) to a wide angle (Q max) too quickly.
During regulation, the oil flows slowly to the large servo piston face 2 via the
groove in the swivel restrictor 1. The motor slowly pivots out (Q max).
When the motor pivots in, the hydraulic oil flows unhindered through the
swivel restrictor 1. The motor pivots in quickly (Q min).

Travel direction solenoid valve

The travel direction solenoid valve 5 prevents engine overspeed when
travelling downhill.
In forward travel direction the solenoid valve 5 is not energised. Spring force
pushes the valve piston 4 to the right against the solenoid valve.
In reverse travel direction the solenoid valve 5 is energised. The solenoid
valve pushes the valve piston 4 to the left against the spring.

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Variable displacement motors

6.3.2 Variable displacement motor 2

Technical data
See section 2.1

Layout

Main components of the variable displacement motor

1 Proportional valve Y57 4 Drive shaft

2 Regulation unit 5 Discharge valve
3 Motor housing 6 Control unit
The variable displacement unit is flange-mounted on the transmission. The
variable displacement motor is an inclined axial tapered piston rotary group
and includes the control and regulation unit.
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Variable displacement motors

Components of the variable displacement motor

1 Drive shaft 14 Orifice 27 Control piston

2 Snap ring 15 Valve piston 28 Proportional solenoid Y57
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3 Shaft seal ring 16 Hex socket screw 29 Regulation adjusting screw

4 Connection U 17 Servo piston seal 30 Adjusting pin
5 Motor housing 18 Servo piston 31 O-ring
6 Piston 19 Threaded pin 32 Q max. adjusting screw
7 Cylinder 20 Control pin 33 Spacer
8 Control lens 21 Regulating spring 1 34 Pressure spring
9 Q min. adjusting screw 22 Connecting plate 35 Centre pin
10 Screw connection 23 Spring cup 36 Drive shaft bearing
11 Pressure spring 24 Spring cup 37 Check valve
12 Pressure relief valve 25 Regulating spring 2 38 Valve insert
13 Discharge valve 26 Control bushing

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Variable displacement motors

Components of the variable displacement motor

1 Screw connection 4 Discharge valve 7 Proportional solenoid

2 Pressure spring 5 Control piston 8 Check valve
3 Pressure relief valve 6 Control bushing 9 Valve insert

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Variable displacement motors

Function description

Basic function

Hydraulic diagram of the variable displacement motor

1 Variable displacement motor 8 Pressure relief valve

2 Check valves 9 Bearing lubrication oil
3 Proportional valve 10 Tank connection to variable
4 Control piston displacement motor 1
5 Servo piston 11 Return oil from discharge valve
6 Discharge valve 12 To collector pipe and oil cooler
7 Orifice M1 Servo pressure test connection
The oil from the pump reaches the motor via pressure port A or B. In the
process, pressure acts on the tapered pistons which move along the cylinder
of the rotary group. The resulting force turns the drive shaft and generates a
certain torque. The torque of the drive shaft depends on the swivel angle
and the operating pressure of the motor. The speed of the drive shaft
depends on the quantity of oil supplied and the swivel angle of the motor.
– When the swivel angle is decreased, the engine speed increases and the
torque is reduced.
– When the swivel angle is increased, the torque increases and the engine
speed is restricted.
The regulation and control unit contained in the closing plate adjusts the
angle of the motor. The variable displacement motor is regulated by the
master controller (UEC-3).
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Variable displacement motors

Electrical/proportional regulation (EP)

Depending on the energisation of the proportional magnet 7, the variable
displacement motor is moved to the required angle.
When the proportional magnet is not energised, the motor is held at the 0°
angle by the high pressure acting on the small servo piston face 2.
When the proportional magnet is energised, above a certain current the
control piston 6 is pushed up against the regulating springs 5 and 4. High-
pressure oil flows via the control piston 6 to the large piston face 1 and the
variable displacement motor moves out to a wider angle.
During regulation, the control piston 3 is pushed down, increasing the
tension in the regulating spring 4. This stops the regulation process if the
current at the proportional magnet is not further increased.
If the current is increased, the force of the two regulating springs is
overcome and the motor continues moving to a wider angle.
The maximum swivel angle is reached at a current of around 600 mA. The
force of the proportional magnet is go great that it overcomes the spring
force even at a wide angle.
The adjusting screw 8 is used for adjusting the regulating springs 5 (basic
setting). Adjust the regulating springs 5 so that the motor is moved to a 25°
angle at 600 mA on the proportional magnet.
The speed of regulation of the variable displacement motor is controlled
solely by the master controller (UEC-3). This means no swivel restrictors
are required.

Cooling by the discharge valve

The discharge valve is used in the closed circuit to prevent heat from
building up. Oil is discharged from the low pressure side of the closed circuit
and fed to the hydraulic tank. The replenishing pump replaces this oil with
cooled oil.
When the machine is at rest, the pressure is the same on both faces of the
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valve piston 4. The two return springs 5 push the valve piston 4 to the centre
position. No oil is discharged in this position.
When the machine moves, the pressure in the duct 6 or 7 increases and
moves the valve piston 4 towards one of the return springs 5. The low
pressure side is opened and a defined quantity of oil flows via the orifice 1
and the pressure relief valve 2 to the hydraulic tank.

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Travel hydraulics Service manual
Variable displacement motors

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 7 Working hydraulics
7.0

Chapter contents
7 Working hydraulics.............................................................. 7.0-1
7.0.1 Working hydraulics L524, L528 ............................................7.0-1
7.0.2 Working hydraulics L538, L542 ............................................7.0-7

7.1 Working hydraulics pump ...............................................................7.1-1

7.1.1 Working hydraulics pump L524, L528 ..................................7.1-1
7.1.2 Working hydraulics pump L538, L542 ..................................7.1-6

7.2 Control block ...................................................................................7.2-1

7.2.1 Control valve block oil leak monitoring .................................7.2-8

7.3 Pilot control .....................................................................................7.3-1

7.3.1 Pilot control unit ....................................................................7.3-4
7.3.2 Pilot control solenoid valve ...................................................7.3-8
7.3.3 Pilot control hydro accumulator ..........................................7.3-10

7.4 Ride control.....................................................................................7.4-1

7.4.1 Stabilisation module .............................................................7.4-5
7.4.2 Ride control hydro accumulator............................................7.4-8

7.5 Lift and tilt cylinders ........................................................................7.5-1

7.5.1 Lift cylinder ...........................................................................7.5-1
7.5.2 Z kinematics tilt cylinder .......................................................7.5-3
7.5.3 P kinematics tilt cylinder .......................................................7.5-5

7.6 Hydraulic tank .................................................................................7.6-1

7.6.1 Filter unit ...............................................................................7.6-3
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7.6.2 Bleeder filter .........................................................................7.6-8

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Working hydraulics Service Manual

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 Service Manual Working hydraulics

7.0.1 Working hydraulics L524, L528

Layout
LBH/Version 01/01.2008/en/dw/06.02.2013

Main components of the working hydraulics

1 Lift cylinder 6 Variable displacement pump with 10 Stabilisation module

2 Tilt cylinder replenishing pump 11 Ride control hydro accumulator
3 Pilot control unit 7 Pilot control hydro accumulator 12 Control block
4 Hydraulic tank 8 Pilot control solenoid valve
5 Working hydraulics pump 9 Compact brake valve

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Working hydraulics Service Manual

Function description

Basic function

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Diagram of the working hydraulics for Z kinematics

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 Service Manual Working hydraulics
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Diagram of the working hydraulics for P kinematics

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Working hydraulics Service Manual

1 Hydraulic tank 30 Stabilisation module 60 Lift cylinder pressure balance

2 Bleeder filter 31 Ride control spool valve 61 Lift cylinder spool valve
3 Return strainer 32 Restrictor check valve 62 Additional equipment
4 Bypass valve 33 Ride control solenoid valve pressure balance
5 Return suction filter 34 Relief valve 63 Additional equipment spool valve
6 Pre-tension valve 35 Safety valve 64 Load valve
7 Replenishing valve with strainer 36 Ride control hydro accumulator 65 Restrictor check valve
8 Travel pump return line 37 Check valve 66 Additional equipment
9 Check valve 38 Pilot control solenoid valve pressure relief valve
10 Servostat return line 39 Check valve 67 Additional equipment
11 Transmission solenoid valve 40 Pilot control unit pressure relief valve
return line 41 Tilt-out valve 68 Lift
12 Compact brake block return line 42 Bucket return-to-dig solenoid pressure relief valve
13 Fan motor return line 43 Tilt-in valve 69 Tilt-in
14 Temperature valve 44 Lift valve pressure relief valve
15 Oil cooler return line 45 Lift kick-out solenoid 70 Tilt-out
16 Oil cooler intake return line 46 Lower valve pressure relief valve
17 Hydraulic oil temperature sensor 47 Float position solenoid 71 Replenishing valve
18 Emergency steering pump 48 Additional equipment valve 72 LS steering signal
intake connection 49 Additional equipment valve 73 Oil supply to servostat
19 Replenishing pump 50 Control block assembly 74 Additional equipment
20 Working hydraulics pump 51 Pre-tension valve 75 Oil from compact brake block
21 Axial piston pump 52 LS steering pressure cut-off 76 Tilt cylinder
22 Servo cylinder 53 LS working hydraulics 77 Lift cylinder
23 Power regulator pressure cut-off
Test connections:
24 Return cylinder 54 Priority valve
P Working hydraulics pump high
25 Restrictors 55 Check valve
pressure
26 Flow controller 56 Restrictor
LS LS signal pressure
27 Control piston for power controller 57 Flow control valve
MX Ride control accumulator
28 Restrictor 58 Tilt cylinder pressure balance
pressure
29 Pilot control hydro accumulator 59 Tilt cylinder spool valve
The working hydraulics are equipped with the following functions:
– Spool valves for lift and tilt cylinders
rd
– 3 control circuit for additional equipment (optional)
– Float position
– Automatic bucket return-to-dig function
– Lift kick-out (optional)
– Ride control (optional)
The working hydraulics system operates in an open circuit. The working
hydraulic pump 20 draws up oil from the hydraulic tank 1 and pumps it
through the control block 50. The returning oil passes through the return
suction filter 5 back to the hydraulic tank 1.
The control block is activated via the hydraulic pilot control. The control block
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contains the spool valves for the lift cylinders, tilt cylinders and additional
equipment. The LS system and the pressure balances in the control block
distribute the flow from the working hydraulics pump to the consumers,
regardless of load.
The ride control system (optional) attenuates the vibrations of the machine
as it travels and thus greatly increases comfort and safety.

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 Service Manual Working hydraulics

Hydraulic tank
The hydraulic tank provides filtered oil for the working hydraulics. The
working hydraulic pump draws up oil from the hydraulic tank via the
connection 4. The returning oil is pumped through the return suction filter 3
back to the hydraulic tank.
The bleeder filter 2 compensates for pressure differences inside the
hydraulic tank by providing appropriate ventilation.
See the detailed descriptions in the section on the hydraulic tank.

Working hydraulics pump

The working hydraulics pump draws up oil from the hydraulic tank and
pumps it to the control block.
The flow controller 2 (load sensing) ensures that the working hydraulics
pump only provides as much oil from the hydraulic tank as the working
hydraulics currently need.
The power controller 1 ensures that the maximum power take-off from the
working hydraulics pump is not exceeded.
See the detailed descriptions in the section on the working hydraulics pump.

Control block
The control block contains the spool valves for the lift cylinders 3, tilt
cylinders 4 and additional equipment 2. The spool valves in the control block
are hydraulically controlled by the pilot control unit.
The main block contains a priority valve which distributes the flow of the
working hydraulic pump to the steering and the working hydraulics. The oil
supply to the steering system always takes priority.
The LS pressure cut-off 5 limits the maximum pressure of the working
hydraulics and the LS pressure cut-off 6 limits the maximum pressure of the
steering system.
Secondary pressure relief valves protect the hydraulic system from pressure
peaks caused by consumers.
See the detailed description in the section on the control block.
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Pilot control

The working hydraulics are activated by a control circuit. The spool valves in
the control block 1 are hydraulically controlled by the pilot control unit 2.

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Working hydraulics Service Manual

The required servo oil is taken from the variable displacement pump 5
(replenishing pump) of the travel hydraulics and directed through the pilot
control solenoid valve 4 to the pilot control unit.
The pilot control hydro accumulator 3 also allows the attachment to be
lowered, tilted in and tilted out when the engine is not running.
See the detailed description in the section on pilot control.

Ride control

The ride control system attenuates the vibrations of the machine as it travels
and thus greatly increases comfort and safety.
The base end of the lift cylinder is connected via the stabilisation module 3
to the hydro accumulator 2. The rod end of the lift cylinder is connected via
the stabilisation module 3 to the hydraulic tank.
See the detailed description in the section on ride control.

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 Service Manual Working hydraulics

7.0.2 Working hydraulics L538, L542

Layout
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Main components of the working hydraulics

1 Lift cylinder 6 Variable displacement pump with 9 Compact brake valve

2 Tilt cylinder replenishing pump 10 Stabilisation module
3 Pilot control unit 7 Pilot control hydro accumulator 11 Ride control hydro accumulator
4 Hydraulic tank 8 Pilot control solenoid valve 12 Control block
5 Working hydraulics pump

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Function description

Basic function

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Diagram of the working hydraulics for Z kinematics

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Diagram of the working hydraulics for P kinematics

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Working hydraulics Service Manual

1 Hydraulic tank 32 Restrictor check valve 60 Lift cylinder pressure balance

2 Bleeder filter 33 Ride control solenoid valve 61 Lift cylinder spool valve
3 Return strainer 34 Relief valve 62 Additional equipment
4 Bypass valve 35 Safety valve pressure balance
5 Return suction filter 36 Ride control hydro accumulator 63 Additional equipment spool valve
6 Pre-tension valve 37 Check valve 64 Load valve
7 Replenishing valve with strainer 38 Pilot control solenoid valve 65 Restrictor check valve
8 Travel pump return line 39 Check valve 66 Additional equipment
9 Check valve 40 Pilot control unit pressure relief valve
10 Servostat return line 41 Tilt-out valve 67 Additional equipment
11 Transmission solenoid valve 42 Bucket return-to-dig solenoid pressure relief valve
return line 43 Tilt-in valve 68 Lift
12 Compact brake block return line 44 Lift valve pressure relief valve
13 Fan motor return line 45 Lift kick-out solenoid 69 Tilt-in
14 Temperature valve 46 Lower valve pressure relief valve
15 Oil cooler return line 47 Float position solenoid 70 Tilt-out
16 Oil cooler intake return line 48 Additional equipment valve pressure relief valve
17 Hydraulic oil temperature sensor 49 Additional equipment valve 71 Replenishing valve
18 Emergency steering pump 50 Control block assembly 72 LS steering signal
intake connection 51 Pre-tension valve 73 Oil supply to servostat
19 Replenishing pump 52 LS steering 74 Additional equipment
20 Working hydraulics pump pressure cut-off 75 Oil from compact brake block
21 Axial piston pump 53 LS working hydraulics 76 Tilt cylinder
22 Return cylinder pressure cut-off 77 Lift cylinder
23 Restrictor 54 Priority valve
Test connections:
24 Servo cylinder 55 Check valve
P Working hydraulics pump
25 Power regulator 56 Restrictor
high pressure
26 Restrictor 57 Flow control valve
LS LS signal pressure
27 Flow controller 58 Tilt cylinder pressure balance
MX Ride control
29 Pilot control hydro accumulator 59 Tilt cylinder spool valve
accumulator pressure
30 Stabilisation module
31 Ride control spool valve
The working hydraulics are equipped with the following functions:
– Spool valves for lift and tilt cylinders
rd
– 3 control circuit for additional equipment (optional)
– Float position
– Automatic bucket return-to-dig function
– Lift kick-out (optional)
– Ride control (optional)
The working hydraulics system operates in an open circuit. The working
hydraulic pump 20 draws up oil from the hydraulic tank 1 and pumps it
through the control block 50. The returning oil passes through the return
suction filter 5 back to the hydraulic tank 1.
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The control block is activated via the hydraulic pilot control. The control block
contains the spool valves for the lift cylinders, tilt cylinders and additional
equipment. The LS system and the pressure balances in the control block
distribute the flow from the working hydraulics pump to the consumers,
regardless of load.
The ride control system (optional) attenuates the vibrations of the machine
as it travels and thus greatly increases comfort and safety.

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Hydraulic tank

Working hydraulics pump

Control block

Pilot control

7.0-11

MJFCIFSS
 Ride control

7.0-12

MJFCIFSS
7.1 Working hydraulics pump
7.1.1 Working hydraulics pump L524, L528

Technical data
See section 2.1

Layout

Main components of the working hydraulics pump

7.1-1
MJFCIFSS
 Components of the working hydraulics pump

7.1-2
MJFCIFSS
Components of the working hydraulics pump

7.1-3
MJFCIFSS
 Function description

Basic function

Hydraulic diagram of the working hydraulics pump

Control of the pump

7.1-4
MJFCIFSS
 Working hydraulics pump with control unit

Pump pressure restriction

LS pressure cut-off in the control block

7.1-5
MJFCIFSS
 7.1.2 Working hydraulics pump L538, L542

Technical data
See section 2.1

Layout

Main components of the working hydraulics pump

7.1-6
MJFCIFSS
Components of the working hydraulics pump

7.1-7
MJFCIFSS
 Components of the regulator unit

7.1-8
MJFCIFSS
Function description

Basic function

Hydraulic diagram of the working hydraulics pump

Control of the pump

Working hydraulics pump with control unit

7.1-9
MJFCIFSS
 Flow regulation

Flow controller (working hydraulics or steering system not active)

7.1-10
MJFCIFSS
 Flow controller (working hydraulics or steering system active)

Pump pressure restriction

LS pressure cut-off in the control block

7.1-11
MJFCIFSS
 Pump output regulation

Pump output diagram

Power regulator in the control phase

7.1-12
MJFCIFSS
 Service Manual Working hydraulics
Control block

7.2 Control block

Technical data
See section 2.1

Layout

Main components of the control block

1 Closing element 7 Main block housing

2 Additional equipment pressure 8 Tilt-out pressure relief valve
relief valve 9 Tilt cylinder spool valve
3 Lift pressure relief valve 10 Lift cylinder spool valve
4 Tilt-in pressure relief valve 11 Additional equipment
5 LS pressure cut-off spool valve
(working hydraulics) 12 Additional equipment
6 LS pressure cut-off pressure relief valve
(steering system)
The control block is installed in the front section. It consists of the main block
rd th
housing 7 and the closing element 1. Other segments for a 3 and 4 control
circuit can be fitted if needed between the main block housing and the
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closing element.
All pressure cut-off valves are installed in the control block.

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Working hydraulics Service Manual
Control block

Components of the control block

1 Main block housing 5 Pre-tension valve 9 LS pressure relief valve

2 Flow control valve 6 Closing element (working hydraulics)
3 Tilt-out pressure relief valve 7 Lift pressure relief valve 10 Priority valve
4 Pressure balances 8 Tilt-in pressure relief valve 11 LS pressure relief valve
(steering system)
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 Service Manual Working hydraulics
Control block

A-A cross section of control block with spool valves for lift cylinder

1 Lift cylinder spool valve 8 Adjusting screw for the spool 14 Lift pressure relief valve
2 Replenishing valve valve stroke 15 Plug
3 Valve insert 9 Lift regulating spring 16 Float position pressure spring
4 Spool valve cover 10 Spring sleeve 17 Restrictor pin
5 Restrictor check valve 11 Plug 18 Spool valve cover
6 Cap nut 12 Main housing 19 Lower regulating spring
7 Counter nut 13 Pressure balance
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B-B cross section of control block with spool valve for tilt cylinder (Z kinematics)

1 Tilt cylinder spool valve 7 Cap nut with counter nut 11 Main housing
2 Replenishing valve 8 Adjusting screw for the spool 12 Pressure balance
3 Valve insert valve stroke 13 Plug
4 Spool valve cover 9 Spring sleeve 14 Tilt-in
5 Restrictor check valve 10 Tilt-out pressure relief valve
6 Tilt-in regulating spring pressure relief valve 15 Tilt-out regulating spring

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Working hydraulics Service Manual
Control block

C-C cross section of control block with LS pressure cut-off valve (working hydraulics)

1 Tilt cylinder load valve 2 Flow control valve 4 LS pressure relief valve
3 Main housing (working hydraulics)

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D-D cross section of control block with priority valve

1 Damping valve 4 Damping valve 7 Plug

2 Plug 5 Main housing 8 Regulating spring
3 Priority valve 6 LS connection

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 Service Manual Working hydraulics
Control block

Function description

Basic function

Hydraulic diagram of the control block (tilt-in function activated)

1 Pre-tension valve 12 Additional equipment 20 Tilt-out pressure relief valve

2 LS steering pressure cut-off pressure balance 21 Replenishing valve
3 LS working hydraulics pressure 13 Additional equipment 22 LS steering signal
cut-off spool valve 23 LS signal to working
4 Priority valve 14 Load valve hydraulics pump
5 Check valve 15 Restrictor check valve 24 Oil supply to servostat
6 Restrictor 16 Additional equipment pressure 25 Tilt cylinder connection
7 Flow control valve relief valve 26 Lift cylinder connection
8 Tilt cylinder pressure balance 17 Additional equipment pressure 27 Additional equipment connection
9 Tilt cylinder spool valve relief valve 28 Oil from compact brake block
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10 Lift cylinder pressure balance 18 Lift pressure relief valve 29 Hydraulic tank connection
11 Lift cylinder spool valve 19 Tilt-in pressure relief valve 30 Working hydraulics pump
P connection
The control block contains the spool valves for the lift cylinders 11 and tilt
cylinders 9, as well as an additional spool valve 13 for additional equipment.
The priority valve 4 divides the flow from the working hydraulics between the
steering and working hydraulics as required. The oil supply to the steering
system always takes priority.
The spool valves are supplied with oil by the pilot control unit. The restrictor
check valves 15 in the control block ensure precise activation of the
individual functions.
LS control with the pressure balances 8, 10 and 12 distribute the oil flow to
the consumers regardless of load.

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Working hydraulics Service Manual
Control block

Secondary pressure relief valves for each function protect the working
attachment, cylinders, hose lines and the control block from overload. At the
same time, the secondary pressure relief valves act as replenishing valves.
The LS pressure cut-off valves 3 (working hydraulics) and 2 (steering system)
protect the working hydraulics pump from excess pressure.
The pre-tension valve 1 preloads the second tank duct in the control block
with a pressure of 10 15 bar. In certain circumstances, this pushes oil via
replenishing valves into the rod end of the lift or tilt cylinders. This prevents a
vacuum in the cylinder chamber.

Working hydraulics in active state

The spool valves in the control block are hydraulically controlled by the pilot
control unit.

Control block in active state (Z kinematics)

When the tilt-out function is activated, servo oil flows from the pilot control
unit to the connection a1. The spool valve 2 is pushed to the right.
The spool valve 2 opens the pump duct P to the pressure balance 4 via the
control notches 1. If the pump pressure exceeds the pressure at the tilt
cylinder, the load valve 3 opens and oil flows through the connection A1 to
the tilt cylinder.
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The oil returning from the tilt cylinder flows through the connection B1 and
the spool valve to the tank channel T.

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 Service Manual Working hydraulics
Control block

Working hydraulics in float position

In the float position, the working attachment lies on the ground under its own
weight. The lift arms can move up and down freely to compensate for
uneven ground.

Control block in float position

At maximum deflection of the LH control lever for lowering the lift arms,
maximum servo pressure acts at the connection a2. The spool valve 5 is
pushed against the regulating spring 1 and the float position pressure spring
2 all the way to the right up to the restrictor pin 3.
In this spool valve position, the base end of the lift cylinder B2 is connected
to the rod end of the lift cylinder A2 via the ring duct 4. The spool valve
remains open to the tank duct T.
The lift arms can now move up and down freely.
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Working hydraulics Service Manual
Control block

7.2.1 Control valve block oil leak monitoring

The travel of the piston rod is determined for each cylinder for control valve
block oil leak monitoring. A marking (marker pen) is made on the piston rod
for this.
Test duration / Test pressure: 10 min. at 150 bar
Note: The pressure is measured at the measurement connection LS. A
pressure of 155 - 165 bar represents a test pressure of 150 bar.
Test temperature for oil at 44 cSt:
The test temperature is to be measured directly on the control valve block.

Hydraulic fluid Viscosity Temperature

Liebherr Hydraulic Basic 68 ISO VG 68 53 °C
Liebherr Hydraulic Basic 100 ISO VG 100 62 °C
Liebherr Hydraulic HVI ISO VG 46 44 °C
Liebherr Hydraulic Plus ISO VG 46 44 °C
Engine oil SAE 20 W 20 53 °C

Cylinder travel:
Tilt Lifting
Unit Ser. no. cylinder cylinder
max. travel max. travel
L524, L528 up to 25489 60 mm
43 mm
Z-kinematics from 25490
L538, L542 up to 25209 44 mm
36 mm
Z-kinematics from 25210
L524, L528
from 17890 14 mm 43 mm
P-kinematics
L538, L542
from 17890 11 mm 36 mm
P-kinematics

Before any replacement of the control valve block the cylinder and the
secondary valve must be checked for leaks (visual check and swap with one
another if necessary).

Procedure for lifting cylinder valve spool

Bring machine to test temperature (see table above).
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With the lift unit at low rpm slowly drive the bucket upwards and check
the pressure at measurement point LS on the working hydraulics pump
whilst doing so.
If the prescribed pressure of 155 165 bar is not reached then the
loading of the bucket should be corrected.
Switch off the diesel engine.
Ascertain the travel of the piston rod of the lifting cylinder under load in 10
minutes.

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 Service Manual Working hydraulics
Control block

Procedure for tilt cylinder valve spool

Bring machine to test temperature (see table above).

Let the diesel engine run at low rpm.

Bring the lift arm and bucket to the transport position.
Tilt the bucket out a little.
Slowly tilt the bucket in and check the pressure (required value 155 165
bar) at measurement point LS on the working hydraulics pump whilst
doing so.
If the prescribed pressure of 155 165 bar is not reached then the
loading of the bucket should be corrected.
Switch off the diesel engine.
Ascertain the travel of the piston rod of the tilt cylinder under load in 10
minutes.

If the permissible leakage values are exceeded:

Contact LIEBHERR CUSTOMER SERVICE.
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Working hydraulics Service Manual
Control block

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7.3 Pilot control
Layout

Main components of the pilot control unit

7.3-1
MJFCIFSS
 Function description

Basic function

Hydraulic plan of the pilot control unit

7.3-2
MJFCIFSS
Pilot control unit

Variable displacement pump with replenishing pump

Pilot control solenoid valve

Control block

7.3-3
MJFCIFSS
 7.3.1 Pilot control unit

Technical data
See section 2.1

Layout

Main components of the pilot control device

7.3-4
MJFCIFSS
Components of the pilot control device

7.3-5
MJFCIFSS
 Function description

Basic function

Hydraulic plan of the pilot control unit

Idle state

Control valve in idle state / Control valve in active state

Regulating phase

7.3-6
MJFCIFSS
Electromagnetic locking

7.3-7
MJFCIFSS
 7.3.2 Pilot control solenoid valve

Technical data
See section 2.1

Layout

Pilot control solenoid valve

Function description

Pilot control solenoid valve

Hydraulic diagram of pilot control solenoid valve

7.3-8
MJFCIFSS
 7.3-9
MJFCIFSS
 7.3.3 Pilot control hydro accumulator
(ID 7619 063)

Technical data
See section 2.1

Layout

Components of the hydro accumulator

Function description

Basic function

Storing pressure for the pilot control

7.3-10
MJFCIFSS
7.4 Ride control
Layout

Main components of the ride control system

Function description

Basic function

7.4-1
MJFCIFSS
 Hydraulic diagram of the ride control system (activated)

Stabilisation module with hydro accumulator

7.4-2
MJFCIFSS
Ride control deactivated

Hydraulic diagram with ride control deactivated

Ride control activated

7.4-3
MJFCIFSS
 Hydraulic diagram with ride control activated

7.4-4
MJFCIFSS
7.4.1 Stabilisation module

Technical data
See section 2.1

Layout

Main components of the stabilisation module

7.4-5
MJFCIFSS
 Components of the stabilisation module

Components of the stabilisation module

7.4-6
MJFCIFSS
Components of the stabilisation module

Function description

Basic function

Hydraulic diagram of the stabilisation module

7.4-7
MJFCIFSS
 7.4.2 Ride control hydro accumulator

Technical data
See section 2.1

Layout

Hydro accumulator with stabilisation module

Function description

Function

Oil filling on the nitrogen side of the hydro accumulator

Cross section of the hydro accumulator

7.4-8
MJFCIFSS
 7.4-9
MJFCIFSS
7.4-10
MJFCIFSS
7.5 Lift and tilt cylinders
7.5.1 Lift cylinder

Technical data
See section 2.1

Layout

Main components of the lift cylinder

Function description

Extension and retraction

7.5-1
MJFCIFSS
 Piston rod guide

Sealing

7.5-2
MJFCIFSS
7.5.2 Z kinematics tilt cylinder

Technical data
See section 2.1

Layout

Main components of the tilt cylinder

Function description

Extension and retraction

7.5-3
MJFCIFSS
 Piston rod guide

Sealing

7.5-4
MJFCIFSS
7.5.3 P kinematics tilt cylinder

Technical data
See section 2.1

Layout

Main components of the tilt cylinder

Function description

Extension and retraction

7.5-5
MJFCIFSS
 Piston rod guide

Sealing

7.5-6
MJFCIFSS
7.6 Hydraulic tank
Layout

Main components of the hydraulic tank

Function description

Basic function

7.6-1
MJFCIFSS
 Filter unit

7.6-2
MJFCIFSS
7.6.1 Filter unit

Technical data
See section 2.1

Layout

Main components of the filter unit

7.6-3
MJFCIFSS
 Components of the filter unit

7.6-4
MJFCIFSS
Function description

Basic function

Basic function of the filter unit

7.6-5
MJFCIFSS
 Oil supply to the replenishing pump

Replenishing pump oil supply Replenishing function

7.6-6
MJFCIFSS
Bypass valve for pressure relief

Return suction filter with bypass valve and return strainer

7.6-7
MJFCIFSS
 7.6.2 Bleeder filter

Technical data
See section 2.1

Layout

Components of the bleeder filter

Function description

Function

7.6-8
MJFCIFSS
Excess pressure in the hydraulic tank

Insufficient pressure in the hydraulic tank

7.6-9
MJFCIFSS
7.6-10
MJFCIFSS
 8 Steering system
8.0

Chapter contents
8 Steering system .................................................................. 8.0-1
8.0.1 Steering system L524, L528 ................................................. 8.0-1
8.0.2 Steering system L538, L542 ................................................. 8.0-5

8.1 Steering pump ................................................................................ 8.1-1

8.2 Servostat ......................................................................................... 8.2-1

8.3 Steering cylinder ............................................................................. 8.3-1

8.4 Emergency steering ........................................................................ 8.4-1

8.4.1 Emergency steering pump ................................................... 8.4-5
8.4.2 Emergency steering pressure switch ................................... 8.4-7
8.4.3 Emergency steering check pressure switch ......................... 8.4-9
8.4.4 Valve block ......................................................................... 8.4-11
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Steering system Service manual

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 Service manual Steering system

8.0.1 Steering system L524, L528

Layout

Main components of the steering system

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1 Servostat 4 Working hydraulics pump 6 Valve block

2 Hydraulic tank 5 Steering cylinder 7 Control block
3 Emergency steering pump
The machine has articulated steering. The steering cylinder moves the front
section and the rear section to each other using the articulated joint.

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Steering system Service manual

Function description

Basic function

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Hydraulic diagram of the steering system

1 Hydraulic tank 17 Emergency steering pump 33 Left pressure relief valve
2 Bleeder filter check pressure switch 34 Left replenishing valve
3 Return strainer 18 Pressure relief valve 35 Right pressure relief valve
4 2.5 bar bypass valve 19 Emergency steering pump 36 Replenishing valve, right
5 Return suction filter 20 Working hydraulics pump 37 Steering cylinder
6 Pre-tension valve 21 Axial piston pump 40 Control block
7 Replenishing valve with strainer 22 Servo cylinder 41 LS steering pressure cut-off
8 Working hydraulics pump leak oil 23 Power regulator 42 Flow distributor valve
9 9 bar check valve 24 Return piston 43 Orifice
10 Oil cooler return line 25 Damping valve 44 Check valve
11 Intake connection from 26 Damping valve 45 LS working hydraulics
replenishing pump 27 Flow controller pressure cut-off
12 Hydraulic oil temperature sensor 28 Control piston for 46 Flow valve
13 Valve block power controller 47 Spool valve

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14 Check valve 29 Orifice Test connections:

15 Check valve 30 Servostat LS LS signal pressure
16 Emergency steering 31 Valve slider P Working hydraulics high
pressure switch 32 Metering pump pressure - steering
The steering system operates in an open circuit. The working hydraulic oil 20
draws up oil from the hydraulic tank 1 and pumps it through the control
block 40 to the servostat 30. The servostat supplies oil to the steering
cylinder when the steering wheel is moved.
In the load sensing system, the control block 40 only delivers as much oil to
the servostat as the steering actually needs. The LS pressure relief valve 41
limits the maximum pressure in the steering system.
The emergency steering system allows steering movement if the working
hydraulics pump fails. The emergency steering pump 19 delivers oil to the
servostat 30.

Hydraulic tank
The hydraulic tank 1 provides filtered oil for the steering system. The
working hydraulic oil pump draws up oil from the hydraulic tank via the
connection 6. The emergency steering pump draws up oil from the hydraulic
tank via the connection 5.
The returning oil from the servostat is pumped back through the connection
4 and the return strainer 3 to the hydraulic tank.
The bleeder filter 2 compensates for pressure differences inside the
hydraulic tank by providing appropriate ventilation.
See the detailed description in the section on the hydraulic tank.

Working hydraulics pump

The working hydraulics pump provides oil for the steering system and the
working hydraulics.
The pump draws up oil directly from the hydraulic tank and pumps it through
the control block to the servostat.
The load sensing system 2 ensures that the working hydraulics pump only
provides as much oil as the steering system or working hydraulics currently
needs. The power controller 1 on the working hydraulics pump prevents
excessive power take-off from the engine.
See the detailed description in the section on the working hydraulics pump.

Control block
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The task of the priority valve in the control block 1 is to distribute the oil flow
from the working hydraulics pump 5 to the steering system and the working
hydraulics. The oil supply to the steering system always takes priority. Only
the amount of oil actually required by the steering is pumped (load sensing).
The priority valve receives the LS signal from the servostat via the
connection 3.
The required amount of oil flows through the connection 4 to the servostat.
The LS pressure relief valve 2 in the control block limits the maximum
pressure in the steering system.
See the detailed description in the section on the control block.

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Steering system Service manual

Servostat
The servostat is connected to the steering column. The steering wheel
actuates the metering pump 2 and valve slider in the servostat, causing the
steering system to move.
The pressure relief valves 1 protect the steering cylinder and servostat from
excessive pressure peaks.
See the detailed description in the section on the servostat.

Steering cylinder
The steering cylinder is connected to the front and rear sections. The
steering cylinder moves the front section and the rear section to each other
using the articulated joint.
The servostat supplies oil to the steering cylinder during steering. Pressure
acts on the base end of the steering cylinder when steering to the right, and
on the rod end when steering to the left. Due to the different piston faces of
the steering cylinder, there are slight differences in the steering speeds to
the left and to the right.
See the detailed description in the section on the steering cylinder.

Emergency steering function

The emergency steering function allows the steering system to be operated
if the engine or the working hydraulics pump fails. The emergency steering
pump is activated by the electronic controller.
See the detailed description in the section on emergency steering.

Emergency steering pump

The gear pump 2 of the emergency steering pump is powered by the electric
motor 3. The electric motor is switched on when necessary via a relay 1.
In emergency steering mode the emergency steering pump draws up oil from
the hydraulic tank and pumps it through the valve block to the servostat.
The emergency steering pump check pressure switch 4 monitors the
pressure of the emergency steering pump during the check.
The pressure relief valve 1 protects the pump from excess pressure. See the
detailed description in the section on the emergency steering pump.
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Valve block
The valve block 4 connects the oil flow from the control block (connection 1) or
the emergency steering pump (connection 2) to the servostat (connection 3).
The emergency steering pressure switch 5 monitors the pressure of the
working hydraulics pump. If the pressure at the switch is too low, the
emergency steering pump is automatically activated. This can happen if the
diesel engine shuts down or if the working hydraulics pump fails.
Check valves in the valve block to prevent the oil from flowing back to the
control block or the emergency steering pump.
See the detailed description in the section on the valve block.

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 Service manual Steering system

8.0.2 Steering system L538, L542

Layout

Main components of the steering system

1 Servostat 4 Working hydraulics pump 6 Valve block
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2 Hydraulic tank 5 Steering cylinder 7 Control block

3 Emergency steering pump
The machine has articulated steering. The steering cylinder moves the front
section and the rear section to each other using the articulated joint.

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Steering system Service manual

Function description

Basic function

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Hydraulic diagram of the steering system

1 Hydraulic tank 17 Emergency steering pump 35 Right pressure relief valve
2 Bleeder filter check pressure switch 36 Replenishing valve, right
3 Return strainer 18 Pressure relief valve 37 Steering cylinder
4 2.5 bar bypass valve 19 Emergency steering pump 40 Control block
5 Return suction filter 20 Working hydraulics pump 41 LS steering pressure cut-off
6 Pre-tension valve 21 Axial piston pump 42 Flow distributor valve
7 Replenishing valve with strainer 22 Return piston 43 Orifice
8 Working hydraulics pump leak oil 23 Orifice 44 Check valve
9 9 bar check valve 24 Servo cylinder 45 LS working hydraulics
10 Oil cooler return line 25 Power regulator pressure cut-off
11 Intake connection from 26 Damping valve 46 Flow valve
replenishing pump 27 Flow controller 47 Spool valve
12 Hydraulic oil temperature sensor 30 Servostat
13 Valve block 31 Valve slider

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 Service manual Steering system

14 Check valve 32 Metering pump Test connections:

15 Check valve 33 Left pressure relief valve LS LS signal pressure
16 Emergency steering 34 Left replenishing valve P Working hydraulics high
pressure switch pressure - steering
The steering system operates in an open circuit. The working hydraulic oil 20
draws up oil from the hydraulic tank 1 and pumps it through the control block
40 to the servostat 30. The servostat supplies oil to the steering cylinder
when the steering wheel is moved.
In the load sensing system, the control block 40 only delivers as much oil to
the servostat as the steering actually needs. The LS pressure relief valve
41 limits the maximum pressure in the steering system.
The emergency steering system allows steering movement if the working
hydraulics pump fails. The emergency steering pump 19 delivers oil to the
servostat 30.

Hydraulic tank
The hydraulic tank 1 provides filtered oil for the steering system. The
working hydraulic oil pump draws up oil from the hydraulic tank via the
connection 6. The emergency steering pump draws up oil from the hydraulic
tank via the connection 5.
The returning oil from the servostat is pumped back through the connection
4 and the return strainer 3 to the hydraulic tank.
The bleeder filter 2 compensates for pressure differences inside the
hydraulic tank by providing appropriate ventilation.
See the detailed description in the section on the hydraulic tank.

Working hydraulics pump

The working hydraulics pump provides oil for the steering system and the
working hydraulics.
The pump draws up oil directly from the hydraulic tank and pumps it through
the control block to the servostat.
The load sensing system 1 ensures that the working hydraulics pump only
provides as much oil as the steering system or working hydraulics currently
needs. The power controller 2 on the working hydraulics pump prevents
excessive power take-off from the engine.
See the detailed description in the section on the working hydraulics pump.

Control block
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The task of the priority valve in the control block 1 is to distribute the oil flow
from the working hydraulics pump 5 to the steering system and the working
hydraulics. The oil supply to the steering system always takes priority. Only
the amount of oil actually required by the steering is pumped (load sensing).
The priority valve receives the LS signal from the servostat via the
connection 3.
The required amount of oil flows through the connection 4 to the servostat.
The LS pressure relief valve 2 in the control block limits the maximum
pressure in the steering system.
See the detailed description in the section on the control block.

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Steering system Service manual

Servostat
The servostat is connected to the steering column. The steering wheel
actuates the metering pump 2 and valve slider in the servostat, causing the
steering system to move.
The pressure relief valves 1 protect the steering cylinder and servostat from
excessive pressure peaks.
See the detailed description in the section on the servostat.

Steering cylinder
The steering cylinder is connected to the front and rear sections. The
steering cylinder moves the front section and the rear section to each other
using the articulated joint.
The servostat supplies oil to the steering cylinder during steering. Pressure
acts on the base end of the steering cylinder when steering to the right, and
on the rod end when steering to the left. Due to the different piston faces of
the steering cylinder, there are slight differences in the steering speeds to
the left and to the right.
See the detailed description in the section on the steering cylinder.

Emergency steering function

The emergency steering function allows the steering system to be operated
if the engine or the working hydraulics pump fails. The emergency steering
pump is activated by the electronic controller.
See the detailed description in the section on emergency steering.

Emergency steering pump

The gear pump 2 of the emergency steering pump is powered by the electric
motor 3. The electric motor is switched on when necessary via a relay.
In emergency steering mode the emergency steering pump draws up oil from
the hydraulic tank and pumps it through the valve block to the servostat.
The emergency steering pump check pressure switch 4 monitors the
pressure of the emergency steering pump during the check.
The pressure relief valve 1 protects the pump from excess pressure. See the
detailed description in the section on the emergency steering pump.
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Valve block
The valve block 4 connects the oil flow from the control block (connection 1) or
the emergency steering pump (connection 2) to the servostat (connection 3).
The emergency steering pressure switch 5 monitors the pressure of the
working hydraulics pump. If the pressure at the switch is too low, the
emergency steering pump is automatically activated. This can happen if the
diesel engine shuts down or if the working hydraulics pump fails.
Check valves in the valve block to prevent the oil from flowing back to the
control block or the emergency steering pump.
See the detailed description in the section on the valve block.

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 Service manual Steering system
Steering pump

8.1 Steering pump

Function description

Steering system oil supply

The steering system is supplied with oil by the working hydraulics pump. The
oil flow of the working hydraulics pump is distributed by the control block to
the working hydraulics and the steering system as required.

L524, L528 Working hydraulics pump L538, L542

8 Power regulator 9 Flow controller

The load sensing system 2 ensures that the working hydraulics pump only
provides as much oil as the steering system currently needs. The power
controller 1 on the working hydraulics pump prevents excessive power take-
off from the engine.
See the detailed description in the section on the working hydraulics pump.
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Steering system Service manual
Steering pump

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 Service manual Steering system
Servostat

8.2 Servostat
Technical data
See section 2.1

Layout

Main components of the servostat

10 Left pressure relief valve 12 Right pressure relief valve
11 Inner rotary slide valve 13 Housing with spool valve
with teeth 14 Metering pump
The servostat is fastened on rubber fittings at the front under the cab. The
rubber fittings prevent noise from the hydraulics from being transferred to the
steel cab frame.
The steering column meshes with the teeth of the internal rotary slider 2.
The internal rotary slider in the servostat is actuated by the steering wheel
and the steering column.
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Steering system Service manual
Servostat

Components of the servostat

1 Closing plate 7 Internal rotary slider 13 Shaft seal ring

2 Metering pump 8 Driver 14 Right pressure relief valve
3 Internal gear 9 Driver journal 15 Leaf springs
4 O-ring 10 Housing 16 Left pressure relief valve
5 Intermediate flange 11 Needle bearing 17 Replenishing valve
6 Outer valve sleeve 12 Guide ring

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 Service manual Steering system
Servostat

Function description

Basic function

Hydraulic diagram of the servostat

1 Left replenishing valve 7 Return line to hydraulic tank
2 Left pressure relief valve 8 Steering cylinder connection
3 Replenishing valve, right 9 Steering cylinder connection
4 Right pressure relief valve 10 Oil from valve block
5 Metering pump 11 Load sensing signal
6 Valve slider
When it is actuated, the servostat directs oil from the working hydraulics
pump to the steering cylinder. The oil supply to the steering cylinder is
precisely metered according to the speed of the steering wheel.
When the steering wheel is turned, the position of the internal rotary slider is
turned in relation to the outer valve sleeve. This opens the valve, allowing a
certain amount of oil to flow through the metering pump to the steering cylinder.

Flow booster
The flow booster allows the small servostat to supply oil to large cylinders. A
specific portion of the flow is directed through the metering pump, and
another portion is pumped through the spool directly to the cylinder.
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Diagram of flow booster

15 Boost ratio 17 Oil via the metering pump

16 Turns of steering wheel 18 Oil via the spool

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Servostat

If the steering wheel is moved slowly, the entire flow is directed through the
metering pump 3. The oil flowing to the steering cylinders depends on the
size of the metering pump. This allows very sensitive steering for travelling
on roads.
At faster steering speeds of more than 10 turns of the steering wheel per
minute, additional holes in the spool open. Some of the oil flows through the
metering pump 3, and more oil flows through the valve slider 4 directly to the
steering cylinder. The volumetric flow ratio is 1 : 1.6. This allows very fast
steering for rough terrain.

Flow regulation (load sensing)

Load sensing ensures that the priority valve in the control block only supplies
the amount of oil currently needed by the steering system. The servostat
reports the required amount of oil via the LS connection to the servostat.
Steering system in inactive state When the steering is not actuated, the connection P on the servostat is blocked.
The LS connection for controlling the priority valve 5 and the working hydraulics
pump 6 is relieved via the valve slider 2 to the tank connection T. This pushes
the priority valve 5 down and all the oil from the working hydraulics pump 6 flows
through the connection 4 to the working hydraulics.

Steering system in inactive state

19 Servostat 24 Working hydraulics pump

20 Valve slider 25 P connection
21 Control block 26 LS connection
22 Working hydraulics oil supply 27 T Tank connection
23 Priority valve
Steering system in active state When the steering is actuated, the valve slider 2 in the servostat 1 is moved.
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The connection P is connected to the connection LS and to the steering

cylinder. The increase in pressure at the connection LS moves the priority valve
5 so far up that sufficient oil flows through the connection P to the servostat.
At the same time, the LS signal also activates the flow controller in the
working hydraulics pump 6. The working hydraulics pump 6 is regulated to
the required flow and supplies oil to the servostat.

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 Service manual Steering system
Servostat

Steering system in active state

28 Servostat 33 Working hydraulics pump
29 Valve slider 34 P connection
30 Control block 35 LS connection
31 Working hydraulics oil supply 36 T Tank connection
32 Priority valve

Pressure cut-off
The pressure relief valves prevent excessive pressure peaks in the steering
system. Pressure peaks can be caused by sudden loads while driving.
Depending on the load direction, the pressure relief valve for steering to the
left 1 or for steering to the right 2 opens.

When the set pressure is reached, the valve cone 6 opens against the
pressure spring 4. Oil flows from the consumer unit 7 to the tank connection 5.
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The opening pressure of the pressure relief valve can be set using the
adjusting screw 3.

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Steering system Service manual
Servostat

Replenishing function
The servostat has two replenishing valves: one for steering to the left and
one for steering to the right.
The replenishing valves prevent vacuums from forming in the steering
cylinder under certain operating conditions. Oil flows through the check valve
2 from the tank duct 1 to the steering cylinder (duct 3). The pin 4 prevents
the check valve 2 from moving too far from the valve seat.

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 Service manual Steering system
Steering cylinder

8.3 Steering cylinder

Technical data
See section 2.1

Layout

Main components of the steering cylinder

1 Rod-end cylinder bearing 3 Cylinder tube 5 Piston

2 Piston rod bearing 4 Piston rod 6 Base-end cylinder bearing
The cylinder base is welded to the cylinder tube 3.
The rod-end cylinder bearing 1 and the base-end cylinder bearing 7 are
fork shaped.
The piston rod bearing 2 is screwed into the cylinder tube 3.
The piston 5 and the piston rod bearing 2 are fitted with Glyd Seal, Rimseal
and Stepseal sealing rings.

Function description

Extension and retraction

The hydraulic cylinder is a double-action cylinder with a piston at one end.
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The maximum forces in the cylinder depend on the maximum operating

pressure and the active surfaces.
When extending, the piston face is active; when retracting, the smaller ring
face is active.
This means the force when extending is greater than when retracting.
The piston speed is inversely proportional to the force. It is faster when
retracting than extending.

Piston rod guide

The piston rod is guided by the guide rings on the piston and in the piston
rod bearing.

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Steering cylinder

Sealing
The scraper ring in the piston rod bearing prevents dirt from penetrating the
piston rod.
The O-rings and the Glyd Seal, Rimseal and Stepseal sealing rings seal the
pressure chambers inside and out.

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 Service manual Steering system
Emergency steering

8.4 Emergency steering

Layout

Main components of the emergency steering

37 Emergency steering button 42 Valve block

38 Emergency steering check 43 Emergency steering pump relay
symbol field 44 Emergency steering pump
39 Emergency steering symbol field 45 Emergency steering check
40 Master controller (UEC3) pressure switch B3a
41 Emergency steering
pressure switch B3
The emergency steering pump 8 and the valve block 6 are mounted on the
right of the rear section. The master controller (UEC3) 4 is mounted on the
rear wall of the cab.
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Steering system Service manual
Emergency steering

Function description

Basic function

Functional diagram of the emergency steering

46 Emergency steering button 51 Valve block

47 Emergency steering check 52 Servostat
symbol field 53 Emergency steering pump relay
48 Emergency steering symbol field 54 Emergency steering pump
49 Master controller (UEC3) 55 Emergency steering check
50 Emergency steering pressure pressure switch B3a
switch B3
The emergency steering system allows continued steering if the working
hydraulics pump or the diesel engine fails. The emergency steering pump
delivers oil to the servostat.
The emergency steering pump is regulated by the master controller (UEC3)
4. The emergency steering pressure switch 5, and the emergency steering
check pressure switch 10 provide the master controller with the necessary
signals. The emergency steering button 1 is for restarting the emergency
steering pump.
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 Service manual Steering system
Emergency steering

Pressure switch test

When you switch on the ignition, the pressure switches are tested. The
pressure switch is powered (24 V) via the fuse F15. When the system is OK,
no signal is returned to the master controller (UEC3) 1. This tells the master
controller 1 that the pressure switch is working properly. The symbol fields 2
and 3 do not light up.
If the pressure switch is defective or if there is moisture in the plug or cable,
a positive signal is sent to the master controller 1.
If the emergency steering pressure switch 7 is defective, the emergency
steering symbol field 2 lights up. If the emergency steering check pressure
switch 4 is defective, the emergency steering check symbol field 3 lights up.

Functional diagram of the emergency steering system

(Ignition on, engine not running)

56 Master controller (UEC3) 60 Emergency steering pump

57 Emergency steering symbol field 61 Valve block
58 Emergency steering check 62 Emergency steering
symbol field pressure switch
59 Emergency steering check
pressure switch

Emergency steering check

Every time the machine is started up, the system performs a brief safety test.
This safety test is not started until the engine control unit sends the
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“engine running” signal to the master controller. This is to prevent the high
current consumption of the emergency steering pump from impairing the
starting procedure.
During the safety test, the emergency steering pump is activated. The pump
runs for 3 seconds until a pressure of 16 bar is reached at the emergency
steering check pressure switch 4. During the test, the emergency steering
check symbol field lights up. The emergency steering is then ready for
operation and the check symbol field goes out.
If the pressure at the emergency steering check pressure switch 4 does not
reach 16 bar, the check symbol field stays lit until the ignition is switched off.
The safety test is interrupted after 3 seconds. The emergency steering field
check symbol field indicates to the driver that the emergency steering
system is defective.

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Steering system Service manual
Emergency steering

Activated emergency steering system

Functional diagram of the emergency steering

If the diesel engine or the working hydraulics pump fails, the emergency
steering function is started automatically. If the pressure drops, the contact
of the emergency steering pressure switch 4 opens. This is detected by the
master controller (UEC3) 1.
The master controller (UEC3) 1 activates the emergency steering pump
relay and the emergency steering pump starts delivering oil. At the same
time the emergency steering symbol field lights up, accompanied by an
audible signal. The emergency steering function is provided for 40 seconds.
After this, the master controller 1 automatically switches off the emergency
steering pump relay.
The emergency steering pump can only be restarted with the emergency
steering button 8. This function is only available for 10 seconds if the ignition
is on.

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 Service manual Steering system
Emergency steering

8.4.1 Emergency steering pump

Technical data
See section 2.1

Layout

Main components of the emergency steering pump

63 Pressure relief valve 65 Electric motor

64 Gear pump 66 Relay
The emergency steering pump is mounted on the right of the rear section.
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Components of the emergency steering pump

1 Electric motor 5 Flange 9 Housing
2 Gear pump 6 Seals 10 Valve housing
3 Connector piece 7 Bushing 11 Pressure relief valve
4 Sealing ring 8 Gears

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Steering system Service manual
Emergency steering

Function description

Basic function
The gear pump of the emergency steering pump is powered by the electric
motor. The electric motor is switched on and off via a relay.
The gear pump draws up oil from the hydraulic tank as needed. The oil is
pumped via the valve block to the servostat. A pressure relief valve protects
the pump from excess pressure.

Gear pump with pressure relief valve

The gear pump 1 of the emergency steering pump is protected by a
pressure relief valve. By restricting the maximum pressure, this also
prevents the electric motor from consuming too much current.
The system pressure pushes the valve piston 2 against the spring 3. If the
maximum pressure is reached, the valve piston 2 opens. This allows
hydraulic oil to flow out to the intake side of the gear pump.
The maximum pressure is determined by the pressure spring 3 and the
adjusting discs 4.

Emergency steering pump relay

The electric motor 5 of the emergency steering pump is switched on and off
via the relay 1. The relay 1 is controlled by the master controller (UEC3) 4.
The relay is designed to switch large currents.

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Emergency steering pump with electric diagram

67 Emergency steering pump relay 70 Master controller (UEC3)
68 Positive current supply 71 Electric motor
69 Switch signal from master 72 Main earth
controller 73

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 Service manual Steering system
Emergency steering

8.4.2 Emergency steering pressure switch

Technical data
See section 2.1

Layout

Components of the electronic pressure switch

74 Restrictor 78 Electronics
75 Housing 79 Plug connection
76 Pressure chamber 80 3-pin connector
77 Thin layer sensor (DMS)
The emergency steering pressure switch 1 is mounted on the valve block 2.
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Function description

Basic function
Electronic pressure switches are for switching electric circuits on and off.
The hydraulic oil passes through the valve 1 into the pressure chamber 2.
The valve 1 is designed so that the hydraulic oil passes through a fine
threaded duct into the pressure chamber 2. This evens out pressure peaks.

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Steering system Service manual
Emergency steering

The thin layer sensor 4 changes its resistance due to the curvature of the
surface 3. When the set value is reached, the integrated electronics 5 close
the electrical contact.
This type of electronic pressure switch is known as “normally open”.

Components of the electronic pressure switch

81 Restrictor 84 Thin layer sensor (DMS)

82 Pressure chamber 85 Electronics
83 Metal surface 86 3-pin connector

Activating the emergency steering function

The emergency steering pressure switch monitors the steering system pressure.
If the diesel engine or the working hydraulics pump fails, the pressure at the
emergency steering pressure switch drops. If the pressure drops, the switch
contact opens. This interrupts the positive signal to the master controller and
the emergency steering system is activated.

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 Service manual Steering system
Emergency steering

8.4.3 Emergency steering check pressure switch

Technical data
See section 2.1

Layout

Components of the electronic pressure switch

87 Restrictor 91 Electronics
88 Housing 92 Plug connection
89 Pressure chamber 93 3-pin connector
90 Thin layer sensor (DMS)
The emergency steering pressure switch 2 is mounted on the emergency
steering pump 1.
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Function description

Basic function
Electronic pressure switches are for switching electric circuits on and off.
The hydraulic oil passes through the valve 1 into the pressure chamber 2.
The valve 1 is designed so that the hydraulic oil passes through a fine
threaded duct into the pressure chamber 2. This evens out pressure peaks.
The thin layer sensor 4 changes its resistance due to the curvature of the
surface 3. When the set value is reached, the integrated electronics 5 close
the electrical contact.
This type of electronic pressure switch is known as “normally open”.

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Steering system Service manual
Emergency steering

Components of the electronic pressure switch

94 Restrictor 97 Thin layer sensor (DMS)
95 Pressure chamber 98 Electronics
96 Metal surface 99 3-pin connector

Activating the emergency steering function

The job of the emergency steering check pressure switch is to test the
emergency steering system.
When the diesel engine is started, the emergency steering pump begins to
pump oil. If the pressure rises to the set level, the switch contact closes. A
positive signal to the master controller is activated and the emergency
steering check is successfully completed.

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 Service manual Steering system
Emergency steering

8.4.4 Valve block

Layout

Components and connections on the valve block

100 Oil from control block 104 Housing

101 Oil from the emergency 105 To servostat
steering pump 106 Control block check valve
102 Emergency steering pump 107 Emergency steering
check valve pressure switch
103 Steering test connection
The valve block is fitted on the frame of the rear section.

Function description

Basic function
The valve block directs the oil from the control block or the emergency
steering pump to the servostat.
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Hydraulic plan of the valve block

108 Oil from control block 111 Emergency steering pump
109 Emergency steering check valve
pressure switch 112 Control block check valve
110 Oil from the emergency 113 To servostat
steering pump 114 Steering pressure test
connection

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Emergency steering

The steering system is supplied with oil by the working hydraulics pump. The
oil flow of the working hydraulics pump is distributed by the control block
(priority valve) to the working hydraulics and the steering system as required.
The pressure switch 2 monitors the pressure of the working hydraulics
pump. If the pressure at the switch 2 is too low, the emergency steering
pump is automatically activated. This can happen if the diesel engine shuts
down or if the working hydraulics pump fails.
The check valves 4 and 5 prevent the oil from flowing back to the control
block or the emergency steering pump.
Valve block during normal
steering function

Valve block during normal steering function

When the steering wheel is turned, the working hydraulics pump delivers oil
from the control block to the connection 1 and via the check valve 7 to the
servostat. The check valve 3 prevents oil from flowing back to the
emergency steering pump.

Valve block during emergency

steering function

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Valve block during emergency steering function

The emergency steering pump delivers oil to the connection 2 and via the
check valve 3 to the servostat. The check valve 7 prevents oil from flowing
back to the emergency control block.

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 9 Brake system
9.0

Chapter contents
9 Brake system ...................................................................... 9.0-1

9.1 Brake system .................................................................................. 9.1-1

9.2 Service brake .................................................................................. 9.2-1

9.2.1 Brake system gear pump...................................................... 9.2-1
9.2.2 Compact brake valve ............................................................ 9.2-3
9.2.3 Service brake hydro accumulator ......................................... 9.2-7
9.2.4 Brake light pressure switch .................................................. 9.2-9
9.2.5 Accumulator charge pressure switch ................................. 9.2-10

9.3 Parking brake .................................................................................. 9.3-1

9.3.1 Disc brake ............................................................................. 9.3-2
9.3.2 Parking brake hydro accumulator ......................................... 9.3-4
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 Service Manual Brake system

9.1 Brake system

Design

Main components of the brake system

1 Compact brake valve Brake circuits: Test connections:
2 Hydraulic oil filter BR1 Front axle brake circuit M4 Front axle brake pressure
3 Gear pump BR2 Rear axle brake circuit M5 Rear axle brake pressure
4 Hydraulic tank BR3 Parking brake circuit
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5 Rear axle
6 Front axle
7 Parking brake calliper
The gear pump 3 is flange-mounted on the engine. Together with the
compact brake valve 1, its job is to charge the hydro accumulators of the
brake system.
The hydro accumulators for the service brake are fitted outside on the cab
floor. The hydro accumulator for the parking brake mounted directly on the
compact brake valve (see compact brake valve).
The service brake is a wet disc brake mounted in the wheel hubs of both axles.
The parking brake is a disc brake attached to the front axle 6.

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Function description

Basic function

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Hydraulic diagram of the brake system

1 Front axle with parking brake 9 Hydraulic tank 19 Pressure control piston for
2 Front axle brake discs 10 Compact brake valve 2nd circuit
3 Brake system hydro 11 Accumulator charge valve 20 Accumulator pressure switch
accumulator 12 Pressure balance pilot valve 21 Brake gear pump
4 Brake light switch 13 Check valve 22 Control valve block
5 Rear axle 14 Inverted shuttle valve (housing preheating)
6 Rear axle brake discs 15 Check valve
Test connections:
7 Rear axle hydro accumulator 16 Parking brake solenoid valve
M3 Accumulator charge pressure
8 Return suction filter 17 Inching angle sensor
M4 Front axle brake pressure
18 Pressure control piston for
M5 Rear axle brake pressure
1st circuit
M6 Parking brake pressure

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 Service Manual Brake system

The service brake is a hydraulic 2-circuit brake system. It acts on the wet
discs in the front and rear axles.
The brake system gear pump 21 draws up oil from the hydraulic tank 9 and
pumps it to the compact brake valve 10. The accumulator charge valve 11 in
the compact brake valve fills the hydro accumulators to a specified oil
pressure.
When the inch/brake pedal is slightly depressed (up to of the way down),
only the hydraulic inching function is activated via the inching angle sensor 17.
When the inch/brake pedal is fully depressed (in the last third), oil flows from the
hydro accumulators 3 and 7 via the pressure control pistons 18 and 19 to the
brake pistons in the front and rear axles. This activates the wet disc brakes. At
the end of the braking procedure, the oil flows into the hydraulic tank.
The parking brake is opened by oil pressure and closed by spring force.
When the parking brake solenoid valve 16 is energised, oil flows from the
parking brake hydro accumulator 3 (port S3) to the front axle brake callipers
and opens them.

Hydraulic tank
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Hydraulic tank with oil level indicator

The hydraulic tank provides filtered oil for the brake system. The gear pump
draws up oil from the hydraulic tank via the connection 4. The returning oil is
pumped back through the connection 1 and the return strainer 2 to the
hydraulic tank.
The bleeder filter compensates for pressure differences inside the hydraulic
tank by providing appropriate ventilation.
See the detailed description in the section on the hydraulic tank.

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Brake system gear pump

The brake system gear pump 2 draws up oil from the hydraulic tank through
the pipe 4 and pumps it through the connection 3 to the compact brake valve.
See the detailed description in the section on the brake system gear pump.

Compact brake valve with hydro accumulator

The compact brake valve performs the following tasks:
– Charging the hydro accumulator
– Inching function when the inch/brake pedal is slightly depressed
– Braking function when the inch/brake pedal is fully depressed
– Activating the parking brake via the parking brake solenoid valve

Compact brake valve with hydro accumulator

The accumulator charge valve fills the hydro accumulators 2, 3 and 4 to a
specified oil pressure. The accumulator charge pressure switch 5 monitors
the pressure in the hydro accumulators.
When the inch/brake pedal is pressed, oil flows from the service brake hydro
accumulators 3 and 4 to the wet disc brake. The contact on the brake light
pressure switch 6 closes and the brake lights light up.
See the detailed description in the section on the compact brake valve.
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 Service Manual Brake system

Service brake
The service brake is a wet disc brake mounted in the front and rear axles.
The oil pressure causes the piston 4 to push the brake discs 1 against the
brake discs 2. The number of brake discs and the brake pressure determine
the braking force.
The piston is sealed with an O-ring 5 and support ring. The piston is returned
to its initial position by the return apparatus 6.
See the detailed description of the wet disc brake in the section on the axles.

Brake discs in the axle

1 Brake disc with lining 5 O-ring seal with support ring 9 Bearing
2 Brake disc 6 Return apparatus 10 Groove nut
3 Axle casing 7 Intermediate gear 11 Support ring
4 Brake piston 8 Axle 12 Brake housing
13 Main housing
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Parking brake
The parking brake is attached to the output shaft of the transmission 4 and
thus acts on all four wheels.

Structure of the parking brake

The parking brake is opened by oil pressure and closed by spring force.
When you start the engine and press the parking brake button, the solenoid
valve 2 in the compact brake valve 1 is activated. Oil flows from the hydro
accumulator 3 to the parking brake 5, where it acts on the brake cylinder 4
and opens the callipers.
When you press the parking brake button again or turn off the engine, the
force of the springs in the brake cylinder closes the brake, thus generating
the required braking torque on the brake disc.
When the parking brake is closed, the LED in the parking brake button and
the parking brake symbol field in the display light up.
See the detailed description in the section on the parking brake.

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 Service Manual Brake system
Service brake

9.2 Service brake

9.2.1 Brake system gear pump

Technical data
See section 2.1

Design

Scavenging pump arrangement

1 Fan motor gear pump 3 Tank supply line

2 Brake system gear pump 4 Compact brake valve
The gear pumps are fitted on the accessory drive of the engine and is driven
by the engine at a specific transmission ratio via a spur gear.
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Brake system gear pump components

1 Driver 6 Gears
2 O-ring 7 Housing
3 Flange 8 Housing cover
4 Seals 9 Shaft seal ring
5 Bearing bushings

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Service brake

Function description

Basic function
The gear pump consists of two intermeshing gears enclosed in a housing.
One of the two gears is driven via the outgoing shaft (driving gear), and the
other driven by the gear teeth.
The fluid taken in is injected into the gaps between the teeth and pumped
outside along the housing from the intake port to the pressure port.

Oil supply for the brake system

The brake system gear pump 3 draws up oil from the hydraulic tank 4. The
oil is pumped via the discharge port to the compact brake valve 1.

Pressure cut-off
The brake system gear pump pressure cut-off is performed by the pressure
relief valve in the compact brake valve. LBH/Version 01/10.2007/en/leh/07.02.2013

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 Service Manual Brake system
Service brake

9.2.2 Compact brake valve

Technical data
See section 2.1

Design
This compact brake valve is attached to the cab floor. It is activated using
the inch/brake pedal.

Main components of the compact brake valve

1 Actuation pedal 6 Accumulator charge valve

2 Inching angle sensor R1 7 Parking brake solenoid valve
3 Brake pressure 8 Accumulator charge
adjusting screw pressure switch
4 Brake light pressure switch 9 Base plate
5 Compact brake valve housing
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Service brake

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Cross section of the compact brake valve

1 Pedal idle position 10 Opening/closing pressure 16 Spring cup
adjusting screw adjusting screw 17 Pressure control spring
2 Base plate 11 Inverted shuttle valve 18 Brake pressure
3 Parking brake check valve 12 Return spring for 2nd adjusting screw
4 Pressure balance check valve brake circuit 19 Seal rings
5 Accumulator pressure test piston 13 Pressure control piston for 20 Pressure control springs
6 Valve insert 2nd brake circuit 21 Spring sleeve
7 Compact brake valve housing 14 Return spring for 1st 22 Actuating piston
8 Pilot valve actuating piston brake circuit 23 Actuation pedal
9 Pressure relief valve 15 Pressure control piston for
1st brake circuit

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 Service Manual Brake system
Service brake

Function description

Basic function

Hydraulic diagram of the compact brake valve

1 Parking brake solenoid valve 10 Flow control nozzle 16 Parking brake connection
2 Inching angle sensor 11 Gear pump P connection 17 Front axle connection
3 Pressure control piston for 12 To the control valve block 18 To the overspeed protection
1st circuit (housing preheating) solenoid valve
4 Pressure control piston for 13 Accumulator charge 19 Brake light pressure switch
2nd circuit pressure switch 20 Rear axle hydro accumulator
5 Inverted shuttle valve 14 Front axle hydro accumulator 21 Hydraulic tank connections
6 Check valve 15 Parking brake hydro M3 Accumulator charge pressure
7 Pressure balance pilot valve accumulator test connection
8 Check valve
9 Accumulator charge valve
The compact brake valve is supplied with oil by a gear pump. The integrated
accumulator charge valve 9 and the pilot valve 7 fill the hydro accumulator
with pressure oil.
If the accumulator charge cut-off pressure is reached, the accumulator
charge valve 9 switches the pump flow to circulate to the connection N.
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If braking causes the accumulator pressure to fall to the accumulator charge

cut-in pressure, the accumulator charge valve 9 switches to accumulator
charging.
The brake circuits of the front and rear axles are separated by the inverted
shuttle valve 5.
The parking brake solenoid valve 1 provides pressure oil to the disc brake.

Service brake
When the pedal is depressed in the first two thirds of its range, the hydraulic
inching function is activated. This function is triggered by the angle sensor
on the compact brake valve.

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Service brake

If the pedal is depressed further, the pressure control pistons of the 2nd circuit
control the pressure in the brake pistons in proportion to the pedal force.
At the end of the braking procedure, the oil flows back to the hydraulic tank.
If one brake circuit fails, the second remains operational due to the
mechanical contact between the two pressure control pistons in the compact
brake valve. The actuation force remains the same.

Parking brake
When you press the parking brake button, the parking brake solenoid valve
1 is opened. The accumulator pressure acts on the cylinders of the disc
brake and opens the brake.

Inching angle sensor

The angle sensor attached to the compact brake valve consists of two
redundant sensors. The angle sensor 1 sends an electrical signal to input
module 1 and the angle sensor 2 sends a signal to the input module 2.
When the inch/brake pedal is pressed, the current to the control pressure
proportional valve (travel hydraulics pump) is reduced. The variable
displacement pump reduces its flow. This hydrostatically brakes the
machine.

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 Service Manual Brake system
Service brake

9.2.3 Service brake hydro accumulator

Technical data
See section 2.1

Design

Components of the hydro accumulator

1 Plug 3 Closing head

2 Membrane 4 Accumulator
The elastic partition between the fluid and the nitrogen is a membrane 2,
which is stretched in the accumulator 4. The closing head 3 prevents the
membrane from being pressed into the inlet opening when the hydro
accumulator is completely empty. The plug 1 allows the accumulator to be
checked and topped up using the filling and testing device.

Function description

Basic function
The purpose of the hydro accumulator is to store hydraulic energy and
supply it when needed.
It has the following applications:
– To act as an attenuator for pressure peaks, for example for the ride
control system or steering attenuation.
– To act an energy reserve to supply energy when needed, for example for
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the brake system.

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Service brake

Storing pressure for the service brake

Hydro accumulator arrangement

1 Compact brake valve 4 Rear axle hydro accumulator
2 Parking brake hydro 5 Accumulator charge pressure
accumulator switch
3 Front axle hydro accumulator 6 Brake light pressure switch
The service brake hydro accumulators allow the brake to be applied a
certain number of times if the service brake pump fails. Oil flows from the
hydro accumulators 3 and 4 through the compact brake valve 1 to the disc
brake.

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 Service Manual Brake system
Service brake

9.2.4 Brake light pressure switch

Technical data
See section 2.1

Design

Components of the pressure switch

1 Connection contact 4 Switch contact

2 Adjusting screw 5 Membrane
3 Pressure spring 6 Housing
The brake light pressure switch 1 is mounted on the compact brake valve 3.

Function description

Basic function
Membrane pressure switches are for switching electric circuits on and off.
The hydraulic pressure acts via a membrane on an adjustable spring. When
a set value is reached, the electric contact closes and the circuit is closed.
This type of membrane pressure switch is known as “normally open”.

Brake light switching function

The job of the brake light pressure switch is to switch on the brake lights.
When the inch/brake pedal is pressed, the pressure on the parking brake
pressure switch rises. When a set level is reached, the contact closes and
the brake lights are switched on.
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Service brake

9.2.5 Accumulator charge pressure switch

Technical data
See section 2.1

Design

Components of the pressure switch

1 Restrictor 5 Electronics
2 Housing 6 Plug connection
3 Pressure chamber 7 3-pin connector
4 Thin layer sensor (DMS)
The accumulator charge pressure switch is mounted on the compact
brake valve.

Basic function
The membrane pressure switches are for switching electric circuits on and
off. The hydraulic pressure is directed via a restrictor hole 1 into the pressure
chamber 3. The thin layer sensor 4 changes its resistance due to the surface
curvature. When a set value is reached, the electric contact closes and the
circuit is closed.
This type of membrane pressure switch is known as “normally open”.
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Accumulator charge pressure monitoring function

The job of the accumulator charge pressure switch is to monitor the
accumulator charge pressure.
If the pressure in one of the brake accumulators falls below the level set for
the pressure switch, the contact closes or opens and the accumulator
charge pressure symbol field lights up. In addition, an audible signal sounds.

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 Service Manual Brake system
Parking brake

9.3 Parking brake

Function description

Basic function of the parking brake

Components of the parking brake

1 Compact brake valve 4 Brake callipers

2 Parking brake solenoid valve 5 Front axle with disc brake
3 Parking brake hydro accumulator
The parking brake is a spring accumulator brake. The parking brake is
opened by oil pressure and closed by spring force.
The parking brake is supplied with oil by the compact brake valve 1. The
accumulator charge valve of the compact brake valve 1 fills the parking
brake hydro accumulator 3 to a specified oil pressure.
The parking brake hydro accumulator 3 provides oil pressure via the
solenoid valve 2 to open the parking brake. The solenoid valve 2 is actuated
using the parking brake button.
When the parking brake is opened, oil flows from the hydro accumulator 3
via the solenoid valve 2 to the disc brake 5.

Function of the parking brake switch

The parking brake can only be released when the engine is running.
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When you start the engine and press the parking brake button 2, the parking
brake solenoid valve is activated. The brake pressure then acts via the open
parking brake solenoid valve on the brake cylinder, and opens the parking
brake against the force of the brake callipers. The parking brake symbol field
3 on the display goes out.
When you press the parking brake button 2 again or turn off the engine, the
force of the springs in the brake cylinder closes the brake, thus generating
the required braking torque on the brake disc. The parking brake symbol
field 3 and the LED 1 in the parking brake button light up.

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Brake system Service Manual
Parking brake

9.3.1 Disc brake

Technical data
See section 2.1

Design

Disc brake components

1 Guide pin 9 Pressure ring 18 Pressure pin

2 Retaining splint 10 Seal 19 Grooved ring
3 Castle nut 11 Snap ring 20 Dust cap
4 Housing 12 O-ring 21 Brake disc
5 Piston 13 Sealing cap 22 Brake pad
6 Bleeder valve 14 Lock nut 23 Permanent magnets
7 Cap 15 Adjusting screw
8 Cup springs 16 Grooved ring
17 Pressure chamber
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The parking brake is a spring-loaded sliding saddle brake which acts on the
brake disc 8 attached outside on the output shaft of the transmission.

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 Service Manual Brake system
Parking brake

Function description

Basic function of the disc brake

Disc brake in open position

The two identical brake pads 22 slide freely on the guide pins 1 which are
fastened in the housing 4. The guide pins 1 are also inserted in a brake pad
bolted to the transmission.
When the brake is applied, it clamps the brake pads 22, creating a braking
torque on the brake disc 21. The braking force of the parking brake meets
the legal requirements:
It is at least 25% of the operating weight of the machine.
The clamping force is generated by the cup spring set 8, which moves the
piston 5 and the adjusting screw 15, the pressure pin 18 and the front brake
pads 22 towards the brake disc 21.
When the front brake pad 22 comes into contact with the brake disc 21, the
reactive force pushes the housing 4 onto the guide pin 1 until the rear brake
pad 22 is also pressed against the brake disc 21.
The parking brake is released by tensioning the entire cup spring set 8. Oil in
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the pressure chamber 17 pushes the piston 5 all the way back against the
force of the cup spring set 8 to the pressure ring 9.

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Brake system Service Manual
Parking brake

9.3.2 Parking brake hydro accumulator

Technical data
See section 2.1

Design

Components of the hydro accumulator

1 Plug 3 Closing head

2 Membrane 4 Accumulator
The elastic partition between the fluid and the nitrogen is a membrane 2,
which is stretched in the accumulator 4. The closing head 3 prevents the
membrane from being pressed into the inlet opening when the hydro
accumulator is completely empty. The plug 1 allows the accumulator to be
checked and topped up using the filling and testing device.

Function description

Basic function
The purpose of the hydro accumulator is to store hydraulic energy and
supply it when needed.
It has the following applications:
– To act as an attenuator for pressure peaks, for example for the ride
control system or steering attenuation.
– To act an energy reserve to supply energy when needed, for example for
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the brake system.

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 Service Manual Brake system
Parking brake

Storing pressure for the parking brake

Components of the parking brake

1 Compact brake valve 4 Brake callipers
2 Parking brake solenoid valve 5 Front axle with brake disc
3 Parking brake hydro accumulator
The parking brake is closed by spring force and opened by the brake oil from
the hydro accumulator 3.
When the parking brake button is pressed, brake oil flows from the hydro
accumulator and releases the parking brake. The parking brake can only be
safely released when the parking brake symbol field is not lit.
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Brake system Service Manual
Parking brake

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 10 Electrical system
10.0

Chapter contents
10 Electrical system ............................................................... 10.0-1

10.1 Electrical system with circuit diagrams ......................................... 10.1-1

10.2 Electrical components................................................................... 10.2-1

10.2.1 Electrical components in the cab ........................................ 10.2-1
10.2.2 Fuse and relay board.......................................................... 10.2-2
10.2.3 Electrical components in the rear section........................... 10.2-5

10.3 Master controller - UC3 (Universal Earth Mover Controller 3)...... 10.3-1

10.4 Battery installation ........................................................................ 10.4-1

10.4.1 Batteries ............................................................................. 10.4-2
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Electrical system Service Manual

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 Service Manual Electrical system
Electrical system with circuit diagrams

10.1 Electrical system with circuit diagrams

Design
The operating voltage of the machine is 24 volts. The batteries (2 x 12 V) are
connected in series.
The two batteries are installed in the right ballast weight.
Components of the electrical The table below (“OSC directory”), lists all the components of the electrical
sxstem system. The entry in the columns for page, enclosure, and location helps
you locate the component in the circuit diagrams.
Abbreviations:
- BH Service hours
- EP Electroproportional
- KS Wiring harness
- LED Light-emitting diode
- LFD Liebherr ride control
- MV Solenoid valve
- PWM Pulse width modulation (proportional solenoid output)
- PMV Proportional solenoid valve
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Machine view 1, left

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Electrical system Service Manual
Electrical system with circuit diagrams

Machine view 2, right

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Machine view 3, above

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 Service Manual Electrical system
Electrical system with circuit diagrams

Function description

Circuit diagrams
The circuit diagrams are on pages 1 to 61. The following list contains the
pages and their main functions.
The circuit diagrams of the electrical system show the function sequences
for the entire machine, including optional equipment. All components and
connections are marked and shown with the appropriate switching code so
that they are clearly identifiable. The keys also list the designations of the
components.
The circuit diagrams are divided into pages. The pages are also divided into
individual sections.
Click the links in the online documentation to skip to the relevant information.

Component designation “-” The designations of the components and connectors are always shown with
-XX..:
- -XX… = Component designation, e.g.
-P1 = Mechanical service hours indicator (optional)

Location code “+” Location codes are shown with +XX. The location codes show where the
components are fitted on the machine.
The following location codes are shown:
- +B Ballast weight, general
- +B1 Left ballast weight
- +B2 Rear ballast weight
- +F Travel drive, general
- +F1 Front axle
- +F2 Rear axle
- +F3 Transmission
- +H Rear section
- +H1 Rear section hatch
- +H2 Rear section below cab, right
- +H3 Rear section below cab, left
- +H4 Right rear section
- +H5 Left rear section
- +K Cab, general
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- +K1 Cab front instruments

- +K2 Cab rear wall
- +K3 Cab roof
- +K4 Cab instruments in side cover, rear right
- +K5 Cab instruments in side cover, rear left
(LBH)/07.02.2013

- +K6 Cab floor

- +M Engine
- +V Front section
- +V1 Front section
- +V2 Lift arm
- +V3 Tilt cylinder

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Electrical system Service Manual
Electrical system with circuit diagrams

Ground pins

Ground pins are arranged on the machine

MP_1 Right rear section, under MP_5 Right rear section MP_7 Rear of the cab roof,
the cab (emergency steering pump) at the right
MP_4 Right rear section, behind MP_6 Left rear wall of cab MP_10 Rear section
the motor (behind the starter)

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PowerPoint
PowerPoint
 Service Manual Electrical system
Electrical components

10.2 Electrical components

10.2.1 Electrical components in the cab
The main electrical/electronic components are located on the cab rear wall

Design
The following components are fitted on the cab rear wall:
- Fuse and relay board
- Voltage converter
- UEC3 - Universal Earth Mover Controller 3
- Warning buzzer
- Diagnostic plug
- Optional components
The electrical and electronic components are mounted under the covering
on the cab rear wall.
LBH/Version 01/07.2007/en/Trainotti Anton

Components on the rear cab wall

1 Warning buzzer H40 3 UEC3 - Universal Earth Mover 5 Rear wiper motor M3
(behind cover) Controller 3 6 Relay and fuse board A4
2 Diagnostic plug 4 Voltage transformer T1
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Electrical system Service Manual
Electrical components

10.2.2 Fuse and relay board

(ID no. 10290013)

Design

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Fuse and relay board

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 Service Manual Electrical system
Electrical components

F1 10 A Quick change device F37 40 A LH_ECU VBAT R9b Alternator exciter resistance
F2 7.5 A Left high beam power supply 2 220
F3 7.5 A Right high beam F38 3.0 A LH_ECU VBAT S1 Safety test button
F4 7.5 A Right low beam controller supply 2 V1 Extinguishing diode K01
F5 7.5 A Left low beam F39 10 A Engine compartment V2 Extinguishing diode K01/87
F6 5 A Left profile light to the left, lighting, auxiliary heater clock* V3 Extinguishing diode K12
right parking light F40 10 A Auxiliary heating control* V4 Extinguishing diode K02
F7 5 A Right profile light, F41 10 A Dust filter - overpressure V5 Extinguishing diode K03
left parking light unit V6 Extinguishing diode K02/87
F07b 10 A terminal 15 Warning light F43 10 A Motor control unit ON V7 Extinguishing diode K03/87
function F44 10 A Brake light V8 Extinguishing diode K5
F8 15 A Radio, compressor seat F45 10 A Gas pedal L524, L528 V14 Extinguishing diode K25
F8a 10 A Interior lighting, socket F46 10 A Joystick steering* V15 Extinguishing diode K26
F9 10 A LH control lever options, F71 10 A Info T 15 H keypad, V16 Extinguishing diode K31a
fan reversal switch lighting V17 Extinguishing diode K31b
F10 3 A Display unit F73 10 A Central lubrication system* V20 Extinguishing diode K33a
F11 3 A Inching angle sensor F74 15 A Heated rear window V21 Extinguishing diode K33b
F12 10 A Spare and mirrors* V22 Extinguishing diode F9 reserve
(Up to Ser. No. 23927) F75 10 A Power output, V23 Extinguishing diode
F12 10 A Signal term. 15 UEC3 12 V for radio F14 preheating
(Valid from Ser. No. 23928) F76 10 A Power output, V24 Extinguishing diode F19 heater
F13 10 A Sweeper 12 V for radio and 12 V socket blower, air conditioning
F14 10 A Separ fuel X1 10 A EU flashing warning jumper V26 Extinguishing diode K15/87
prewarming system X2 10 A EU flashing warning jumper V27 Extinguishing diode K18/87
F15 10 A LH-Control lever, Signal X3 10 A USA flashing V28 Extinguishing diode Y14
term. 15 UEC3, fuel level warning jumper V32 Extinguishing diode K244/87a
sensor, coolant level, X4 10 A 0 OHM Exciter jumper* V33 Extinguishing diode K244/87
emergency steering pressure X5 10 A 100 OHM Exciter jumper* V33c Reversing light blocking diode
switch and air filter X6 10 A 220 OHM Exciter jumper V34 Extinguishing diode K245/87a
contamination K1 Direction indicator relay V35 Extinguishing diode K245/87
(Up to Ser. No. 23927) K01 Ignition starter switch relief relay V36 Extinguishing diode K246/87a
F15 10 A LH-Control lever, fuel terminal 15 V37 Extinguishing diode K246/87
level sensor, coolant level, K02 Starter terminal 50 V38 Extinguishing diode K243/87a
emergency steering pressure K03 Engine stop relay* V39 Extinguishing diode K243/87
switch und air filter V40 Extinguishing diode K228/87a
K5 Relay terminal D+
contamination V41 Extinguishing diode K228/87
K10 Relays for heated rear window
(Valid from Ser. No. 23928) V42 Extinguishing diode K271/87a
and mirrors*
F16 40 A Starter terminal 50 V43 Extinguishing diode K271/87
F17 40 A Engine stop* K12 Radio / 12 V socket relay V44 Extinguishing diode K271
F18 10 A Rear washer pump terminal 58 V45 Extinguishing diode K228
F19 10 A Air conditioning control K15 Lift kick-out relay* V46 Extinguishing diode K243
unit, pressure switch B27 K18 Bucket return-to-dig relay V48 Extinguishing diode K246
F19a 15 A Air conditioning control K25 Relay for hazard lights in (USA) V49 Extinguishing diode K245
unit, terminal 30 K26 Relay for hazard lights in (USA) V50 Extinguishing diode K244
F20 15 A Front wiper/washer K31a Front left working floodlight relay V54 Extinguishing diode K209
pump, horn K31b Front right working V55 Extinguishing diode K18
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F21 15 A Profile light, driving light floodlight relay V56 Extinguishing diode K15
F22 15 A UEC3 VDC3 K33a Rear left working floodlight relay V57 Extinguishing diode K10
F23 15 A UEC3 VDC2 K33b Rear right working V80 Alternator excitation
F24 15 A UEC3 VDC4 floodlight relay blocking diode
F25 10 A Flashing beacon, heated K209 Dust filter excess pressure V81 Alternator excitation
rear window activation system relay* blocking diode
(LBH)/07.02.2013

F26 15 A Diagnostic plug, K228 Visual reverse warning V82 Alternator excitation
UEC3 VDC1 system relay* blocking diode
F27 10 A Profile light F6 / F7 K229 Visual reverse warning V83 Direction indicator
F28 10 A Spare (weighing device)* system relay* blocking diode
F29 25 A Ignition switch K230 Automatic run-off relay* V84 Direction indicator
F30 15 A Supply voltage converter K243 Reserve blocking diode
F31a 10 A Front left working floodlight K244 Reserve V87 Direction indicator
F31b 10 A Front right K245 Central lubrication relay* blocking diode
working floodlight K246 Ride control relay* V88 Direction indicator
F33a 10 A Rear left working floodlight K270 Immobiliser relay* blocking diode

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Electrical system Service Manual
Electrical components

F33b 10 A Rear right working K271 Fuel preheating relay* V89 Direction indicator
floodlight R9a Alternator exciter blocking diode
F35 10 A Spare resistance 100 V90 Hydraulic quick change device
F36 40 A LH_ECU VBAT reserve blocking diode
For further fuses, see also “Electrical components in the rear section”
* Options

Function description

Basic function
The relay and fuse board houses and connects the electrical components.
The relay and fuse board does not have a control function.
However, the other electrical and electronic components are powered via the
relay and fuse board.

Working floodlight fuse function

The function of the working floodlights can be selected by plugging the fuses
F31A, F31B, F33A and F33B:
- When the fuses are plugged to terminal 30 the working floodlights work
as soon as the main switch is turned on.
- When the fuses are plugged to terminal 15 the working floodlights only
work when the ignition is turned on.
You can also choose a mixed function, for example by plugging the front
working floodlights to terminal 15 and the rear floodlights to terminal 30.

Fuse test
The fuses on the relay and fuse board are divided into three categories.
- Fuses for power supply from terminal 30
- Fuses for power supply from terminal 15
- Fuses to protect various functions (e.g. low beam, profile lights /
parking light)
Each fuse has an LED and can be tested by pressing the button S1.
The fuse test depends on the electrical status.
Only the fuses of the activated circuit can be tested:
- When the main switch is on (terminal 30) only the LEDs on terminal 30
power supply fuses light up when the button S1 is pressed.
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- When the main ignition is on (terminal 15) the LEDs on terminal 30 and
terminal 15 power supply fuses light up when the button S1 is pressed.
- The LEDs to protect the various functions only light up when the
corresponding function is activated. If an LED does not light up, the fuse
is defective.
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 Service Manual Electrical system
Electrical components

10.2.3 Electrical components in the rear section

Components on the rear right of the rear section

Components on the rear left of the rear section

K04 Preglow relay F010 10 A heating flange

S15 Main switch feedback fuse
F07a 10 A hazard warning F03 200 A emergency steering
system fuse pump fuse
F02 100 A preglow fuse
F01 100 A main fuse

How the relay K04 works

The relay K04 controls the intake air pre-heating flange.
The preglow system is controlled by the engine control unit A700D and
depends on the following criteria:
- Coolant temperature
- Intake air temperature
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Electrical components

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 Service Manual Electrical system
UEC3 - Universal Earth Mover Controller 3

10.3 Master controller - UC3 (Universal

Earth Mover Controller 3)
The master controller UEC3 is fitted under the cover on the rear wall of the
cab behind the driver's seat.
The UEC3 is fitted with a plug connector to communicate with the various
components.

Design

Master controller UEC3

1 Plug X3 4 Plug X4
2 UEC3 Housing 5 Screws for fixing control board
3 Housing ventilation valve to cooler
(Goretex)

Plug assignment
Plug X3 Plug connector, 40-pin Deutsch DRC

1 RS232 TxD – diagnostic plug 21 CAN bus HIGH 1

2 BSL_C2 boot loader activation 22 CAN bus HIGH 2 –
3 Signal input for emergency diagnostic plug
steering pressure switch B3 23 Unassigned
4 Signal input for brake pressure 24 Central lubrication system filling
switch B19 level indicator (optional)
5 Front axle speed sensor (B1) 25 Unassigned
6 Unassigned 26 Hydraulic oil temperature
7 Engine temperature sensor sensor (B8)
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(unassigned) 27 Unassigned
8 1 Inching sensor input 28 Fuel sensor signal input (B25)
9 Unassigned 29 LH control lever reverse
10 LH control lever reverse switch (S2)
switch (S2) 30 Power supply 1 F26 T 30
11 RS232_RxD – diagnostic plug 31 CAN bus LOW 1
(LBH)/07.02.2013

12 RS232_GND – diagnostic plug 32 CAN bus LOW 2

13 Emergency steering check 33 Input (spare)
pressure switch signal input B3a 34 Input (spare)
14 Central lubrication system cycle 35 Unassigned
input (optional) 36 Hydraulic oil temperature
15 Variable adjustment motor sensor (B8) earth
engine speed input B2 37 Unassigned
16 Earth reserve 38 Power supply T 15
17 Earth reserve 39 LH control lever forward
18 2 Inching sensor input switch (S2)

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UEC3 - Universal Earth Mover Controller 3

19 LH control lever forward 40 Main power supply earth

button (S2)
20 Unassigned

Plug assignment
Plug X4 Plug connector, 40-pin Deutsch DRC
1 Indicator signal 21 Input signal buzzer
2 Unassigned 22 Signal input for option button 3
3 Signal input for option button 3 23 Input signal button for fan
4 Unassigned reversal
5 Proportional solenoid valve for 24 Unassigned
travel pump (Y59) 25 Fan proportional solenoid valve
6 F22 Power supply 3 (Y13)
(terminal 15) 26 Unassigned
7 Parking brake solenoid valve 27 Central lubrication system*
(Y10) 28 Warning buzzer (H40)
8 Solenoid valve output option 2 29 Variable adjustment
(Y11) (3 A) motor 1 Q max (Y58)
9 Ride control solenoid valve 30 Reverse travel direction
(Y20) (optional) solenoid valve (Y3) + travel
10 Solenoid valve output option 3 direction detection solenoid
(Y12) (3 A) valve (Y26)
11 Signal from high beam switch 31 Main power supply earth
12 Unassigned (MP6_b)
13 Unassigned 32 Signal input for option button 2
14 Joystick steering input activated 33 Unassigned
15 Proportional solenoid valve for 34 Terminal 61 (charge control)
variable adjustable motor 2 alternator D+
(Y57) 35 F23 Power supply 2
16 Forward travel direction (terminal 15)
solenoid valve (Y2) 36 F24 Power supply 4
17 Emergency steering pump relay (terminal 15)
(K011) 37 Solenoid valve fan reversal
18 Solenoid valve coupling open (Y50)
(Y60) 38 Solenoid valve coupling close
19 Optional output (3 A) (Y61)
20 Optional output (3 A) 39 Working hydraulics lockout
solenoid valve (Y14)
40 Reversing light and reverse
warning device (B16)

Function description
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Basic function
The master controller UEC3 is responsible for the following functions:
- Controlling the display unit A13 via CAN bus
- Data exchange with the engine control unit
(LBH)/07.02.2013

- Parking brake
- Controlling the travel hydraulics
- Controlling the working hydraulics
- Controlling the ride control option
- Controlling the fan system
- Emergency steering pump control
- Recording service codes
- Data input and output via diagnostic plug

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UEC3 - Universal Earth Mover Controller 3

- Controlling the heater/air conditioner

- Controlling the central lubrication (Liebherr)
Controlling the display unit The display unit is controlled via a CAN bus. The UEC3 performs a lamp
check of the display unit every time the ignition is turned on.

Engine monitoring The engine monitoring system is controlled by the engine control unit.
system control
The CAN bus transfers the data from the UEC3 to the display unit.
If the set parameters are exceeded, the UEC3 also activates various
safety functions:
- Activating the warning buzzer
- Activating the warning lamps in the display unit
- Power reduction via the travel pump solenoid valve Y59
- Service code
Chapter 19 on malfunctions contains a detailed description.

Parking brake control The parking brake is activated using the parking brake switch. To activate
the parking brake solenoid valve Y10, the following conditions are required:
- The preselected travel direction must be neutral
- The engine must have been started
- The signal from the service brake button must be active
- The parking brake switch must be set to ON
If one of these conditions is absent, the driver hears a short triple beep.

Travel direction control The travel direction is controlled using the forward or reverse travel direction
switch S2.
The following are necessary for the forward and reverse travel direction
solenoid valves Y2 and Y3 to be activated:
- The engine must have been started
- The parking brake must be released
- The travel direction switch must be set to neutral
If one of these conditions is absent, the driver hears a short triple beep.

Travel range control The travel range: fixed gear 1, A1-2 or A1-3 is controlled by the buttons S27
and S28.
Travel range “A1-3” is always selected when the ignition is turned on.
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This setting can be altered using the SCULI diagnostic software.

Controlling the The working hydraulics lockout is activated using the button S19.
working hydraulics
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The working hydraulics lockout is always activated when the engine is

not running.
The working hydraulics lockout can be deactivated while the engine (ignition
turned on) is not running as long as the S19 is pressed.
This setting can be altered using the SCULI diagnostic software.
The following settings are possible:
AHS start-up stored: After the engine is started, the last condition of the
working hydraulics lockout is restored.

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UEC3 - Universal Earth Mover Controller 3

AHS start-up ON The working hydraulics lockout is always activated

after the engine is started
AHS start-up OFF The working hydraulics lockout is always deactivated
after the engine is started
This setting can be altered using the SCULI diagnostic software.

Controlling the The ride control system (LFD) is activated using the button S16.
ride control system On standard machines without LFD this function is always deactivated on
the UEC3 (Opt LFD_speed) and cannot be activated using the switch.
If the ride control function is integrated later, it must be enabled on the UEC3.
If ride control is installed and activated, the following options are available:
The driver can press and hold down the LFD button for longer than two
seconds to switch between SPEED and ON when ride control is activated.
The change is shown as a text (is no service code is present) in the speed,
clock and service hours display:
- SPEED for SPEED mode
- ONOFF for ON mode
SPEED Mode Activation and deactivation speeds can be set
If the driver selects ride control (and there is no service code present), it is
shown as a text on the speed, clock and service hours display:
- LFD 0: function off
- LFD 1: function on and displayed
This setting can be altered using the SCULI diagnostic software.

Controlling the fan system The fan system is regulated automatically depending on the temperatures
of the:
- Hydraulic oil temperature sensor B8
- Coolant temperature sensor T04 / B708
- Charge air temperature sensor T02 / B707
The air conditioning also affects the fan regulation.
The fan solenoid Y13 is activated with pulse width modulation.
Chapter 5 contains a detailed description of the cooling system.

Emergency The emergency steering pump is controlled automatically according to the

steering pump control hydraulic pressure at the pressure switch B3.
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However, the emergency steering pump can also be activated manually

using the button S10 for as long as the button is pressed (max. 40 sec.).
For reasons of safety, the emergency steering pump is activated by the
UEC3 every time the engine is started (safety check). The emergency
steering pump must actuate the safety switch B3a by a hydraulic pressure.
(LBH)/07.02.2013

It is switched off again by the UEC3 after 2 seconds and when the switching
point is reached.
If for any reason the pressure is not reached, the emergency steering pump
is also switched off again after 3 seconds (no emergency steering possible).
This condition is indicated by the warning lamp H24.
If the steering system is working properly the pressure switch B3 is
activated, which means there is a voltage signal present at the UEC3
electronic controller.

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UEC3 - Universal Earth Mover Controller 3

If the steering system fails (pressure drop at the pressure switch B3) the
voltage signal to the UEC3 electronic controller is deactivated and the
emergency steering pump is started.

Recording service codes The UEC3 records all detected errors as service codes. These include:
- Interruptions
- Short circuit
- Values outside tolerance ranges
stored as service code.
Data input and output via To transfer data via the diagnostic plug, a diagnostic cable is needed
diagnostic plug (the ID number can be found in chapter 1 on tools).
The diagnosis can be made using SCULI or a terminal program (such
as Hyperterminal).
For a detailed description of SCULI, see the description (“Sculi user
manual”) in the service documentation.
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UEC3 - Universal Earth Mover Controller 3

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 Service Manual Electrical system
Battery installation

10.4 Battery installation

The electrical system operates at 24 volts.

Design

Battery arrangement

1 Batteries 1 and 2 in the right 3 Fuses F07, F010

ballast weight 4 Main fuses F01, F02, F03
2 Main switch
The batteries are installed in the right ballast weight. The two batteries are
connected in series.
The battery main switch S1 disconnects the battery circuit (-) from the
vehicle earth.
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The following components are powered directly by the battery.

- M1 Starter terminal 30
- G1 Generator terminal B+
- F01 100 A main fuse
- F02 100 A preglow fuse
(LBH)/07.02.2013

- F03 200 A fuse for emergency steering pump

- F07a 10 A fuse for hazard lights

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Battery installation

10.4.1 Batteries
(ID 6001692)

Technical data
See section 2.1
Apart from the terminals, the batteries require no maintenance during
normal operation.

Battery arrangement

1 Battery 3 Drip catcher

2 Back-ignition protection
The battery has a gas escape mechanism and is equipped with back-ignition
protection and a drip catcher.
The free channels must be sealed with dummy plugs.

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 11 Transmission
11.0

Chapter contents
11 Transmission..................................................................... 11.0-1

11.1 Transmission................................................................................. 11.1-1

11.2 Mechanical transmission .............................................................. 11.2-1

11.3 Electronic control unit ................................................................... 11.3-1

11.3.1 Master controller (UEC3) .................................................... 11.3-1
11.3.2 Speed sensor ..................................................................... 11.3-4
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Mechanical transmission

11.1 Transmission
Layout
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Main components of the transmission system

1 Control unit 4 Master controller (UEC3) 6 Output speed sensor
2 2plus1 gearbox 5 Coupling valves Y60, Y61 7 Motor 2 speed sensor
3 Replenishing pump

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Mechanical transmission

Basic function
The transmission system consists of the gearbox, the master controller (UEC3),
the control unit A11 and the hydraulic supply system of the replenishing pump
and the coupling valves.
The gearbox is attached directly to the rear axle of the wheel loader. The
coupling valves are bolted onto a bracket on the left of the rear section.
The master controller (UEC3) is mounted in the cab on the rear wall behind the
driver's seat. The control unit A11 is on the right console in the cab.
The replenishing pump supplies the gearbox with servo oil and lubricating oil
and is integrated in the travel hydraulics pump.
The basic functions of the transmission are:
– Collecting the drive power of the variable displacement motors
– Adjusting the speed and drive torque of the variable displacement motors
to that of the axle input shaft
– Distributing the power output between the front and rear axles.

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Mechanical transmission

11.2 Mechanical transmission

Technical data
See section 2.1

Layout
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Horizontal sectional view of the 2plus1 transmission

1 Cardan shaft flange 6 Lubricating oil line 11 Negative piston
2 Dust protection ring 7 Transmission housing 12 Pressurised oil chamber –
3 Shaft seal 8 Coupling discs replenishing pressure (34 bar)
4 Output speed sensor 9 Coupling piston 13 Piston return spring
5 Rear axle connecting flange 10 Cup spring

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Mechanical transmission

Function description
The transmission is mounted on the rear axle and is driven by two flange-
mounted variable displacement motors in a parallel hydraulic circuit.
The motors drive the two input shafts.
The output speed sensor is positioned on the transmission output 5. The cardan
shaft which connects it to the front axle is flange-mounted here.
The transmission has its own oil system (not connected to the differential).
The torque from the motor 2 (left) is directed via the input shaft to a coupling set
8. The hydraulically actuated clutch consists of an inside-geared coupling cage,
an outside-geared coupling hub, discs, piston, press plate and return springs.
The outside-geared steel discs and inside-geared friction discs are arranged
alternately. The outside-geared discs are connected to the coupling cage and
the inside-geared discs are connected to the coupling hub in such a way that
they cannot twist.
When travel range 3 is selected, a coupling valve is actuated. This allows
pressurised oil to flow from the replenishing pump to the negative piston. The oil
pressure pushes the negative piston against the cup springs. This relieves the
pressure on the discs and opens the clutch.
When the clutch is closed (travel ranges 1 and 2), power is transmitted from the
two oil motors to the output shaft. The spring force pushes together the steel
and friction discs, and they connect the coupling cage and hub so that they turn
together. The oil in front of the piston escapes through a coupling valve.

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 Service manual Transmission
Mechanical transmission

Gearshift strategy

1st and 2nd gear - mechanical

In 1st gear, the clutch 6 is closed. The torques from both travel motors are used
to provide maximum tractive force.
The output from the right travel motor 7 is transferred via the output gear of the
input shaft to the drive gear of the drive shaft.
The power from the left travel motor 8 is transferred from the input shaft via the
clutch 6 to the output gear of the input shaft. The power is then transferred via
the output gear to the output shaft.

1st or 2nd gear, clutch closed with pilot oil flow

1 Y61 clutch closed 5 Replenishing pump

2 0.8 mm modulation valve 6 Clutch
3 0.3 mm flushing valve 7 Travel motor 1 - RA
4 Y60 clutch open 8 Travel motor 2 - EP

1st gear - hydraulic

Both travel motors are held at the maximum angle. This gives the maximum
tractive force. The speed is governed entirely by the action of the travel
hydraulics pump.
The pressurised oil from the replenishing pump 5 is directed via the clutch
closed solenoid valve Y61 1 and the flushing valve 3 to the clutch 6. The flushing
valve 3 almost completely depressurises the oil and ensures a pilot flow.

2nd gear - hydraulic

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The two travel motors are hydraulically and electrically proportionally regulated.
This achieves a higher speed.
When switching from 1st to 2nd gear, there is no shifting in the gearbox.

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Mechanical transmission

3rd gear - mechanical

In 3rd gear, the clutch 6 is opened. Only the torque from travel motor 1 is used.
The output from the right travel motor 7 is transferred directly from the output
gear of the input shaft to the drive gear of the drive shaft.
The travel motor 8 is separated from the drive train by the open clutch 6.

3rd gear, clutch open

1 Y61 clutch closed 5 Replenishing pump

2 0.8 mm modulation valve 6 Clutch
3 0.3 mm flushing valve 7 Travel motor 1 - RA
4 Y60 clutch open 8 Travel motor 2 - EP

3rd gear - hydraulic

When you shift up to 3rd gear, the clutch open solenoid valve Y60 is energised.
The pressurised oil from the replenishing pump 5 flows past the flushing valve 3
directly to the negative piston of the clutch 6. This opens the clutch and travel
motor 2 - EP returns to an angle of 0°. All the oil from the travel hydraulics pump
then flows to travel motor 1 – RA, which thus reaches a higher speed and
ensures further acceleration.
Excess oil from the replenishing pump is returned to the tank via the flushing
valve 3 and the modulation valve 2.

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Mechanical transmission

Shifting down from 3rd to 2nd gear

Shifting down to 2nd gear takes place in two phases.
The first phase is the rapid draining phase.
During the rapid draining phase, the clutch closed solenoid valve Y61 is
briefly energised. Oil flows from the clutch 6 past the flushing valve 3 and the
modulation valve 2 directly to the tank. The fast flushing phase speeds up
the gearshift.

Shifting down - clutch closes with rapid draining

1 Y61 clutch closed 5 Replenishing pump
2 0.8 mm modulation valve 6 Clutch
3 0.3 mm flushing valve 7 Travel motor 1 - RA
4 Y60 clutch open 8 Travel motor 2 - RA
The second phase is the modulation phase.
After the rapid draining phase, the clutch closed solenoid valve Y61 is
switched off again. Oil flows from the clutch 6 past the flushing valve 3 and
then gradually through modulation valve 2 to the tank. The modulation phase
allows smooth shifting down to 2nd gear.
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Shifting down - clutch closes with modulation

1 Y61 clutch closed 5 Replenishing pump
2 0.8 mm modulation valve 6 Clutch
3 0.3 mm flushing valve 7 Travel motor 1 - RA
4 Y60 clutch open 8 Travel motor 2 - EP

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Mechanical transmission

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 Service manual Transmission
Electronic control unit

11.3 Electronic control unit

11.3.1 Master controller (UEC3)
(ID no. 8924810)
For a detailed description of the master controller (UEC3), see section 10.2.

Layout
The master controller (UEC3) is mounted under a plastic cover on the rear
cab wall.

Function description
Master controller (UEC3)
Basic function
The master controller (UEC3) is the "brain" of the machine control system.
The master controller (UEC3) controls and monitors all connected sensors and
actuators, as well as external CAN modules.
The application software in the master controller (UEC3) strictly follows the
following time cycles:
– Receiving all input data from the external sensors and CAN modules
(ECU)
– Performing all calculations in the application software with the input data;
calculating the output data
– Sending all output data to the connected actuators and external CAN
modules (ECU); these then convert the commands to actions.
A laptop can be connected to the UEC3 via a serial interface.
Using the SCULI software, the service engineer can make settings, perform
diagnosis and view operating data in the master controller.
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Electronic control unit

Block diagram of transmission

1 Gas pedal 4 Display unit 7 2plus1 gearbox

2 LH control lever 5 Control unit 8 Output speed sensor
3 Master controller (UEC3) 6 Gear shifting solenoid valves 9 Motor 2 speed sensor

Selecting travel ranges

When the electrical system is turned on, travel range A1-3 is automatically
selected. The transmission remains in neutral until the parking brake is released
and the travel direction is selected. Other travel ranges can be selected by
pressing the “Shift Up” (1) or “Shift Down” (2) buttons on the control unit A11.
The selected travel range is indicated on the display.
The following travel ranges can be selected:
A 2 - 3 – Not activated
A 1 - 3 – Automatic travel range 1st to 3rd gear
A 1 - 2 – Automatic travel range 1st and 2nd gear
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2 – Not activated
1 – Fixed 1st gear
T – Tempomat
N – Neutral

Gearshift strategy
The UEC3 constantly monitors the speed signals and the pump and motor
positions, and selects the most suitable gear in the automatic travel ranges.
The travel ranges can be changed at any speed. If the speed is too high for the
Display unit A13 new travel range, the UEC3 slows the machine by changing the current to the
pump and the variable displacement motor(s). When the speed is appropriate
for the new travel range after hydrostatic braking, the UEC3 automatically
changes the travel range.

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Electronic control unit

Maximum speed Vmax

If the task in hand requires a reduced maximum speed, you can reduce the
maximum speed by pressing the button 3.
This function is only available when travelling forward in fixed gears 1 and 2.
The current speed when the Vmax button is pressed is stored. This preselected
speed is not exceeded, even at full throttle. If you press the the Vmax button
when the machine is not moving, a maximum speed of around 5 km/h is stored.
The Vmax function is deactivated when you press the Vmax button again or
change the travel range.
If reverse travel direction is selected, the UEC3 shifts to automatic travel range
A1-3 and the Vmax function is deactivated.

Special functions - hydraulic oil adjustment

The “travel range down” button can be used to activate this mode. With the
ignition turned on, press the button until the segment display shows P7 “X Hyd”.
The “display unit brightness control” button can be used to change the
hydraulic oil.
The setting is also required for the rapid filling phase of the transmission.
The following conditions are possible, and will be shown in the segment display
P7 of the display unit:
Travel range selection Brightness
control – 1 valid for hydraulic oil - Liebherr Hydraulic Basic 68 (20W20)
– 2 valid for hydraulic oil - Liebherr Hydraulic Plus 15 - 46
– 3 valid for hydraulic oil - Liebherr Hydraulic HVI (10W40)
– 4 valid for hydraulic oil - Liebherr Hydraulic Basic 100 (SAE 30)

Segment display P7
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Electronic control unit

11.3.2 Speed sensor

(ID 7009274)

Technical data
See section 2.1

Layout
The input and output speeds of the transmission are recorded by speed sensors
and monitored by the master controller (UEC3).

Speed sensors on the transmission

1 Output speed sensor 2 Variable displacement motor 2

speed sensor

Function description

Basic function
The sensors generate an AC signal with a frequency proportional to the speed
and number of teeth of the corresponding gear. This signal is recorded by the
master controller (UEC3) and converted to the speed. LBH/Version 01/01.2008/EN/nk/07.02.2013

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 12 Axles and cardan shaft
12.0

Chapter contents
12 Axles and cardan shaft ...................................................... 12.0-1

12.1 Front axle ...................................................................................... 12.1-1

12.1.1 Differential .......................................................................... 12.1-2
12.1.2 Wheel hub .......................................................................... 12.1-5

12.2 Rear axle....................................................................................... 12.2-1

12.2.1 Differential .......................................................................... 12.2-2
12.2.2 Wheel hub .......................................................................... 12.2-5

12.3 Cardan shaft ................................................................................. 12.3-1

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 Service manual Axles and cardan shaft
Front axle

12.1 Front axle

Technical data
See section 2.1

Layout

Main components of the axle

1 Differential 3 Axle casing / brake housing

2 Parking brake 4 Wheel hub
The axle consists of the differential 1 with the tapered gear and 45% self-
locking differential, the axle casing and wheel hubs 4, which have planetary
gears with tapered roller bearings.
The service brake is installed in the left and right axle casing 3.
The parking brake 2 is a dry disc brake and is flange-mounted on the axle
drive input shaft.

Function description

Basic function
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These are the basic functions of the axle:

– Increasing and transferring the drive torque
– Transferring the vertical device forces to the wheels
The gear output torque is transmitted via the drive shaft to the axle input
shaft. The torque is increased to the wheel torque by the ratio of the tapered
gear in the differential housing and that of the planetary drives in the wheel
hubs. The input speed is reduced to the wheel speed accordingly.
The vertical operating load of the machine is transmitted from the
rear section via the bolted connection to the axle casing. The axle
casing transmits this load to the wheel hubs so that the machine is
supported by the wheels.

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Front axle

12.1.1 Differential

Layout

Sectional view of the differential

1 Axle shaft housing 6 Compensating tapered gear
2 Differential housing 7 Locking discs
3 Axle tapered gear 8 Brake housing connecting flange
4 Tapered roller bearing 9 Main nut
5 Crown wheel
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Function description

Speed balance of the left and right wheels

When turning a corner, the left and right wheels cover different distances.
The speeds of the two wheels are then different. The correct speed for each
wheel is induced by the rolling condition.
The axle input shaft determines the average speed of the two output shafts
via the crown wheel 5. The crown wheel 5 drives the differential housing 2
and thus the four facing compensation tapered gears 6 of the differential.
These rest on the tooth faces of the adjacent axle tapered gears 3 and thus
drive the output shafts. The compensation tapered gears 6 have a balancing
function and turn about their own axes to compensate for various wheel
speeds. The speed reduction of one wheel is compensated by the increased
speed of the other wheel.

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Front axle

Self-locking function
The locking discs 7 on the left and right of the axle tapered gears 3
counteract the relative movement between the axle tapered gear 3 and the
differential housing 2 with a braking force proportional to the torque. The
braking torque acts on the side on slippery ground and thus supports the
side with good traction.
The locking discs 7 consist of outer discs which are mounted in the
differential housing and of non-twisting inner discs linked to the axle tapered
gears 3. The drive torque on the tooth edges of the compensating discs 6
and the tapered gears 3 in the differential housing 2 generate forces which
separate the teeth. These act as axial reaction forces on the tapered gears
3, which in turn support the locking discs 7 and thus generate braking force.
The drive force is then transferred via the cup spring 5, the differential
housing 2 and the locking discs 7 with a certain locking torque. The locking
discs 7 transfer this to the tapered gears 3, which are in turn meshed with
the output shafts. The drive torque is then transferred with the locking value
to the wheel with good ground traction.
The locking torque depends on the load and always maintains a constant
ratio to the input torque. The locking value is the ratio of the torque
differential and the total torque of both wheels.

Wheel fastening
The wheels are fastened onto the flanges of the wheel hubs by wheel nuts.
They are centred by the spherical collar nuts.

Axle lubrication
The differential and the wheel hubs have a separate oil systems. Oil filler
and drain plugs are fitted on the wheel hubs and differential housing
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Axles and cardan shaft Service manual
Front axle

Parking and service brake

Layout

Brake discs in the axle

1 Inner discs 7 Intermediate gear

2 Outer discs 8 Output shaft
3 Axle casing 9 Bearing
4 Brake piston 10 Groove nut
5 O-ring seal with support ring 11 Support ring
6 Return apparatus 12 Brake housing connecting flange
13 Main housing
The service brake is a wet disc brake fitted in the left and right axle casings.
The inner discs 1 are connected via the intermediate gear 7 to the output
shaft 2, and the outer discs 2 are connected to the teeth in the axle casing 3
in such a way that they cannot twist.
When pressure oil acts on the brake piston 4, it pushes the outer and inner
discs against the support ring 11. When not actuated, the springs of the
return mechanism 6 push the brake piston 4 back to its initial position. The
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brake discs lose contact and the drag torque is minimised.

The parking brake is mounted on the axle input. For a detailed description
see the section on the brake system.

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 Service manual Axles and cardan shaft
Front axle

12.1.2 Wheel hub

Layout

Cross-section of the wheel hub

1 Axle casing 7 Planetary bearing

2 Output shaft 8 Planetary bearing
3 Shaft seal ring 9 Thrust washer
4 Cartridge seal ring 10 Ring gear
5 Hub 11 Ring gear carrier
6 Planetary gear 12 Cylindrical roller bearing
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Front axle

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 Service manual Axles and cardan shaft
Rear axle

12.2 Rear axle

Technical data
See section 2.1

Layout

Main components of the axle

1 Transmission 3 Axle casing / brake housing

2 Oscillating bearing – main 4 Wheel hub
housing/differential

The axle consists of the main housing with the tapered gear and 45% self-
locking differential 2, the axle casing 3 and wheel hubs 4, which have
planetary gears with tapered roller bearings. The transmission 1 is directly
mounted on it.
The service brake is installed in the left and right axle casing 3.

Function description

Basic function
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These are the basic functions of the axle:

– Increasing and transferring the drive torque
– Transferring the vertical device forces to the wheels
The gear output torque is transmitted directly to the axle input shaft. The
torque is increased to the wheel torque by the ratio of the tapered gear in the
differential housing and that of the planetary drives in the wheel hubs. The
input speed is reduced to the wheel speed accordingly.
The vertical operating load of the machine is transmitted from the
front section via the screwed connection to the axle casing. The axle
casing transmits this load to the wheel hubs so that the machine is
supported by the wheels.

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Rear axle

12.2.1 Differential

Layout

Sectional view of the differential

1 Axle shaft housing 6 Compensating tapered gear

2 Differential housing 7 Locking discs
3 Axle tapered gear 8 Brake housing connecting flange
4 Tapered roller bearing 9 Main nut
5 Crown wheel

Function description
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Speed balance of the left and right wheels

When turning a corner, the left and right wheels cover different distances.
The speeds of the two wheels are then different. The correct speed for each
wheel is induced by the rolling condition.
The axle input shaft determines the average speed of the two output shafts
via the crown wheel 5. The crown wheel 5 drives the differential housing 2
and thus the four facing compensation tapered gears 6 of the differential.
These rest on the tooth faces of the adjacent axle tapered gears 3 and thus
drive the output shafts. The compensation tapered gears 6 have a balancing
function and turn about their own axes to compensate for various wheel
speeds. The speed reduction of one wheel is compensated by the increased
speed of the other wheel.

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Rear axle

Self-locking function
The locking discs 7 on the left and right of the axle tapered gears 3
counteract the relative movement between the axle tapered gear 3 and the
differential housing 2 with a braking force proportional to the torque. The
braking torque acts on the side on slippery ground and thus supports the
side with good traction.
The locking discs 7 consist of outer discs which are mounted in the
differential housing and of non-twisting inner discs linked to the axle tapered
gears 3. The drive torque on the tooth edges of the compensating gears 6
and the tapered gears 3 in the differential housing 2 generate forces which
separate the teeth. These act as axial reaction forces on the tapered gears
3, which in turn support the locking discs 7 and thus generate braking force.
The drive force is then transferred via the cup spring 5, the differential
housing 2 and the locking discs 7 with a certain locking torque. The locking
discs 7 transfer this to the tapered gears 3, which are in turn meshed with
the output shafts. The drive torque is then transferred with the locking value
to the wheel with good ground traction.
The locking torque depends on the load and always maintains a constant
ratio to the input torque. The locking value is the ratio of the torque
differential and the total torque of both wheels.

Wheel fastening
The wheels are fastened onto the flanges of the wheel hubs by wheel nuts.
They are centred by the spherical collar nuts.

Axle lubrication
The differential and the wheel hubs have separate oil systems. Oil filler and
drain plugs are fitted on the wheel hubs and differential housing
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Axles and cardan shaft Service manual
Rear axle

Parking and service brake

Layout

Brake discs in the axle

1 Inner discs 10 Intermediate gear

5 Outer discs 11 Output shaft
6 Axle casing 12 Bearing
7 Brake piston 13 Groove nut
8 O-ring seal with support ring 14 Support ring
9 Return apparatus 15 Brake housing connecting flange
16 Main housing
The service brake is a wet disc brake fitted in the left and right axle casings.
The inner discs 1 are connected via the intermediate gear 7 to the output
shaft 2, and the outer discs 2 are connected to the teeth in the axle casing 3
in such a way that they cannot twist.
When pressure oil acts on the brake piston 4, it pushes the outer and inner
discs against the support ring 11. When not actuated, the springs of the
return mechanism 6 push the brake piston 4 back to its initial position. The
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brake discs lose contact and the drag torque is minimised.

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 Service manual Axles and cardan shaft
Rear axle

12.2.2 Wheel hub

Layout

Cross-section of the wheel hub

1 Axle casing 7 Planetary bearing

2 Output shaft 8 Planetary bearing
3 Shaft seal ring 9 Thrust washer
4 Cartridge seal ring 10 Ring gear
5 Hub 11 Ring gear carrier
6 Planetary gear 12 Cylindrical roller bearing
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Axles and cardan shaft Service manual
Rear axle

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 Service manual Axles and cardan shaft
Cardan shaft

12.3 Cardan shaft

Technical data
See section 2.1

Layout

Components of the drive shaft

1 Flange 4 Shaft driver 7 Pin driver
2 Universal joint 5 Hub liner 8 Universal joint
3 Driving collar 6 Connector tube 9 Flange
The drive shaft has one universal joint at the output of the transmission, a
universal joint at the input of the front axle and a slider to compensate the
length.

Function description

Function
The drive shaft transfers the torque from the transmission to the front axle.
The universal joints at either end of the drive shaft allow it to compensate the
angle between the drive and the output. The angle needs to be
compensated due to the articulated steering.
The shaft driver and hub liner can be displaced axially to mesh together.
This compensates the length. Tolerances in assembly and slight movements
during operation (articulated steering) make this necessary.
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Cardan shaft

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 13 Machine frame and ballast
weight
13.0

Chapter contents
13 Machine frame and ballast weight ..................................... 13.0-1

13.1 Machine frame .............................................................................. 13.1-1

13.2 Articulation bearing ....................................................................... 13.2-1

13.3 Articulation lock ............................................................................. 13.3-1

13.4 Ballast weight ................................................................................ 13.4-1

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 Service manual Machine frame and ballast weight
Machine frame

13.1 Machine frame

Layout
The machine frame consists of the front section and the rear section. These
are connected by the articulation bearing.

Main components of the machine frame

1 Front section 3 Oscillating bearing 5 Articulation lock

2 Articulation bearing 4 Rear section

Function description
The articulation bearing allows the machine to be steered and the front and
rear section to balance around the machine's longitudinal axis.
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To steer the machine, the machine frame is articulated to the left or right
around the articulation bearing.
The machine frame transfers the forces of the lift arms to the axles.
The frame carries all the most important components of the machine, such
as the engine and the cab.

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Machine frame

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 Service manual Machine frame and ballast weight
Articulation bearing

13.2 Articulation bearing

Layout
The articulation bearing is fitted between the front and rear sections.

Articulation bearing
1 Front section 2 Rear section 3 Articulation bearing

Main components of the articulation bearing

1 Pressure flange 6 Swivel bearing
2 Cylinder screw 7 Cone tension element
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3 Bushing 8 Shaft seal ring

4 Bearing cover 9 Cylinder screw
5 Shims 10 Bearing pin

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Articulation bearing

Oscillating bearing

1 Hex bolt 9 Disc

2 Disc 10 Hex nut
3 Beam 11 Hex nut
4 Locking pin 12 Clamp plate
5 T-piece 13 Rubber buffer
6 Screw 14 Hex bolt
7 Metal-elastic block 15 Rear section
8 Bearing fork

Function description
The articulation bearing connects the front and rear sections.
It makes the following functions possible:
– Steering the machine by articulating the machine frame to the left or right.
– Balancing the machine by turning the front and rear sections along the
longitudinal axis of the machine.

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Articulation lock

13.3 Articulation lock

Layout

Articulation lock
1 Locking bar 2 Linch pin

Function description

Basic function
The articulation lock arrests the articulated joint of the machine. This means
the steering is blocked, for example when transporting the machine.

Engage the articulation lock

– Insert the locking bar.

– Fasten the locking bar 1 in the bottom position using the linch pin 2.

Releasing the articulation lock

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– Pull out the linch pin 2.

– Lift up the locking bar 1 and fix it in the top position using the linch pin.

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Articulation lock

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 Service manual Machine frame and ballast weight
Ballast weight

13.4 Ballast weight

(ID 8921259, 8921260, 8921277)

Technical data
See section 2.1

Layout
The ballast weight consist of two parts. They are bolted on the left and right
sides on the back of the rear section.

Ballast weight layout

1 Left/right ballast weight

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Ballast weight

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 14 Central lubrification system
14.0

Chapter contents
14 Central lubrification system ............................................... 14.0-1

14.1 Manual central lubrication ............................................................. 14.1-1

14.2 LIEBHERR automatic central lubrication system (optional) ......... 14.2-1

14.2.1 Central lubrication pump EP-1 ........................................... 14.2-4
14.2.2 Progressive distributor MX-F .............................................. 14.2-5
14.2.3 Central lubrication pump controller EP-1 and operation .... 14.2-8
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 Service Manual Central lubrification system
Manual central lubrication

14.1 Manual central lubrication

Design

Lubricating rail on the rear section

1 Rear steering cylinder lubrication 3 Front oscillating bearing 5 Front axle oscillating bearing
connection lubrication point lubrication connection
2 Rear steering cylinder 4 Rear oscillating bearing 6 Rear axle oscillating bearing
lubrication point lubrication point lubrication connection

Function description
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Basic function
The central lubricating rail is for lubricating points which are difficult
to access.

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Manual central lubrication

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 Service Manual Central lubrification system
Automatic central lubrication system

14.2 LIEBHERR automatic central

lubrication system (optional)
Design

Components of the central lubrication system

1 Central lubrication pump 8 Grease fitting for manual

2 Rapid fill coupling lubrication
3 Agitator 9 Main supply line
4 Transparent reservoir 10 Main progressive distributor MX-F
5 Level sensor connection 11 Secondary progressive distributor
6 Grease fitting 12 Lubricant supply lines
7 Pressure relief valve 13 Lubrication points
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The central lubrication pump is located under the left cab access.
The distributors are arranged centrally to the respective lubrication points.
The central lubrication pump and the progressive distributors provide the
specified quantity of grease to the connected lubrication points.

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Overview of lubrication points Z-kinematics

1 Central lubrication pump 3 Main progressive distributor 5 6x secondary

2 Inductive switch for 4 6x secondary progressive distributor
lubrication cycles progressive distributor

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 Service Manual Central lubrification system
Automatic central lubrication system

Overview of lubrication points P-kinematics

1 Central lubrication pump 4 5x secondary 6 6x secondary

2 Main progressive distributor progressive distributor progressive distributor
3 Inductive switch for 5 3x secondary
lubrication cycles progressive distributor

Function description

Progressive lubrication
The automatic central lubrication system is a progressive system. It
lubricates progressively, i.e. all lubricating points in succession.
The main distributor is fitted with an inductive switch, which signals the
lubrication cycles to the Master controller - UC3
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Overall system
The electrically powered central lubrication pump pumps the grease to the
main progressive distributor, which distributes it to the secondary progres-
sive distributors. The secondary progressive distributors pump the grease to
the lubrication points. The Master controller - UC3 control the lubrications
cycles and pauses of the central lubrication pump.

Safety function
– The pressure relief valve on the central lubrication pump monitors lubri-
cation. If a lubrication point receives no grease from the distributor, the
progressive distributor is blocked. The pressure in the central lubricating
system increases. If the pressure rises above the permitted limit, grease

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Automatic central lubrication system

escapes from the pressure relief valve. During this time, there are no
impulses (lubrication cycles) for the Master controller - UC3.
– If the lubrication cycles are not performed in a specified time, the Master
controller - UC3 switch off the lubrication system. The driver is notified by
the flashing LEDs on the central lubrication button and a service code.

14.2.1 Central lubrication pump EP-1

Technical data
See section 2.1

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Central lubrication pump EP-1

1 DC motor 7 Strainer
2 Pump housing 8 Transfer piston
3 Cam 9 Check valve
4 Level sensor (inductive) 10 Pressure relief valve
5 Transparent reservoir 11 Pressure ring
6 Agitator

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Automatic central lubrication system

Function description

Pump action
A DC motor 1 continually drives the cam 3 with a pressure ring 11.
The cam raises and lowers the transfer piston 8. This provides the suction and
pumping action of the transfer piston. The built-in check valve 9 prevents the
pumped medium from being sucked back out of the main supply line.
The agitator 6 pushes the lubricant out of the transparent reservoir 5 through
a strainer 7 to the pump housing 2. This eliminates air bubbles in the grease.

Checking the grease quantity

When all three LEDs on the central lubrication button light up, there is
insufficient grease. This condition is reported by the level sensor.
The reservoir is a transparent cylinder, in which the rubber stripper on the
agitator can be seen. This allows you to check the grease level.

Filling
The reservoir can be filled via the tapered grease fitting using a standard
lubrication pump or via the rapid fill coupling using the grease gun.

Safety function
The pressure relief valve 10, which is set to 280 bar, prevents excess pressure
in the line system.

14.2.2 Progressive distributor MX-F

Technical data
See section 2.1

Design
The progressive distributors are manufactured with variable discs. The
advantage of this is that the distributors can be extended or reduced according
to the number of lubrication points.
The flow per stroke depends on the piston diameter. The progressive
distributor needs at least three pumping elements in order to work properly.
The distributors must always be installed horizontally.
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Automatic central lubrication system

Main progressive distributor

1 Start element 4 Middle element
2 Middle element with actuator 5 Inductive switch for
piston and inductive switch for lubrication cycles
lubrication cycles 6 Inductive switch LED
3 Inductive switch housing 7 End element

Secondary progressive distributor

1 Start element (without piston) 4 Connecting line

2 Middle element with 5 Dummy plug
flow engraved 6 End element
3 Screw connection
Linkage with gears connects the elements to the distributor blocks.
O-rings are installed as seals between the elements.
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Automatic central lubrication system

Function description

Basic function

Piston positions of the progressive distributor MX-F

A - C Piston positions I - III Pistons 1 - 6 Grease duct outlets
The progressive distributors act hydraulically and distribute the lubricant in
series to each outlet.
The lubricant flows via the entrance of the distributor through all the
distributor discs to the piston I (piston position A). The piston pushes to the
left and presses the lubricant out of the left pressure chamber of the piston
to the outlet 1 (piston position B). Pistons II and III then pump the lubricant to
the outlets 2 and 3.
After piston III moves, the lubricant flows to the left side of piston I (piston
position C). The piston I pushes to the right and presses the lubricant out of
the right pressure chamber of the piston to the outlet 4.
Pistons II and III then pump the lubricant to the outlets 5 and 6.
After piston II moves, the lubricant again flows to the right side of piston I
(piston position A) and a new cycle of the progressive distributor begins.
This function is repeated as long as lubricant is pumped to the distributor.
Malfunctions
Malfunctions can occur in the lubricant lines or inside the distributor.
Malfunctions include:
– Clogged lubricant lines
– Twisted bearing casings
These prevent the flow of lubricant, and thus block the distributors.
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When the distributor is blocked, lubricant flows out of the pressure relief
valve on the central lubrication pump.

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Automatic central lubrication system

14.2.3 Central lubrication pump controller EP-1 and operation

Technical data
See section 2.1

Function description

Basic function
The central lubrication pump EP-1 is regulated by the Master controller - UC3.
It is operated via CAN bus from the control unit to the Master controller -
UC3.
The feedback from the grease level sensor 2 and the lubrication cycle
inductive switch 9 comes via the Master controller - UC3.

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Central lubrication system control

1 Central lubrication pump 5 Master controller - UC3
2 Grease level sensor 6 Power supply from fuse F73
3 Central lubrication button 7 Inductive switch for lubrica-
and LEDs tion cycles
4 CAN bus connections
If the ignition is switched off or the parking brake is engaged, the Master
controller - UC3 stop lubrication. The remaining cycles are stored and after the
engine is started or the parking brake released, lubrication is continued at the
point where it was interrupted.

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Automatic central lubrication system

Non-scheduled lubrication intensity (cycle settings)

The following settings can be made with the central lubrication button:
– Press briefly for less than 2 seconds: non-schedule lubrication
– Hold down for more than 2 seconds: set lubrication intensity 75%,
100%, 125%
The LEDs show the following states when the ignition is switched on.
– LED 1 - 75% lubrication (light-duty operation)
– LED 2 - 100% lubrication (medium-duty operation)
– LED 3 - 125% lubrication (heavy-duty operation)
– LEDs 1 + 2 + 3 flash & service code – system fault
– LEDs 1 + 2 + 3 light up – grease has reached minimum level
– LED 1 or 2 or 3 flashes – indicates lubrication intensity during operation:
75 / 100 / 125%

Adjusting the lubrication intensity

Press the central lubrication button for more than 2 seconds to switch to
setting mode.
With each further press of the button, the mode is switch up one level; after
the highest mode it returns to the first. 75% - 100% - 125% - 75%.....

Non-scheduled lubrication
Using the central lubrication system button, you can perform non-scheduled
lubrication at any time when the ignition is switched on, even when the
parking brake is engaged (with the set lubrication and cycle time).
The pump motor switches off after the set number of cycles and the set
cycle time begins.

Lubrication sequences
A Lubrication (cycles) 2 Medium-duty lubrication 3 Heavy-duty lubrication sequence
1 Light-duty lubrication sequence sequence
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Fault in the system (cycle error)

The cycles are checked with a set time.
Each completed cycle resets this time. If there is no cycle within the set time, the
system is stopped – LEDs 1, 2 and 3 flash and the service code E2017 appears.

Grease reservoir level too low

The LEDs in the central lubrication button light up if the grease supply in the
reservoir falls too low.
The all three LEDs stay on until the grease is topped up.
The driver can also check the grease level by looking at the reservoir.

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Automatic central lubrication system

Filling the reservoir

The tapered grease fitting 3 can be used to fill the reservoir.
For fast filling, the rapid filler pump 1 on coupling 2 can be used.

Fast filling with cartridge

1 Rapid filler pump 2 Quick coupling
3 Grease fitting
Grease specifications: see the section on lubricants and fuels in the mainte-
nance chapter.

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 15 Coverings and access
15.0

Chapter contents
15 Coverings and access ....................................................... 15.0-1

15.1 Coverings ...................................................................................... 15.1-1

15.2 Cab access ................................................................................... 15.2-1

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Coverings and access Service manual

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 Service manual Coverings and access
Covering

15.1 Coverings
Layout

Covering components

1 Plastic cover 3 Cooler hood 5 Engine hood

2 Front left and right mud guards 4 Rear left and right mud guards
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Coverings and access Service manual
Covering

Front mud guard, plastic cover

1 Front mud guard 2 Front section
3 Plastic cover
The plastic cover 3 is fastened with four bolts to the front of the front section
2. The two front mud guards 1 are each fastened with two bolts to the front
section 2.
The two rear mud guards 1 and 3 are each fastened with two bolts to the
rear section 2.

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Rear mud guards, cooler hood and engine hood

1 Tank cover 4 Engine hood

2 Rear right mud guard 5 Rear section
3 Cooler hood 6 Rear left mud guard
The engine hood 4 can be opened using gas-filled springs. The two rear
mud guards 2 and 6 are each fastened with four bolts to the rear section 5.
The cooler hood 3 can also be opened using gas-filled springs.

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 Service manual Coverings and access
Cab access

15.2 Cab access

Only get on and off the machine using the access aids provided.

Layout

Cab access

1 Cab access 3 Cab access handrail

2 Step 4 Wheel box handrail
The cab access 1 is connected to the rear left mudguard and fastened to the
rear section with five bolts. The bottom rung is connected by two rubber
brackets to the access.

Function description
The left cab access is for entering and leaving the cab and for accessing
certain maintenance points.
The right cab access is an emergency exit and for accessing certain
maintenance points.
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Coverings and access Service manual
Cab access

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 16 Cab, heating, air conditioning
16.0

Chapter contents
16 Cab, heating, air conditioning............................................ 16.0-1

16.1 Cab, heating and air-conditioning ................................................. 16.1-1

16.2 Instrument panel ........................................................................... 16.2-1

16.2.1 Display unit A13 .................................................................. 16.2-2
16.2.2 Control unit A11 .................................................................. 16.2-4
16.2.3 Switch functions .................................................................. 16.2-7
16.2.4 LIEBHERR control lever ..................................................... 16.2-8

16.3 Heating, ventilation, air conditioning ............................................. 16.3-1

16.3.1 Heating/air conditioning unit ............................................... 16.3-2
16.3.2 Blower ................................................................................. 16.3-3

16.4 Air conditioning system (optional) ................................................. 16.4-1

16.4.1 Air conditioning compressor ............................................... 16.4-4
16.4.2 Condenser .......................................................................... 16.4-5
16.4.3 Dryer collector unit.............................................................. 16.4-6
16.4.4 Pressure switch .................................................................. 16.4-8
16.4.5 Evaporator .......................................................................... 16.4-9
16.4.6 Temperature sensors B26, B26a (anti-icing mechanism) 16.4-10
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 Cab, heating, air conditioning

16.1 Cab, heating and air-conditioning

The cab is a safety cab which has been tested and approved according to the
ROPS/FOPS specifications. It is elastically supported on the rear section.
The cab is equipped with heating and ventilation as standard.
On request, an air conditioning system can be installed as an option.
The cab can be accessed from the left side of the machine via the steps and
the door.
The right window can be used as an exit in emergencies.

Design
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View of driver's cab

1 Radio speaker 10 Steering column 18 Right control panel with
2 Sun visor adjustment lever control units
3 Interior lights with switch 11 Gas pedal with angle sensor 19 Ashtray
4 Interior mirror 12 Adjustable LH control 20 Socket/cigarette lighter
5 Radio compartment lever panel 21 Ignition switch
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6 Heater/ventilation/air- 13 Display unit 22 Adjustable arm rest

conditioning outlet nozzles 14 LIEBHERR control lever 23 Diagnostic plug
(9 in total) 15 Panel adjustment pedal 24 Fuse box
7 Inch/brake pedal with 16 Window opener lever 25 Glove compartment
angle sensor 17 Control lever fitting for optional 26 Driver’s seat
8 Steering column switch working functions 27 Glove compartment
9 Adjustable steering column with
steering wheel

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Driver's cab, outside view from right

1 Right side of cab 4 Air conditioning system

2 Fresh air filter expansion valve *
3 Heating and 5 Heater water connections
air-conditioning housing 6 Valve and water valve
control motors

Function description

ROPS/FOPS strength
The driver's cab complies with the ROPS/FOPS regulations.
ROPS (Roll Over Protective Structure) takes into account mechanical rigidity
in the event of the machine rolling over.
FOPS (Falling Object Protective Structure) governs the rigidity of the cab
when object fall onto it.
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 Cab, heating, air conditioning
Instrument panel

16.2 Instrument panel

All important operating, display and control elements are arranged ergono-
mically on the instrument panel.
The display unit which indicates the operating condition of the wheel loader,
is located in the upper field of view, slightly to the right of centre.
The LH control lever is in a separate console, which can be adjusted back
and forth using a foot pedal.
The controls are arranged in the right-hand control panel.
The fuses are on the left behind the driver’s seat.

Design

Instrument panel
1 Display unit A11 4 Main control unit CAN bus A11
2 LH control lever 5 Switch console 2
3 Switch console 1 6 Switch console 3
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Instrument panel

16.2.1 Display unit A13

The display unit A13 is on the front right A pillar.

Display unit A13

1 Travel speed display P6 19 Air filter contamination symbol field H7

2 Emergency steering check symbol field H24 20 Preglow monitor symbol field H2
3 Emergency steering symbol field H8 21 Segment display P7 for engine speed, time,
4 Brake system accumulator pressure symbol operating hours, service codes, oil type
field H19 (Software version)
5 Joystick steering symbol field H27 22 Battery charge control symbol field H6
6 Gear oil overheating symbol field H14 23 High beam symbol field H12
(not activated) 24 Direction indicator symbol field H10
7 Forward travel direction symbol field H3 25 Stop symbol field H36
8 Working hydraulics lockout symbol field H5 26 Display H37 for ridge type, current travel range,
9 Reverse travel direction symbol field H9 fan reversal
10 Hydraulic oil overheating symbol field H23 27 Overspeed protection indicator H38
11 Automatic travel range 2-3 symbol field H35 28 Fuel supply symbol field H1
(not activated) 29 Fuel supply display P2
12 Automatic travel range 1-3 symbol field H34 30 Engine overheating and coolant level symbol
13 Automatic travel range 1-2 symbol field H33 field H13
14 Fixed gear 2 symbol field H31 (not activated) 31 Coolant temperature display P3
15 Fixed gear 1 symbol field H30 32 Engine oil pressure symbol field H4
16 Tempomat T symbol field H29 33 Engine oil pressure display P5
17 Neutral position N symbol field H32
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18 Parking brake symbol field H11

Design
The display unit A13 consists of:
– LCD indicators
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– Symbol fields
– Segment displays
The LCD display 21 contains segment displays for:
– Clock
– Service codes
– Engine speed
– Service hours
The LCD display 26 contains segment displays for:

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Instrument panel

– Tractive force adjustment

– Current travel range
Symbol fields for:
– Warning messages
– Travel direction
– Travel ranges
Segment fields for:
– Fuel supply
– Engine oil pressure
– Coolant temperature
– Travel speed
Each symbol field is either red, yellow, green or orange.
The 9-pin plug connector for communication with the central controller
UEC3 A6 is attached to the rear.

Function description

Plug assignment
Connector A13.X1 SUB-D / 9-pin male (communication with central controller UEC3 A6)

1 Weight 6 Unassigned
2 Power supply (F10) 7 Unassigned
3 CAN bus CAN_L 8 Unassigned
4 CAN bus CAN_H 9 Unassigned
5 Unassigned
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Instrument panel

16.2.2 Control unit A11

Control unit A11 is installed between the mechanical switches in the
instrument panel on the right.

Design
Backlit membrane keypads with buttons (function symbol and LEDs)

Control unit A11

1 Control unit A11 - controlled via a CAN bus 10 Blower duct selector button (middle area) S42
2 Parking brake button S17 11 Air conditioning ECO mode button S45
3 Ride control (LFD system) button S16 12 Temperature down button S40
4 Travel range up button S27 13 Decrease fan speed button S34
5 Travel range down button S28 14 Temperature up button S39
(additional function: oil type setting for gear shifting) 15 Increase fan speed button S38
6 Engine speed, clock and service hours button S30 16 Defrost button S47
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(additional function: setting the clock) 17 Fresh/circulated air button S44

7 Display unit brightness control button S31 (additional function: Valve synchronisation for
(additional function: purge mode for fuel system heater/air conditioning)
L538, L542) 18 Air conditioning auto mode button S46
8 Blower duct selector button (footwell) S41 19 Central lubrication system button (optional) S50
9 Blower duct selector button (head area) S43 20 Emergency steering button S10
21 Tempomat button S29
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22 Working hydraulics lockout button S19

Basic function
The control unit operates the various machine functions.
The control unit is connected to the central controller UEC3 A6 via the CAN bus.
The control unit A11 works once the main switch is turned on (terminal 15).

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Instrument panel

Function description
The control unit A11 is connected to the central controller UEC3 A6 via the
CAN bus.
The function control unit A11 works as soon as the ignition is turned on
(terminal 15).
When a button is pressed, a signal is sent via CAN bus to the central
controller UEC3 A6.
The buttons have LEDs, which can signal the following conditions:
– All three LEDs on or off – button with switch function
– All three LEDs only light up when the button is pressed – button with
push function
– The LEDs go on or off individually each time the button is pressed –
button with control function
The functions of each button are described in the operating manual for each
machine: “Operating the control units”.

Function test
When the ignition is turned on, all the LEDs light up for the duration of
the test.
If there is a fault or failure in a module (CAN bus module) the LEDs remain lit
after the test (safety-critical condition). In this case, the system cannot be
started up.

Special functions - bleeding the fuel system L538, L542

(secondary circuit)
The “display unit brightnes control” button is used to bleed the additional fuel
system (secondary circuit).
Once the ignition is turned on, the purge mode can be activated by pressing
the button.
It is active once the three LEDs begin to blink.
The mode is automatically deactivated once a certain engine speed
is reached.
Display unit brightness control

Special functions - Hydrayulic oil adjustment

The “travel range down” button can be used to activate this mode. With the
ignition turned on, press the button until the segment display shows P7 “X Hyd”.
The “display unit brightness control” button can be used to change the
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hydraulic oil.
The setting is also required for the quick-filling phase of the gear switch
coupling.
The following conditions are possible, and will be shown in the segment
Travel range selection Brightness
control
display P7 of the display unit:
– 1 valid for hydraulic oil - Liebherr Hydraulic Basic 68 (20W20)
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– 2 valid for hydraulic oil - Liebherr Hydraulic Plus 15 - 46

– 3 valid for hydraulic oil - Liebherr Hydraulic HVI (10W40)
– 4 valid for hydraulic oil - Liebherr Hydraulic Basic 100 (SAE 30)
Segment display P7

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Instrument panel

Special features - setting date and time

The “display mode” and “display unit brightness control” buttons can be used
to set the date and time.
With the ignition on, press the display mode button to switch to the clock.
Press the display mode button to activate the mode. Press again to switch
through the menu.
Keep pressing the display unit brightness control button to increase the
selected position.
Mode Brightness control

Segment display P7
Speacial functions - valve synchronisation for heater/air
conditioning
Use the “circulated air” button to synchronise the valves.
Synchronisation is activated when you press the “circulated air” button with
the ignition on. Activation is indicated by the three LEDs flashing.
All installed servo motors move to the minimum and maximum positions.
The end positions are detected by means of the current consumption.
The built-in potentiometer is used to store the end positions in the heating/air
Recirculated air conditioning controller (A21). These values are used to regulate the servo
motors during normal operation.

Plug assignment
Connector A11/X1 Deutsch / 12-pin male (communication with UEC3 master controller A6),

1 Power supply F71 7 CAN bus CAN_High

2 Weight 8 CAN bus CAN_Low
3 CAN bus CAN_High 9 Terminating resistor
4 CAN bus CAN_Low 10 Unassigned
5 Unassigned 11 Unassigned
6 Unassigned 12 Unassigned

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Instrument panel

16.2.3 Switch functions

The switches are installed between the control unit A11 in the instrument
panel on the right.

Design
Backlit switches with touch and switch functions and integrated
function symbol.

Switch layout

1 Hazard warning system switch S4 7 * Audible back-up alarm deactivation switch

2 Profile lights and low beam switch S6 S43 (optional)
3 Bucket return-to-dig switch S14 8 * Lift kick-out switch S22 (optional)
4 Rear windshield wiper and washer system 8 * Comfort control switch S45 (optional)
switch S13 9 Heated rear window switch S46
5 Flashing beacon switch S9 (optional) 10 Float position switch S18
6 Quick change device switch S23 (optional) 11 Rear working floodlight switch S8 (optional)
7 * Reversible fan drive button S203 (optional) 12 Front working floodlight switch S7
* The switch position is assigned several times. When options are fitted with
the same switch assignment, a free position is used for the switch.
All listed switch options are already installed.
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Instrument panel

16.2.4 LIEBHERR control lever

The LIEBHERR (LH) control lever contains the switch for selecting the
travel direction.
Buttons for additional functions can be fitted on the top.
The LH control lever also controls the movements of the working attachment
via the lift and tilt cylinders.

Design

Control lever with switch

1 LH control lever 4 Additional equipment button

2 Option button 5 Travel direction switch
3 Additional equipment button

Function description

Basic function
When the electrical system is switched on, the automatic travel range A1-3
is selected and the travel drive is set to neutral N.
Both are indicated by the LC display (H34) and the symbol field N (H32).
The travel direction switch 5 must be moved to neutral N after the parking
brake is released before a travel direction can be preselected.

Switching travel direction

You can switch travel direction using the button 5 on the LH control lever.
The solenoid valves for forward and reverse travel direction can only be acti-
vated after the parking brake is released.
The travel direction is shifted to neutral by closing the parking brake or
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shifting the travel direction switch to neutral N (middle position).

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Instrument panel

Additional function buttons (optional)

If an option is installed or retrofitted, the buttons 3 and 4 can be used to
operate it.

Plug assignment
Connector S2 12-pin Deutsch

1 Power supply (+) F15 6 Weight

2 Reverse travel direction 7 Option button switching signal
constant signal 8 Option button power supply F9
3 Reverse travel direction 9 Additional equipment power
switching signal supply F9
4 Forward travel direction 10 Additional equipment
switching signal switching signal
5 Forward travel direction 11 Additional equipment power
constant signal supply (+) F9
12 Additional equipment
switching signal
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 Cab, heating, air conditioning
Heating, ventilation, air conditioning

16.3 Heating, ventilation, air conditioning

Technical data
See section 2.1
The driver's cab is equipped with a hot water heater and an air conditio-
ning system.
Optionally, an air conditioning system or automatic air conditioning is available.
The intake air is filtered through three serviceable dry filter cartridges and
directed to the adjustable air flow nozzles in the cab through the
heat exchanger.

Design
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Heater

1 Fresh air filter service cover 6 Heater/fan unit

2 Heater/fresh air fan covering 7 Driver's cab
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3 Fresh air filter (pre-filter) 8 Recirculation filter

4 Fresh air intake slots 9 Circulated air filter cover
5 Fresh air filter (fine filter)

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Heating, ventilation, air conditioning

16.3.1 Heating/air conditioning unit

The heating/air conditioning unit is housed in the right side of the cab.

Design

Heating/air conditioning unit layout

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1 Servo motor for footwell nozzles 6 Air conditioning evaporator 11 Water valve servo motor
2 Servo motor for middle nozzles (only available with air 12 Water valve
(only available with air conditioning system) 13 Head area
conditioning system) 7 Heating/air conditioning blower ventilation connection
3 Servo motor for 8 Heating/air conditioning control 14 Footwell ventilation connection
windscreen/head area nozzles electronics (A21) 15 Middle ventilation connection
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4 Flap control housing 9 Fresh/recirculated air flap 16 Front and side window
5 Heat exchanger 10 Fresh/recirculated air flap ventilation connection
servo motor

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Heating, ventilation, air conditioning

Function description

How the heater works

The heating and air conditioning control electronics (A21) are connected via
CAN bus to the heating/air conditioning control unit.
The heat exchanger is supplied with hot water from the engine cooling system.
It is regulated using an electrically controlled water valve.
The water valve controls the heating power.
The intake air can be controlled using the fresh/recirculated air flap.
The airflow is regulated using the various blower speed levels on the heating/
air conditioning system.
* When the air conditioning is in automatic mode, the speed levels are
automatically controlled by the heating/air conditioning control electronics.

Flap control
The driver can set the flaps manually as required, using the heating/air con-
ditioning control unit.
* When the air conditioning is in automatic mode, the flaps are automatically
controlled by the heating/air conditioning control electronics.

16.3.2 Blower
The blower is part of the heating and ventilation unit.

Design
The blower is a 6-speed radial fan for ventilation, heating and air condi-
tioning in the cab.

Function description

Basic function
The blower sucks air (axial intake) 4 through the fresh/recirculated air
duct and blows it out of the radial outlet 5 to the evaporator and through the
heat exchanger.
The air flow is regulated by changing the blower speed.
It is operated and regulated using the air conditioning control unit. At level 0
the blower is switched off. Level 6 is maximum air flow.
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Air conditioning system

16.4 Air conditioning system (optional)

Technical data
See section 2.1

Design
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Components of the air conditioning system

1 Expansion valve 4 Compressor (with magnetic 7 Condenser

2 Heat exchanger in the coupling Y22) 8 Pressure switch B27
heating/air conditioning unit 5 Intake side filling coupling 9 Dryer collector unit
3 Temperature sensors B26, 6 Discharge side filling coupling
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B26a heat exchanger

(anti-icing mechanism)

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Air conditioning system

Function description

Basic cooling function

Diagram of cooling circuit

1 Air conditioning compressor 8 Heater/air conditioning a Liquid refrigerant, high pressure

2 Magnetic coupling control electronics b Liquid/gaseous refrigerant, high pressure
3 Condenser 9 Temperature sensors c Liquid/gaseous refrigerant, low pressure
4 Fan 10 Condensation tray d Gaseous refrigerant, low pressure
5 Pressure switch 11 Evaporator
6 Dryer collector unit 12 Blower
7 Sight glass 13 Expansion valve
The air conditioning compressor 1 draws in the refrigerant in gas form and
increases its energy level (pressure and thermal energy).
The heat thus generated is transferred to the condenser 3. The heat
dissipation lowers the energy potential.
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The cooled refrigerant liquefies. This change of state further reduces the
energy in it.
The refrigerant, which still has bubbles in it, passes into the dryer collector
unit 6, where it is filtered and dried, and then, with the bubbles removed,
through the rising pipe to the expansion valve 13 on the evaporator.
The liquid, pressurised refrigerant is sprayed through the expansion valve 13
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into the depressurised evaporator 11.

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This allows the refrigerant to expand. The expansion reduces the pressure
energy in the refrigerant and very quickly cools the evaporator.
The evaporator 11 is exposed to hot air from the cab and transfers the
heat to the refrigerant. This thermal exchange cools the cab air and heats
the refrigerant.
The heated refrigerant evaporates and turns to gas. This change of state
requires additional energy from the (warm) evaporator, which further
reduces the temperature.

Temperature regulation
The temperature is regulated by the cyclical activation and deactivation of
the magnetic coupling 2 of the air conditioning compressor during operation,
or by mixing hot air from the heater, as for example in defrost mode.
The frequency of switching is controlled by the temperature sensors in the
evaporator and the program in the heating/air conditioning control elec-
tronics (see the technical data).
The temperature is also regulated at the expansion valve. The pressure and
temperature are recorded at the evaporator outlet and the injection quantity
is precisely metered.
These monitoring elements prevent the evaporator from icing up.

Defrost mode
When the windows are misted up, the cab air must be dried. This is done by
operating the air conditioning and the heater at the same time. The cab air
can absorb more moisture when it is heated. The air flowing past the cool
evaporator releases the moisture in the form of condensation.
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Air conditioning system

16.4.1 Air conditioning compressor

Technical data
See section 2.1

Design

Sectional view of the compressor

1 Intake connection 5 Swash plate

2 Discharge connection 6 Piston
3 Oil filler plug 7 Outlet valve
4 Magnetic coupling 8 Inlet valve
The air conditioning compressor with its magnetic coupling 4 is attached to
the engine and driven by a V-ribbed belt.
The compressor is equipped with an axial piston rotary group 6, a swash
plate 5 and flap valves. Liebherr/Version 01/07.2007/en/Trainotti Anton

Function description

Basic function
The refrigerant compressor acts as a pump which draws in the gaseous refri-
gerant from the evaporator, compresses it and pumps it to the condenser.
It is bidirectional, which means that the refrigerant compressor can be used
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for both directions of rotation.

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Functions of the compressor oil

There are the main functions of the compressor oil:
– Reducing friction, wear and noise
– Hydrostatic transmission of force to the various components of the air
conditioning compressor
– Dissipating heat
– Increasing density
– Lubricating the drive components (piston, shaft seal, bearing)

Magnetic coupling
The pulley runs freely on the compressor shaft and is permanently driven by
the V-ribbed belt.
The power transmission between the pulley and the compressor shaft is
controlled by a magnetic coupling 4.
This is activated by the temperature switch in the evaporator or the pressure
switch on the dryer collector unit.
By periodic activation of the compressor, the evaporator is kept at a temp-
erature of between +1 °C (uncoupling) and +4 °C (coupling), this preventing
the air conditioning unit from icing up.
If the pressure rises above 24 bar or below 2 bar on the pressure side of the
compressor, it is also uncoupled.

16.4.2 Condenser

Technical data
See section 2.1

Design
The condenser is part of the cooling system.
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Condenser with connections

1 Swivel bearing for cleaning 4 Refrigerant outlet (to dryer)

2 Condenser holder frame 5 Cleaning access cover
3 Refrigerant intake 6 Condenser
(from compressor)

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Function description

Basic function
The forced ventilation condenser directs the heat output of the refrigera-
tion circuit to the ambient air and in the process condenses the
gaseous refrigerant.
When the air conditioning system is switched on, the cooling system fan
speed is automatically increased.

16.4.3 Dryer collector unit

Technical data
See section 2.1

Design
The dryer collector unit is located under the left cab access.
It is connected to the outlet of the condenser and the intake of the evaporator.

Cross section of the dryer filter

1 Sight glass with indicator beads 3 Filter element

2 Rising pipe 4 Dryer granules
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Function description

Basic function
The refrigerant, which is cooled but still has bubbles in it, passes from the
condenser to the dryer collector unit.
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The circulation pressure forces the refrigerant inside through the filter ele-
ment 3 and the dryer granules 4.
The bubbles are removed from the refrigerant and it passes through the
rising pipe 2 to an outlet port connected by a hose to the expansion valve of
the evaporator.

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Sight glass

Sight glass
1 White filling level bead 2 Orange moisture indicator bead
The sight glass is located in the upper third of the dryer collector unit.
The sight glass has the following purposes:
– Checking the refrigerant level during operation
– Checking the moisture content of the refrigerant
– Checking contamination of the refrigerant circuit
Sight glass functions Checking the refrigerant level during operation
– Once the system has been running for about five minutes (to allow the
refrigerant to distribute), the white level indicator bead should be near the
top of the sight glass. As the engine speed increases, the level rises
slightly. The refrigerant should flow through the sight glass with no visible
bubbles during operation. If gas bubbles appear, it is normally due to
insufficient refrigerant in the system.
Sometimes the refrigerant is not sufficiently condensed due to insufficient
heat extraction at the condenser (contamination), which can result in
bubbles in the sight glass.
Checking the moisture content of the refrigerant
– There is a small orange indicator bead 2 in the sight glass. If it turns light
grey, there is too much moisture in the system.
In this case the system must be completely drained and evacuated. The oil
in the compressor must also be replaced. The entire dryer collector unit must
be replaced too.
Checking contamination of the refrigerant circuit
– A sudden change of colour in the sight glass indicates a problem in the
system. A change in colour is normally caused by overheating in the
refrigerant circuit. This is normally due to internal or external
contamination.
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Air conditioning system

16.4.4 Pressure switch

(ID 10014164)

Technical data
See section 2.1

Design

Dryer

1 Pressure switch 2 Dryer collector unit

The pressure switch is attached to the dryer collector unit in the air conditio-
ning circuit.

Function description

Basic function
The pressure switch monitors the pressure in the cooling circuit. It deactivates
the magnetic coupling and therefore the compressor if the pressure is too low
or too high.
This prevents the compressor from running dry if there is too little refrigerant
(insufficient pressure).
Deactivation is also necessary when the pressure is too high. This prevents
damage to components in the system.
Excess pressure may be caused by:
– Too much refrigerant in the circuit
– Excess temperature due to a dirty condenser or defective fan control
– The filter in the dryer collector unit may be very dirty
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– The expansion valve may be iced up (too much moisture in the

refrigerant) or dirty (blocked).
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Air conditioning system

16.4.5 Evaporator

Technical data
See section 2.1

Design

Evaporator with expansion valve

1 Hose fitting holder 4 Evaporator

2 Expansion valve 5 Temperature sensors B26, B26a
3 Air conditioning system (anti-icing mechanism)
sealing rings
The evaporator is fitted in the heater/air conditioner and is part of the refrige-
rant circuit. The heating/air conditioning unit is housed in the right side of
the cab.

Function description

Basic function
The evaporator is a heat exchanger which cools the cab air.
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The pressurised refrigerant, which is cooled and liquefied by the condenser,

is sprayed through the expansion valve 2 into the evaporator 4, where there
is a vacuum.
The drop in pressure allows the refrigerant to expand. The expansion causes
a great drop in the thermal energy. The refrigerant is cooled.
The thermal energy taken from the cab air via the fins on the evaporator 4
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evaporates the refrigerant.

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16.4.6 Temperature sensors B26, B26a (anti-icing mechanism)

(ID 10412227)

Technical data
See section 2.1

Design
The sensor element of the temperature sensor consists of an NTC thermistor
which is connected to the bracket housing by heat-conducting paste.

Function description
The sensor is a temperature sensor with an NTC characteristic.
This means the resistance in the sensor falls as the temperature increases.
The resistance curve of the temperature sensor is not linear.

80000

70000

60000
Temperature sensor B26
50000

40000

30000

20000

10000

0
-20 -10 0 10 20 30 40 50 60

°C

Temperature sensor resistance curve

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 17 Lift arms and quick-change
device
17.0

Chapter contents
17 Lift arms and quick-change device .................................... 17.0-1

17.1 Lift arms with Z kinematics ........................................................... 17.1-1

17.1.1 Bucket bearing.................................................................... 17.1-3

17.2 Lift arms with P kinematics ........................................................... 17.2-1

17.3 Hydraulic quick-change device for Z lift arms .............................. 17.3-1

17.4 Hydraulic quick-change device for P lift arms.............................. 17.4-1

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 Service manual Lift arms and quick-change device
Lift arms with Z kinematics

17.1 Lift arms with Z kinematics

Technical data
See section 2.1

Layout

Main components of the Z lift arms

1 Connecting link 4 Bucket return-to-dig 7 Lift cylinder

2 Linkage proximity switch 8 Bucket stops
3 Contact face for linkage 5 Tilt cylinder 9 Bucket bearing
6 Bucket arm

The lift arms are fitted on the front section of the machine. The lift arms are
designed with Z-bar kinematics. This means that the tilt cylinder, linkage and
connecting link form a Z shape. The Z shape can be seen from the right side.
Parallel load movement is not guaranteed with lift arms with Z-kinematics.
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The Z lift arms can be equipped with a hydraulic quick-change device (optional).
Two lift cylinders and a tilt cylinder are attached to the lift arms.
The lift arms are bolted to the front section via the bucket arm bearings and
Z kinematics the cylinder bearings on the base of the cylinder.
The bearing points on the lift arms have seals to protect them against dirt
and corrosion.
The lift cylinders are mounted at the piston rod end on the bucket arm and at
the cylinder base end on the front section.
The tilt cylinder is mounted at the piston rod end on the linkage and at the
cylinder base end on the front section.
The mechanical bucket return-to-dig device is mounted on the tilt cylinder.

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Lift arms with Z kinematics

Function description

Basic function
The lift arms bear and move the attached equipment or implement.
Movements of the bucket arm

Bucket arm movement

The bucket arm is raised or lowered by extending or retracting the
lift cylinders.
You can find details on this in the section on the working hydraulics.
Movements of the
working attachment

Bucket movement
The bucket is tilted in or out by extending or retracting the tilt cylinder.
You can find details on this in the section on the working hydraulics.
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Lift arms with Z kinematics

17.1.1 Bucket bearing

Layout

Main components of the bucket bearing

1 Bucket arm 4 Bearing pin retainer 6 Radial seal

2 Grease fitting 5 Bearing pin 7 Bearing bushing
3 Bucket bearing plate
The bearings at the bucket coupling points have radial seals 6.
In addition, the bearings on the bucket arm 1 to the front section, as well as
for the lift cylinders and on the connecting link, have radial seals.
For each bearing borehole there is a lubrication duct from the grease fitting 2
to the lubricating groove of the bearing bushing 7.

Function description
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Bearing seal
The bearing seal protects the bearing from penetration of dirt, water and
other aggressive substances.
Penetration causes wear and corrosion of the bearing pin, the bearing faces
and borehole.

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Lift arms with Z kinematics

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Lift arms with P kinematics

17.2 Lift arms with P kinematics

Technical data
See section 2.1

Layout

The lift arms are fitted on the front section of the machine.

1 Hydraulic quick-change device 4 Bucket arm 7 Connecting link

2 Front linkage 5 Tilt cylinder 8 Rear linkage
3 Front connecting link 6 Automatic bucket return-to-dig 9 Lift cylinder
function 10 Bucket stops
The P lift arms are designed with parallel kinematics.
This means that the tilt cylinder, front and rear linkage, connecting link and
bucket arm form a parallelogram.
The parallel kinematics permit parallel guidance of the load over the entire
lifting range during lifting or lowering, for example with a forklift.
The P lift arms are equipped with a hydraulic quick-change device. The
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hydraulic quick-change device is standard equipment.

Two lift cylinders and two tilt cylinders are attached to the lift arms.
P kinematics The lift arms are bolted to the front section via the bucket arm bearings,
cylinder bearings on the base of the cylinder and the connecting links on
the rear.
The bearing points on the lift arms have seals to protect them against dirt
and corrosion.
The lift cylinders are mounted at the piston rod end on the bucket arm and at
the cylinder base end on the front section.
The tilt cylinders are mounted at the piston rod end on the front linkage and
at the cylinder base end on the rear linkage.
The automatic bucket return-to-dig device is mounted on the left tilt cylinder.

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Lift arms with P kinematics

Function description

Basic function
The lift arms bear and move the attached equipment or implement.
Movements of the bucket arm

Bucket arm movement

The bucket arm is raised or lowered by extending or retracting the lift cylinders.
You can find details on this in the section on the working hydraulics.
Movements of the
working attachment

Bucket movement
The bucket is tilted in or out by extending or retracting the tilt cylinder.
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 Service manual Lift arms and quick-change device
Hydraulic quick-change device for Z lift arms

17.3 Hydraulic quick-change device for

Z lift arms
Technical data
See section 2.1

Layout

Main components of the quick-change device

1 Hydraulic quick-change device 4 Hydraulic lines 7 Mechanical indicator

2 Grease fitting 5 Hydraulic cylinder 8 Cover
3 Left locking pin 6 Right locking pin

The quick-change device is fitted to the lift arms of the machine. It is used for
quickly changing the various attachments on the lift arms.
The quick-change device also has brackets for attaching and holding the
working attachment.
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The hydraulic lines 4 lead to the hydraulic cylinder 5 via bulkhead fittings.
The hydraulic cylinder and the locking pins are fitted in a bracket and
protected from dust and damage by a cover 8.

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Hydraulic quick-change device for Z lift arms

Function description
The quick-change device is activated and deactivated using the quick-
change device switch on the control console in the side cover.
The quick-change device is operated using the LH control lever.
The working hydraulics pump supplies the hydraulic cylinder of the quick-
change device with oil directly via a solenoid valve and hydraulic hoses.
When hydraulic pressure acts on the base end of the cylinder piston, the
locking pins are extended.
When hydraulic pressure acts on the rod end of the cylinder piston, the
locking pins are retracted.

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 Service manual Lift arms and quick-change device
Hydraulic quick-change device for P lift arms.

17.4 Hydraulic quick-change device for

P lift arms
Technical data
See section 2.1

Layout

Main components of the quick-change device

1 Hydraulic quick-change device 4 Hydraulic lines 7 Right locking pin

2 Grease fitting 5 Hydraulic cylinder 8 Cover
3 Left locking pin 6 Mechanical indicator

The hydraulic quick-change device is standard on machines with P lift arms.

The quick-change device is fitted to the lift arms of the machine.
It is used for quickly changing the various attachments on the lift arms.
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Quick-change device version:

– Combined electrohydraulic version
Electric activation and deactivation using switch.
Hydraulic operation using the additional control lever.
– Mechanical locking indicator of the quick-change device.
You can find detailed operating instructions in the operating manual.
The quick-change device has brackets for attaching and holding the
working attachment.
The hydraulic lines 4 lead to the hydraulic cylinder 5 via bulkhead fittings.
The hydraulic cylinder and the locking pins are fitted in a bracket and
protected from dust and damage by a cover 8.

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Hydraulic quick-change device for P lift arms.

Function description
The quick-change device is activated and deactivated using the quick-
change device switch on the control console in the side cover.
The quick-change device is operated using the LH control lever.
The working hydraulics pump supplies the hydraulic cylinder of the quick-
change device with oil directly via a solenoid valve and hydraulic hoses.
When hydraulic pressure acts on the base end of the cylinder piston, the
locking pins are extended.
When hydraulic pressure acts on the rod end of the cylinder piston, the
locking pins are retracted.

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 18 Equipment and accessories
18.0

Chapter contents
18 Equipment and accessories .............................................. 18.0-1

18.1 Loading bucket ............................................................................. 18.1-1

18.2 Forklift ........................................................................................... 18.2-1

18.3 Connection sizes .......................................................................... 18.3-1

18.3.1 Bucket – direct attachment ................................................. 18.3-2
18.3.2 Bucket – quick-change device............................................ 18.3-3
18.3.3 Dimensions - Z kinematics, direct attachment ................... 18.3-4
18.3.4 Dimensions - Z kinematics, quick-change device
attachment .......................................................................... 18.3-5
18.3.5 Dimensions - P kinematics ................................................. 18.3-6
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 Service manual Lift arms and quick-change device
Loading Bucket

18.1 Loading bucket

Technical data
See section 2.1

The loading bucket is one of many different attachments that can be fitted to
the lift arms.
The bucket is normally fitted directly to the lift arms. If the lift arms are fitted
with an optional quick-change device, the bucket is attached to that.
The following section describes the loading bucket with teeth.

Layout
The bottom cutting edge varies according to the application.
The various designs include:
– Welded tooth holder with plug-in teeth
– Four-section, reversible undercut blade

Bucket with teeth

1 Tooth 3 Bottom cutting edge

2 Tooth holder 4 Locking pin
The tooth 1 is plugged into the holder 2 and secured with a crosswise
locking pin 4.
The tooth holder 2 is welded to the bottom cutting edge 3.
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Loading Bucket

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 Service manual Lift arms and quick-change device
Forklift

18.2 Forklift
Technical data
See section 2.1
The forklift is one of many different attachments that can be fitted to the lift
arms.
The forklift is mounted either directly on the lift arms or onto the quick-
change device.
The following section describes the forklift with adjustable prongs.

Layout
The forklift consists of the fork carrier and adjustable fork prongs.

Forklift
1 Fork carrier 2 Fork prongs
The fork prongs 2 are attached to the fork carrier 1 and are secured against
slipping with the fork lock on the upper fork hook.
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Forklift

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 Service manual Lift arms and quick-change device
Connections sizes

18.3 Connection sizes

General information:
The connection sizes provide information when fitting equipment not
supplied by Liebherr.
This is defined as any equipment not bought from Liebherr.
Note that all genuine Liebherr equipment is optimally designed for used with
the machines.
This means that equipment not supplied by Liebherr can impair the
operation of the wheel loader and the machine cannot be guaranteed to
work in the best manner.
Also, equipment not supplied by Liebherr which is poorly or inadequately
designed may damage the machine. Liebherr accepts no liability for damage
caused by equipment which it does not supply.
When fitting attachments, check that the stability described in EN 474
is maintained.
Furthermore, the maximum axle loads and total weight of the machine
(see the type plate) may not be exceeded.
Equipment not manufactured according to the Liebherr connection sizes
must be inspected and approved by the specialist department at Liebherr.
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Connections sizes

18.3.1 Bucket – direct attachment

Limit stop 1

Limit stop 2

Limit stop 1
(Tilt- in limit stop)
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Limit stop 2
(Tilt-out-limit stop)

This drawing may not be copied, reproduced or made accessible to third

parties without our permission. Violation of this will lead to claims for
compensation and, if deliberate, is punishable by law.
All information in this drawing must be kept confidential.

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Connections sizes

18.3.2 Bucket – quick-change device

Connections on the
quick-change device
20S-M (M30x2)

Hydr. function 2

Hydr. function 1
LBH/Version 01/10.2007/EN/nk/06.02.2013

open
Limit stop

close
This drawing may not be copied, reproduced or made accessible to third
parties without our permission. Violation of this will lead to claims for
compensation and, if deliberate, is punishable by law.
All information in this drawing must be kept confidential.

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Connections sizes

18.3.3 Dimensions - Z kinematics, direct attachment

350 mm wide

ground

LBH/Version 01/10.2007/EN/nk/06.02.2013

ground

This drawing may not be copied, reproduced or made accessible to third

parties without our permission. Violation of this will lead to claims for
compensation and, if deliberate, is punishable by law.
All information in this drawing must be kept confidential.

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Connections sizes

18.3.4 Dimensions - Z kinematics, quick-change device

attachment

350 mm wide

ground
LBH/Version 01/10.2007/EN/nk/06.02.2013

ground

This drawing may not be copied, reproduced or made accessible to third

parties without our permission. Violation of this will lead to claims for
compensation and, if deliberate, is punishable by law.
All information in this drawing must be kept confidential.

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Connections sizes

18.3.5 Dimensions - P kinematics

ground

LBH/Version 01/10.2007/EN/nk/06.02.2013

ground

This drawing may not be copied, reproduced or made accessible to third

parties without our permission. Violation of this will lead to claims for
compensation and, if deliberate, is punishable by law.
All information in this drawing must be kept confidential.

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 19 Service codes and diagnosis
19.0

Chapter contents
19 Service codes and diagnosis............................................. 19.0-1

19.1 Malfunctions .................................................................................. 19.1-1

19.1.1 Service codes indicated on the display unit (A13) ................. 19.1-1
19.1.2 FATAL service code ........................................................... 19.1-3
19.1.3 Critical service code ........................................................... 19.1-3
19.1.4 ERROR service code ......................................................... 19.1-4
19.1.5 WARNING service code ................................................... 19.1-11
19.1.6 INFO service code ............................................................ 19.1-13
19.1.7 UNDEFINIERT service code ............................................ 19.1-14
19.1.8 ERROR Motor service code L524, L528 .......................... 19.1-15
19.1.9 ERROR Motor service code L538, L542 .......................... 19.1-21
19.1.10 WARNING service code L538, L542 ................................ 19.1-47
19.1.11 Audible and visible warning symbols L524 – L528 Stage III19.1-48
19.1.12 Audible and visible warning symbols L538 – L542 Stage III19.1-50
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Service codes and diagnosis Service code

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 Service code Service Codes, Diagnose
Malfunctions

19.1 Malfunctions
Warning and error messages
– Various faults are indicated by the corresponding symbol fields (visually) or
by display instruments on the instrument panel.
– Some warning functions are accompanied by audible warning signals.
Finding and eliminating errors and malfunctions
– Faults can often be traced back to incorrect operation or servicing of
the machine.
Therefore, carefully read the appropriate section of the operating
manual each time a fault occurs.
– Analyse the cause of the fault and correct it immediately.

19.1.1 Service codes indicated on the display unit (A13)

The main electronics (master) monitor many of the machine’s functions. It
monitors for short circuits, cable rupture, external voltage and incorrect input and
output signals. In addition, the main electronics (master) continuously check the
program sequence and communication with the display unit.

Display unit
LBH/Version 01/07.2007/en/lbhhae0/06.02.2013

1 Service code display 2 STOP indicator

If a fault occurs while you are setting up or operating the machine, it is shown on
the display unit and stored in the error memory.

Error indicator

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Service Codes, Diagnose Service code
Malfunctions

Service code display

The service codes are classed in the following groups:
– FATAL: This is a fault which only concerns the master
controller UEC3.
– CRITICAL: This is a fault which only concerns the master
controller UEC3.
– ERROR: This is a fault in the various electrical components or
wiring.
– WARNING: This is information on the condition of the power
supply, CAN bus or diesel engine.
– INFO This is information on modifications made.
– UNDEFINIERT The error cannot be classified as it was transferred to
other modules.
– ERROR Motor This is a fault in the various electrical components
or wiring.
– WARNING Motor This is a fault in the on-board system voltage.
The following must be taken into account:
– The service codes “CRITICAL” and “ERROR” are shown in segment field
1 of the display unit and stored in the service code memory.
– For “ERROR Motor” service codes, a replacement code
(SUMMENFEHLER) is generated on the display unit.
The actual error is not displayed, but is stored in the master
controller UEC3.
A warning tone accompanies all service codes (CRITICAL, ERROR and
SUMMENFEHLER).
– The service codes “FATAL, WARNING, INFO, UNDEFINIERT, ERROR
Motor and WARNING Motor” are not shown in the display unit but are
stored in the service code memory.

Effects of a fault
Every malfunction has a defined effect. This is specified in the “Effect” column of
the service code table.
If errors occur which can damage the machine, the entire machine is shut down.
Neutral travel direction is automatically selected and the machine coasts to a
halt.
Make a note of the service code, as it may disappear from the segment field of
the display unit when the ignition is switched off. LBH/Version 01/07.2007/en/lbhhae0/06.02.2013

Analyse and rectify the fault.

List of abbreviations
LFD Liebherr ride control system
LH-ECU Liebherr engine control unit (A700D)
PWM Pulse width modulated outputs (proportional solenoid)
RAM Memory
REF Reference (comparison)
sec Seconds
t Fault time; how long a fault must be active to trigger a
service code
Ubat Battery power supply (terminal 30)
V Volts

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 Service code Service Codes, Diagnose
Malfunctions

19.1.2 FATAL service code

Function
This is a fault which only concerns the master controller UEC3.

Fatal - This kind of malfunction causes the system to be shut down

Service
Effect Cause Remedy
code
EB000 System cannot be started UEC3: CPU is defective UEC3: replace CPU
UEC3: flash memory, CRC
defect / occasional, constant Reload software or UEC3:
EB001 System cannot be started
fault in hardware, incorrect replace CPU:
software programmed
EB002 System cannot be started UEC3: SRAM fault UEC3: replace CPU
UEC3: watchdog (hardware)
EB003 System cannot be started UEC3: replace CPU
defective
UEC3: error in internal Reload software or UEC3:
EB00D System cannot be started
redundant state memory replace CPU
UEC3: internal controller
Reload software or UEC3:
EB00E System cannot be started voltages VCC/Verve do not
replace CPU
match
UEC3: internal controller voltage Reload software or UEC3:
EB00F System cannot be started
VMS defective replace CPU
System cannot be started or UEC3: defective 2nd shutdown
EB010 UEC3: replace CPU
system shut down stage
System cannot be started or UEC3: fault while comparing
EB011 UEC3: replace CPU
system shut down internal redundant Ad signals

19.1.3 Critical service code

Function
This is a fault which only concerns the master controller UEC3.

Critical - This kind of malfunction is accompanied by a 1-second warning tone

LBH/Version 01/07.2007/en/lbhhae0/06.02.2013

Service
Effect Cause Remedy
code
Travel direction valve: invalid Check solenoid valves Y2, Y3 or
E5050 Driving is not possible
initial forward/reverse conditions UEC3 (A6) control unit
CAN: engine control unit timeout
System cannot be shut down or Check engine control unit or
EA02D (digital module 91), hardware
started CAN wiring
defective, error in CAN wiring
CAN: engine control unit timeout
System cannot be shut down or Check engine control unit or
EA02E (analogue module 92), hardware
started CAN wiring
defective, error in CAN wiring
CAN: engine control unit timeout
System cannot be shut down or Check engine control unit or
EA02F (John Deere), hardware
started CAN wiring
defective, error in CAN wiring
CAN: main keypad timeout
System cannot be shut down or Check main keypad (A11) or
EA030 (A11), hardware defective, fault
started CAN wiring
in CAN wiring

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L542 - 435 / from 17895
Service Codes, Diagnose Service code
Malfunctions

19.1.4 ERROR service code

Function
This is a fault in the various electrical components or wiring.

ERROR - This kind of malfunction is accompanied by a 1-second warning tone

Service
Effect / en Cause / en Remedy MG_III / en
code
Emergency steering pressure
Check emergency steering
E2000 No emergency steering function switch is closed even though the
pressure switch B3 and wiring
engine is not running
Emergency steering pressure
Check emergency steering
E2001 No emergency steering function switch does not switch after the
pressure switch B3 and wiring
engine starts
Emergency steering: Check
failed (B3a emergency steering Check emergency steering
E2002 No emergency steering function
pump check pressure switch did pressure switch B3a and wiring
not switch)
Emergency steering: Emergency
Check emergency steering
E2003 No emergency steering function steering pump pressure switch
pressure switch B3a and wiring
check closed without check
Clean cooling system, check fan
The output of the travel pump is Hydraulic oil temperature: pressure (fan speed), hydraulic
E2013
reduced temperature above 95 °C oil temperature switch B8 (at 20
°C - 1112 )
Brake system accumulator
Check accumulator pressure
pressure symbol field H19 lights
Brake accumulator pressure: switch B19 (switching point 120
E2016 up, after 2 minutes warning beep
pressure too low bar), wiring, accumulator charge
sounds constantly, travel
valve, gear pump
direction cannot be selected
All three LEDs on the control Central lubrication system:
Check distributor, grease lines
E2017 unit switch flash, central electrical fault at output (cable
and lubrication points
lubrication system does not work rupture) of grease line fault
All three LEDs on the control Central lubrication system: filling Top up central lubrication
E204B
unit switch light up level low system
Basket mode: invalid mode input
E205C Check switch wiring
combination.
Basket mode: invalid emergency
E205D Check switch wiring
off input combination.
STOP symbol field H24 flashes, Emergency steering pump check
Emergency steering pump check
E3000 no emergency steering function pressure switch B3a; check
LBH/Version 01/07.2007/en/lbhhae0/06.02.2013

pressure switch: shorted to earth

available wiring or UEC3
STOP symbol field H8 flashes, Emergency steering pump
Emergency steering pump
E3001 no emergency steering function pressure switch B3; check wiring
pressure switch: shorted to earth
available or UEC 3
Brake system accumulator
Brake accumulator pressure
pressure symbol field H19 lights Brake accumulator pressure
E3002 switch B19; check wiring or UEC
up, condition of the service switch: shorted to earth
3
brake cannot be detected
Fuel level cannot be detected - Fuel level sensor: under voltage Fuel level sensor B25; check
E300B
minimum filling level displayed <1 V wiring or UEC 3
Fuel level cannot be detected - Fuel level sensor: over voltage Fuel level sensor B25; check
E300C
minimum filling level displayed >4 V wiring or UEC 3
Hydraulic oil overheating symbol
field H23 lights up, fan running Hydraulic oil temperature Hydraulic oil temperature sensor
E3010
at high speed, driving only sensor: shorted to earth B8; check wiring or UEC 3
possible in fixed gear 1 or 2

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MJFCIFSS L538 - 433 / from 17893
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 Service code Service Codes, Diagnose
Malfunctions

ERROR - This kind of malfunction is accompanied by a 1-second warning tone

Service
Effect / en Cause / en Remedy MG_III / en
code
Hydraulic oil overheating symbol
field H23 lights up, fan running Hydraulic oil temperature Hydraulic oil temperature sensor
E3011
at high speed, driving only sensor: Interruption B8; check wiring or UEC 3
possible in fixed gear 1 or 2
Continued driving is only Power take-off speed sensor: Power take-off speed sensor B1;
E3014
possible in fixed gear 1 shorted to earth check wiring or UEC 3
Continued driving is only Power take-off speed sensor: Power take-off speed sensor B1;
E3015
possible in fixed gear 1 Interruption check wiring or UEC 3
Central lubrication system (filling Central lubrication system (filling
E3024 No central lubrication function level) inductive switch: shorted level) inductive switch B44;
to earth check wiring or UEC 3
Central lubrication system Central lubrication system
Central lubrication system not
E302B (cycles) inductive switch: (cycles) inductive switch B43;
available
shorted to earth check wiring or UEC 3
Variable displacement motor 1 -
Check inductive sensor B1
E303B No output speed available output speed: inductive sensor
(1050 ) or wiring
shorted to supply voltage
Variable displacement motor 2:
Check inductive sensor B2
E3046 inductive sensor shorted to
(1050 ) or wiring
supply voltage
Engine speed: value outside Check inductive sensor B2
E3047 No engine speed available
valid range (1050 ) or wiring
Check inductive sensor B2
E3048 No engine speed available Engine speed: sensor fault (1050 ) wiring or engine control
unit
Check temperature sensor
Charge air temperature: value
E3049 Reduced engine power B707, wiring or engine control
outside valid range
unit
Check temperature sensor
Charge air temperature: sensor
E304A Reduced engine power B707, wiring or engine control
fault
unit
Check temperature sensor
No coolant temperature Coolant temperature: value
E304B B708, wiring or engine control
available outside valid range
unit
Check temperature sensor
No coolant temperature Coolant temperature: sensor
E304C B708, wiring or engine control
available fault
unit
Engine oil pressure: value Check pressure sensor B701,
E304D No engine oil pressure available
outside valid range wiring or engine control unit
Check pressure sensor B701,
LBH/Version 01/07.2007/en/lbhhae0/06.02.2013

E304E No engine oil pressure available Engine oil pressure: sensor fault
wiring or engine control unit
Speed cannot be changed using Gas pedal: sensor value outside Check angle sensor R5, wiring
E3057
gas pedal valid range or UEC3 (A6) control unit
Speed cannot be changed using Check angle sensor R5, wiring
E3058 Gas pedal: sensor fault
gas pedal or UEC3 (A6) control unit
Parking brake symbol field H11
Parking brake: short circuit at Parking brake solenoid valve
E4000 flashes, parking brake cannot be
output Y10; check wiring or UEC 3
released, driving not possible
Parking brake symbol field H11
Parking brake: interruption at Parking brake solenoid valve
E4001 flashes, parking brake cannot be
output Y10; check wiring or UEC 3
released, driving not possible
Working hydraulics lockout
Working hydraulics lockout is Working hydraulics lockout:
E4002 solenoid valve Y14; check wiring
constantly activated short circuit at output
or UEC 3
Working hydraulics lockout
Working hydraulics lockout is Working hydraulics lockout:
E4003 solenoid valve Y14; check wiring
constantly activated interruption at output
or UEC 3

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Service Codes, Diagnose Service code
Malfunctions

ERROR - This kind of malfunction is accompanied by a 1-second warning tone

Service
Effect / en Cause / en Remedy MG_III / en
code
Fan motor proportional valve
E400A Fan turns at full speed Fan: short circuit at output
Y13; check wiring or UEC 3
Fan motor proportional valve
E400B Fan turns at full speed Fan: interruption at output
Y13; check wiring or UEC 3
Variable displacement motor 1
Fixed gear 2 activated, kick- Variable displacement motor 1:
E401A proportional valve YEP1; check
down not possible short circuit at output
wiring or UEC 3
Variable displacement motor 1
Fixed gear 2 activated, kick- Variable displacement motor 1:
E401B proportional valve YEP1; check
down not possible interruption at output
wiring or UEC 3
Fixed gear 1 is activated and
Variable displacement motor 2
variable displacement motor 1 is Variable displacement motor 2:
E401E proportional valve YEP2; check
set to a wide angle to prevent short circuit at output
wiring or UEC 3
overspeed
Fixed gear 1 is activated and
Variable displacement motor 2
variable displacement motor 1 is Variable displacement motor 2:
E401F proportional valve YEP2; check
set to a wide angle to prevent interruption at output
wiring or UEC 3
overspeed
Fixed gear 1 is activated and Variable displacement motor 2:
Variable displacement motor 2
variable displacement motor 1 is the measured return current at
E4021 proportional valve YEP2; check
set to a wide angle to prevent output does not match the
wiring or UEC 3
overspeed output current
Forward travel direction (pump Forward travel direction solenoid
E4022 Only reverse travel possible
1): short circuit at output valve Y2; check wiring or UEC 3
Forward travel direction (pump Forward travel direction solenoid
E4023 Only reverse travel possible
1): interruption at output valve Y2; check wiring or UEC 3
Reverse travel direction (pump Reverse travel direction solenoid
E4024 Only forward travel possible
1): short circuit at output valve Y3; check wiring or UEC 3
Reverse travel direction (pump Reverse travel direction solenoid
E4025 Only forward travel possible
1): interruption at output valve Y3; check wiring or UEC 3
Control pressure proportional
Control pressure (pump 1): short
E402A Driving is not possible valve Y15; check wiring or UEC
circuit at output
3
Control pressure proportional
Control pressure (pump 1):
E402B Driving is not possible valve Y15; check wiring or UEC
interruption at output
3
Control pressure (pump 1): the
Control pressure proportional
measured return current at
E402D Driving is not possible valve Y15; check wiring or UEC
output does not match the
3
output current
LBH/Version 01/07.2007/en/lbhhae0/06.02.2013

Emergency steering pump:

Emergency steering check
electrical fault at output Check relay K011, wiring or
E4067 symbol field H24 lights up,
(surge/short circuit or line UEC3 (A6) control unit
emergency steering unavailable
interruption)
Central lubrication system:
All three LEDs on the control
electrical fault at output Check relay K245, wiring or
E4068 unit switch flash, central
(surge/short circuit or line UEC3 (A6) control unit
lubrication system does not work
interruption)
Option 1: electrical fault at Check option 1 output, wiring or
E4069 Option 1 not available
output (surge/short circuit) UEC3 (A6) control unit
Option 1: electrical fault at Check option 1 output, wiring or
E406A Option 1 not available
output (power interrupted) UEC3 (A6) control unit
Check option 2 solenoid valve
Option 2: electrical fault at
E406B Option 2 not available Y11, wiring or UEC3 (A6) control
output (surge/short circuit)
unit

19.1-6 of 52 copyright by L524 - 659 / from 17890

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MJFCIFSS L538 - 433 / from 17893
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 Service code Service Codes, Diagnose
Malfunctions

ERROR - This kind of malfunction is accompanied by a 1-second warning tone

Service
Effect / en Cause / en Remedy MG_III / en
code
Check option 2 solenoid valve
Option 2: electrical fault at
E406C Option 2 not available Y11, wiring or UEC3 (A6) control
output (power interrupted)
unit
Check option 3 solenoid valve
Option 3: electrical fault at
E406D Option 3 not available Y12, wiring or UEC3 (A6) control
output (surge/short circuit)
unit
Check option 3 solenoid valve
Option 3: electrical fault at
E406E Option 3 not available Y12, wiring or UEC3 (A6) control
output (power interrupted)
unit
Check OPEN coupling solenoid
OPEN coupling: electrical fault
E406F Travel range restricted valve Y60, wiring or UEC3 (A6)
at output (surge/short circuit)
control unit
Check OPEN coupling solenoid
OPEN coupling: electrical fault
E4070 Travel range restricted valve Y60, wiring or UEC3 (A6)
at output (power interrupted)
control unit
Check CLOSEcoupling solenoid
CLOSEcoupling: electrical fault
E4071 Travel range restricted valve Y61, wiring or UEC3 (A6)
at output (surge/short circuit)
control unit
Check CLOSEcoupling solenoid
CLOSEcoupling: electrical fault
E4072 Travel range restricted valve Y61, wiring or UEC3 (A6)
at output (power interrupted)
control unit
Variable displacement motor 1: Check variable displacement
E4073 Travel range restricted electrical fault at output (fault motor 1 solenoid valve Y58,
current) wiring or UEC3 (A6) control unit
Check OPEN coupling solenoid
OPEN coupling: electrical fault
E4074 Travel range restricted valve Y60, wiring or UEC3 (A6)
at output (fault current)
control unit
Check CLOSEcoupling solenoid
CLOSEcoupling: electrical fault
E4075 Travel range restricted valve Y61, wiring or UEC3 (A6)
at output (fault current)
control unit
Variable displacement motor Synchronise variable
E5022 Travel slow or impossible
synchronisation complete displacement motors again
Inching angle sensor R1: check
Inching angle sensor: different
E5027 No inching function available redundant signals, maximum
values from sensors 1 and 2
current difference ±10 %
Inching angle sensor constantly
Clean the inch pedal so that it
E502C No inching function available less than 100 % for longer than
moves properly
2 minutes (inch pedal dirty)
Inch function was deactivated
E502D No inching function available Inching function activation
using parameters
LBH/Version 01/07.2007/en/lbhhae0/06.02.2013

Machine switches to neutral, Check conditions of use,

Variable displacement motor 2
E5031 driver can select travel direction variable displacement motor 2
speed sensor: overspeed
again after speed is reduced speed sensor B2 or wiring
Operation conditions, speed
Machine switches to neutral, Speed sensor – output /
sensor - output / (variable
E5032 driver can select travel direction (variable displacement motor 1):
displacement motor 1) check B1
again after speed is reduced Overspeed
or wiring
Travel direction selection cannot Travel direction switch: invalid Check travel direction switch
E5035
be clearly detected switching condition S2a or wiring
Variable displacement motor Adjust variable adjustment motor
E503A The motor retains the old value balance 2 maximum current too 2 control range (loosen adjusting
low screw)
Variable displacement motor Adjust variable adjustment motor
E503B The motor retains the old value balance 2 maximum current too 2 control range (tighten adjusting
high screw)

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L528 - 660 / from 17891
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L542 - 435 / from 17895
Service Codes, Diagnose Service code
Malfunctions

ERROR - This kind of malfunction is accompanied by a 1-second warning tone

Service
Effect / en Cause / en Remedy MG_III / en
code
Variable displacement motor Adjust variable adjustment motor
E503C The motor retains the old value balance 2 minimum current too 2 control range (tighten adjusting
high screw)
Variable displacement motor Adjust variable adjustment motor
E503D The motor retains the old value balance 2 minimum current too 2 control range (loosen adjusting
low screw)
Difference between variable
Check replenishing pressure or
displacement motor speed 2 and
E504D OPEN and CLOSEcoupling
take-off speed in 1st and 2nd
solenoid valves Y60 and Y61
gear
Check OPEN and
E504E Engine speed 2 in 3rd gear CLOSEcoupling solenoid valves
Y60 and Y61
Depends on the fault. - (see
Always shown with another error
E5052 Gear shifted for safety reasons additional code in the error
code (travel range restricted)
memory)
Depends on the fault. - (see
Always shown with another error
E5053 Gear disabled due to fault additional code in the error
code (travel range restricted)
memory)
Automatical engine speed
E505F Block curve calibration activated None
demand activated
E5066 Drive shaft: overspeed Reduce speed
Travel direction switched to Coupling not closed in 1st and Check hydraulic system and
E5068
neutral 2nd gear couplings
Coolant temperature symbol
L524, Clean cooling system, check fan
field (H13) flashes, STOP
L528 Coolant temperature above 110 speed, coolant temperature
symbol field lights up,
°C for more than 3 seconds sensor T04, thermostat in
continuous warning buzzer
E6000 engine
sounds
Coolant temperature symbol
L538, Clean cooling system, check fan
field (H13) flashes, STOP
L542 Coolant temperature above 100 speed, coolant temperature
symbol field lights up,
°C for more than 3 seconds sensor B708, thermostat in
continuous warning buzzer
E6000 engine
sounds
L524,
Warning buzzer sounds Clean cooling system, check fan
L528 Charge air temperature above
intermittently, engine has speed, charge air temperature
75 °C for more than 3 seconds
reduced power sensor B707
E6001
L538,
Warning buzzer sounds Clean cooling system, check fan
L542 Charge air temperature above
LBH/Version 01/07.2007/en/lbhhae0/06.02.2013

intermittently, engine has speed, charge air temperature

88°C for more than 3 seconds
reduced power sensor T02
E6001
L524,
Warning buzzer sounds Clean cooling system, check fan
L528 Fuel temperature above 95 °C
intermittently, engine has speed, fuel temperature sensor
for more than 10 seconds
reduced power T02
E6002
L538,
Warning buzzer sounds Clean cooling system, check fan
L542 Fuel temperature above 75 °C
intermittently, engine has speed, fuel temperature sensor
for more than 10 seconds
reduced power B709
E6002
Warning buzzer sounds Drain water from fuel pre-filter,
E6003 intermittently, engine has Water in fuel pre-filter check pre-filter water detector
reduced power B710
Check oil level, engine oil
Engine oil pressure symbol field
pressure (2 bar at 1000 rpm, 3
(H4) lights up, STOP symbol
E6004 Engine oil pressure too low bar at 2100 rpm), pressure relief
field (H36) lights up, continuous
valve, engine oil pressure
warning buzzer after 10 sec.
sensor B701, wiring

19.1-8 of 52 copyright by L524 - 659 / from 17890

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MJFCIFSS L538 - 433 / from 17893
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 Service code Service Codes, Diagnose
Malfunctions

ERROR - This kind of malfunction is accompanied by a 1-second warning tone

Service
Effect / en Cause / en Remedy MG_III / en
code
Replace/clean air filter, check air
Air filter contamination symbol Air filter contamination: vacuum
E6006 filter contamination vacuum
field (H7) lights up switch switched
switch B4, wiring
Coolant temperature symbol
field (H13) and STOP symbol Check coolant level, check
E6008 Coolant level too low
field light up, continuous warning coolant level sensor B13
buzzer sounds
Depends on the fault. - (see
Calculation error depends on the Always given for an additional
E600C additional code in the error
fault service code
memory)
Emergency engine shutdown: Check speed sensor B711,
E600D Engine shuts down
speed sensors 1 and 2 defective B712
Faulty injector (pump element Check injector (pump element
E600E Engine not running smoothly
solenoid) solenoid), wiring
Engine electronics detected
E600F Engine shuts down Check engine control unit, wiring
internal error
Power reduction can be
triggered by: coolant
E6010 Engine has reduced power Engine power reduction active temperature, charge air
temperature, fuel temperature,
altitude (atmospheric pressure)
Engine altitude power reduction
E6011 Engine has reduced power active (from 2250 m above sea None
level)
Charge control symbol field (H6)
E6016 lights up, parking brake cannot Alternator not supplying power Check alternator G3 or wiring
be released
Coolant temperature symbol
Engine temperature too high (> Clean cooling system and check
E601A field (H13) flashes, STOP
108 °C) fan speed
symbol field lights up
Calculation error, engine (John
Deere) - module sent a Read service code from ECU
STOP symbol field H36 lights
E601C CRITICAL error code. - This is A700 with MURPHY GAGE,
up, continuous warning buzzer
shown in the display unit instead note engine service code list
of the engine service code.
Calculation error, engine (John
Deere) - module sent a Read service code from ECU
E601D NORMAL error code. - This is A700 with MURPHY GAGE,
shown in the display unit instead note engine service code list
of the engine service code.
LBH/Version 01/07.2007/en/lbhhae0/06.02.2013

Charge control symbol field H6

E601E lights up, parking brake cannot Alternator not supplying power Check alternator G3 or wiring
be released
Coolant temperature symbol
L524, Coolant temperature above
field H13 and STOP symbol field
L528 Coolant temperature has 113°C for 7 s. Clean cooling
light up, continuous warning
exceeded safety threshold system, check fan speed, check
buzzer sounds, driving only
E601F coolant temperature sensor T04
possible in 1st gear
Coolant temperature symbol
L538, Coolant temperature above 107
field H13 and STOP symbol field
L542 Coolant temperature has °C for 7 s. Clean cooling system,
light up, continuous warning
exceeded safety threshold check fan speed, check coolant
buzzer sounds, driving only
E601F temperature sensor B708
possible in 1st gear
Charge air temperature above
L524, STOP symbol field H36 lights
91 °C for 7 s. Clean cooling
L528 up, continuous warning buzzer Charge air temperature has
system, check fan speed, check
sounds, driving only possible in exceeded safety threshold
charge air temperature sensor
E6020 1st gear
T02

L524 - 659 / from 17890 copyright by 19.1-9 of 52

L528 - 660 / from 17891
L538 - 433 / from 17893 MJFCIFSS
L542 - 435 / from 17895
Service Codes, Diagnose Service code
Malfunctions

ERROR - This kind of malfunction is accompanied by a 1-second warning tone

Service
Effect / en Cause / en Remedy MG_III / en
code
Charge air temperature above
L538, STOP symbol field H36 lights
80 °C for 7 s. Clean cooling
L542 up, continuous warning buzzer Charge air temperature has
system, check fan speed, check
sounds, driving only possible in exceeded safety threshold
charge air temperature sensor
E6020 1st gear
B707
L524, STOP symbol field H36 lights Fuel temperature above 100 °C
L528 up, continuous warning buzzer Fuel temperature has exceeded for 7 s. Clean cooling system,
sounds, driving only possible in safety threshold check fan speed, check fuel
E6022 1st gear sensor T05
L538, STOP symbol field H36 lights Fuel temperature above 90 °C
L542 up, continuous warning buzzer Fuel temperature has exceeded for 7 s. Clean cooling system,
sounds, driving only possible in safety threshold check fan speed, check fuel
E6022 1st gear sensor B709
Engine calculation error,
analogue module has sent an Read service code from ECU
Calculation error - depending on
E6023 internal error code. - This is A700, note engine service code
the fault
shown in the display unit instead list
of the engine service code.
Engine calculation error, digital
module has sent an internal Read service code from ECU
Calculation error - depending on
E6024 error code. - This is shown in the A700, note engine service code
the fault
display unit instead of the engine list
service code.
L524, Engine oil pressure symbol field
L528 H4 and STOP symbol field H36 Engine oil pressure has gone Check engine oil pressure, fault
light up, continuous warning below safety curve in pressure sensor P04 or wiring
E6025 buzzer
L538, Engine oil pressure symbol field
Check engine oil pressure, fault
L542 H4 and STOP symbol field H36 Engine oil pressure has gone
in pressure sensor B701 or
light up, continuous warning below safety curve
wiring
E6025 buzzer
CAN bus: display unit timeout ,
EA005 No display unit function hardware defective, fault in CAN Check display unit A13 or wiring
wiring
CAN bus: air conditioning
Air conditioning controller does Check air conditioning controller
EA006 controller timeout, hardware
not work A21 or CAN wiring
defective, fault in CAN wiring
Calculation error, main keypad Depends on the fault. - (see
Calculation error depends on the
EA024 module sent an internal error additional code in the error
fault
code memory)
LBH/Version 01/07.2007/en/lbhhae0/06.02.2013

Calculation error, display unit Depends on the fault. - (see

Calculation error depends on the
EA025 module sent an internal error additional code in the error
fault
code memory)
Air conditioning module Depends on the fault. - (see
EA031 calculation error - module sent additional code in the error
an internal error code. memory)
Outputs supplied by VDC_2 do
EB00A not work (Y2, Y3, Y10, Y20, UEC3: power supply 2 absent Check fuse F23 or wiring
Y60, H52, H53)
Outputs supplied by VDC_3 do
EB00B UEC3: power supply 3 absent Check fuse F22 or wiring
not work (Y12, Y58, Y61, K245)
Outputs supplied by VDC_4 do
EB00C not work (Y11, Y50, Y57, Y59, UEC3: power supply 4 absent Check fuse F24 or wiring
Opt.1)
Fan turns at full speed, excess UEC3: fault with internal voltage
EB012
temperature indicated VCC_EXT
UEC3: error synchronising Reload software or UEC3:
EB02A
topple structure replace CPU

19.1-10 of 52 copyright by L524 - 659 / from 17890

L528 - 660 / from 17891
MJFCIFSS L538 - 433 / from 17893
L542 - 435 / from 17895
 Service code Service Codes, Diagnose
Malfunctions

ERROR - This kind of malfunction is accompanied by a 1-second warning tone

Service
Effect / en Cause / en Remedy MG_III / en
code
EB037 Machine software was updated

19.1.5 WARNING service code

Function
This is information on the condition of the power supply, CAN bus or
diesel engine.

Warning - The error is not displayed, but is stored in the UEC3.

Service
Effect Cause Remedy
code
Gas pedal angle sensor: Synchronise gas pedal angle
E5023 Engine does not take up fuel
synchronisation not completed sensor R5
Inch pedal angle sensor: Synchronise inching angle
E5024 No inching function available
synchronisation not completed sensor R1
Variable displacement motor
Couplings open --> driving is not Finish variable displacement
synchronisation not completed
E5025 possible, no hydrostatic brake motor synchronisation, reset
or not concluded with
effect parameters
parameters
Check conditions of use, instruct
Overspeed - engine/pump
E5033 Engine speed too high driver on driving on slopes,
damage
check engine speed
Batteries overheating, electrical Check alternator or engine
E6009 On-board voltage too high
components may fail electronics
Check alternator, battery, wiring
E600A Engine difficult to start On-board voltage too low
or engine electronics
Battery voltage below 25 V
Battery charge symbol field (H6)
E6026 despite engine running longer Check alternator, wiring
lights up
than 5 minutes
Check CAN bus wiring or
EB004 System cannot be started UEC3: PC bus not available
replace UEC3
UEC3: IPC bus, no Check CAN bus wiring or
EB005 System cannot be started
acknowledgement (NO ACK) replace UEC3
UEC3: EEPROM, read or write
EB006 System cannot be started UEC3: replace CPU
error in driver
Check CAN bus wiring or
EB007 System cannot be started UEC3: PC bus timeout
replace UEC3
LBH/Version 01/07.2007/en/lbhhae0/06.02.2013

UEC3: watchdog (hardware),

EB008 System cannot be started error during check, voltage at UEC3: replace CPU
output DA5
The control unit cannot be
EB009 UEC3: power supply 1 absent Check fuse F26 or wiring
operated
UEC3: error frames on CAN line
EB013 Check wiring and modules
1
UEC3: error frames on CAN line
EB014 Check wiring and modules
2
UEC3: CAN memory full, CAN Reload software or check
EB015
message lost modules
UEC3: EEPROM: application
UEC3: configure CPU (machine
EB019 No operation possible configuration data could not be
data)
read
UEC3: EEPROM: service hours None (if problem recurs, UEC3:
EB01A No service hours available
could not be read replace CPU)
EB01B UEC3: EEPROM: application None (if problem recurs, UEC3:

L524 - 659 / from 17890 copyright by 19.1-11 of 52

L528 - 660 / from 17891
L538 - 433 / from 17893 MJFCIFSS
L542 - 435 / from 17895
Service Codes, Diagnose Service code
Malfunctions

Warning - The error is not displayed, but is stored in the UEC3.

Service
Effect Cause Remedy
code
status information could not be replace CPU)
read
UEC3: EEPROM: application None (if problem recurs, UEC3:
EB01C
statistics could not be read replace CPU)
None (if problem recurs, reload
UEC3: EEPROM: service hours
EB01D program and UEC3: replace
could not be saved
CPU)
UEC3: EEPROM: application None (if problem recurs, reload
EB01E status information could not be program and UEC3: replace
saved CPU)
UEC3: EEPROM: application None (if problem recurs, reload
EB01F status information could not be program and UEC3: replace
saved CPU)
Service code system started - at
least one error has occurred
since the system was started
EB020 Additional information
and must be recorded in the
EEPROM. --> Store system start
time
Reload software or UEC3:
EB025 UEC3: defective topple structure
replace CPU
Reload software or UEC3:
EB026 UEC3: topple too long
replace CPU
Reload software or UEC3:
EB027 UEC3: topple ID not found
replace CPU
Reload software or UEC3:
EB028 UEC3: error writing topple
replace CPU
Reload software or UEC3:
EB029 UEC3: topple structure repaired
replace CPU
UEC3: CRC fault in the topple Reload software or UEC3:
EB02B
structure replace CPU
UEC3: topple structure: page Reload software or UEC3:
EB02C
switch error replace CPU

LBH/Version 01/07.2007/en/lbhhae0/06.02.2013

19.1-12 of 52 copyright by L524 - 659 / from 17890

L528 - 660 / from 17891
MJFCIFSS L538 - 433 / from 17893
L542 - 435 / from 17895
 Service code Service Codes, Diagnose
Malfunctions

19.1.6 INFO service code

Function
This is information on modifications made.

Info - The error is not displayed, but is stored in the UEC3.

Service
Effect Cause Remedy
code
E204C Service hours were changed
Emergency steering was
E204D
activated
AC-unit: Learning mode is
E204E
activated
Basket mode: emergency off
E205E None
activated.
Basket mode: OFF mode
E205F None
activated.
E2060 Basket mode: mode 1 activated. None
E2061 Basket mode: mode 2 activated. None
Overspeed protection indicator Variable displacement motor 2 Slow down machine using
E504C
H38 flashes overspeed protection activated service brake
Overspeed protection indicator Engine overspeed protection Slow down machine using
E504F
H38 flashes activated service brake
Overspeed protection indicator Variable displacement motor 1 Slow down machine using
E5051
H38 flashes overspeed protection activated service brake
Transmission switch coupling Hydraulic oil setting was
E505D None
quick filling function changed changed (by driver).
A drive component exceeded
the speed threshold. The
E5067
maximum speed of the machine
was saved.
The three LEDs on the display
E601B unit brightness control button Purge mode activated None
S31 flash
Check connection T30 from
UEC3: controller not properly
EB016 battery; check fuse F26 or load
shut down
new software
UEC3: controller properly shut
EB017 None
down
UEC3: EEPROM: calibration
EB018 UEC3: replace CPU
data could not be read
LBH/Version 01/07.2007/en/lbhhae0/06.02.2013

UEC3: Service code queue full -

one or more service code entries
EB021 Additional information
have been lost due to the
EEPROM memory being full.
UEC3: Service code system
reset - indicates that the service
EB022 code memory has been Additional information
completely deleted (by service
engineer)
UEC3: Existing service codes
acknowledged - indicates that all
EB023 existing service codes have Additional information
been acknowledged (by service
engineer)
UEC3: service code lost, not
EB024 Additional information
enough memory

L524 - 659 / from 17890 copyright by 19.1-13 of 52

L528 - 660 / from 17891
L538 - 433 / from 17893 MJFCIFSS
L542 - 435 / from 17895
Service Codes, Diagnose Service code
Malfunctions

Info - The error is not displayed, but is stored in the UEC3.

Service
Effect Cause Remedy
code
UEC3: Service code system
reset - indicates that the service
EB02D Additional information
code memory has been
completely deleted (system)
UEC3: service code lost, too
EB032 many service codes for affected Additional information
range (error/info)
UEC3: time was changed (by
EB033 Additional information
driver or service)

19.1.7 UNDEFINIERT service code

Function
The error cannot be classified as it was transferred to other modulöes

Undefined - The error is not displayed, but is stored in the UEC3.

Service
Effect Cause Remedy MG_III
code
Depends on the fault. - (see
UEC3: error code received by
EB02E None additional code in the error
CAN module (system object)
memory)
Depends on the fault. - (see
UEC3: error code received by
EB02F None additional code in the error
CAN module (sync. object)
memory)
UEC3: error code received by Depends on the fault. - (see
EB030 None CAN module (system object), additional code in the error
level changed memory)
UEC3: error code received by Depends on the fault. - (see
EB031 None CAN module (sync. object), level additional code in the error
changed memory)
Depends on the malfunction UEC3: error code received by
EB034 Depends on the malfunction
Engine calculation error CAN module (J1939)

LBH/Version 01/07.2007/en/lbhhae0/06.02.2013

19.1-14 of 52 copyright by L524 - 659 / from 17890

L528 - 660 / from 17891
MJFCIFSS L538 - 433 / from 17893
L542 - 435 / from 17895
 Service code Service Codes, Diagnose
Malfunctions

19.1.8 ERROR Motor service code L524, L528

Function
This is a fault in the various electrical components or wiring; or values
outside the permissible range.

ERROR Motor L524, L528 - This kind of malfunction is accompanied by a 1-second calculation error warning tone
Service Code
MURPHY Effect Cause Remedy
SCULI
Gage
Gas pedal position: gas pedal
Accelerator pedal not Gas pedal sensor: check
0x03001D00 29.04 sensor 1: voltage OOR high:
working pedal position
range exceeded
Gas pedal position: sensor 1: Gas pedal sensor:
Accelerator pedal not
0x0D001D00 29.13 voltage for teaching range calibrate line resistance
working
exceeded or too low 220 ohm
Check accelerator pedal
Accelerator pedal position:
Accelerator pedal not sensor; check cabling,
0x03005B00 91.03 sensor 2 throttle voltage OOR
working check 220 Ohm cable
high (91.03)
resistance
Check accelerator pedal
Accelerator pedal position:
Accelerator pedal not sensor; check cabling,
0x04005B00 91.04 sensor 2 throttle voltage OOR
working check 220 Ohm cable
low (91.04)
resistance
Gas pedal position: sensor 2: Gas pedal sensor:
Accelerator pedal not
0x0D005B00 91.13 voltage for teaching range calibrate line resistance
working
exceeded or too low 220 ohm
Gas pedal sensor:
Accelerator pedal not Gas pedal position: gas pedal:
0x0E005B00 91.14 calibrate line resistance
working voltage does not match
220 ohm
Fuel delivery pressure: fuel
Fuel system: check lines,
0x11005E00 94.17 Warning pressure low – minimally
filters
critical condition
Water in fuel indicator: water in
Fuel water sensor: check
0x04006100 97.04 Warning fuel indicator – voltage OOR
voltage
low: fallen below range
Water in fuel indicator: water Water in the system:
0x10006100 97.16 Warning
detected in fuel check water sensor
Engine oil pressure: oil
Engine power is reduced Sensor, wiring or oil
LBH/Version 01/07.2007/en/lbhhae0/06.02.2013

0x01006400 100.01 pressure low – most severe

to 40% pressure
level (100.01)
Engine oil pressure: oil
0x03006400 100.03 Warning pressure voltage OOR high Wiring, sensor
(100.03)
Engine oil pressure: oil
Engine oil pressure
0x04006400 100.04 Warning pressure: voltage OOR low:
sensor: check voltage
fallen below range
Engine oil pressure: oil
Oil pressure too low,
0x12006400 100.18 Warning pressure low – moderately
sensor, line
severe level (100.18)
Engine oil pressure: oil
0x1F006400 100.31 Warning pressure detected at zero Wiring, sensor
engine speed (100.31)
Charge pressure: voltage OOR Check charge pressure,
0x04006600 102.04 Warning
low: fallen below range voltage

L524 - 659 / from 17890 copyright by 19.1-15 of 52

L528 - 660 / from 17891
L538 - 433 / from 17893 MJFCIFSS
L542 - 435 / from 17895
Service Codes, Diagnose Service code
Malfunctions

ERROR Motor L524, L528 - This kind of malfunction is accompanied by a 1-second calculation error warning tone
Service Code
MURPHY Effect Cause Remedy
SCULI
Gage
Manifold air temperature:
Engine power is reduced Wiring, sensor, cooling
0x00006900 105.00 manifold air temperature: high
to 40% system
– most severe level (105.00)
Manifold air temperature:
0x03006900 105.03 Warning manifold air temperature: Wiring, sensor, ECU
voltage OOR high (105.03)
Manifold air temperature:
0x04006900 105.04 Warning manifold air temperature: Wiring, sensor, ECU
voltage OOR low (105.04)
Manifold air temperature:
0x0F006900 105.15 Warning manifold air temperature high – Wiring, sensor
least severe level (105.15)
Manifold air temperature:
Engine power is reduced manifold air temperature: high
0x10006900 105.16 Wiring, sensor
to 80% – moderately severe level
(105.16)
Barometric pressure:
0x02006C00 108.02 Warning barometric pressure invalid ECU
(108.02)
Engine coolant temperature:
Engine power is reduced Temperature, sensor,
0x00006E00 110.00 coolant temperature high –
to 40% cooling system
most severe level (110.00)
Engine coolant temperature:
0x03006E00 110.03 Warning coolant temperature voltage Sensor, wiring
OOR high (110.03)
Engine coolant temperature:
0x0F006E00 110.15 Warning coolant temperature high – Sensor, wiring
least severe level (110.15)
Engine coolant temperature:
coolant temperature high –
0x10006E00 110.16 Warning Sensor, wiring
moderately severe level
(110.16)
Injector metering rail pressure
Warning, power loss, not Wiring, leak, dirt on
0x03009D00 157.03 #1 pressure: fuel pressure
running smoothly system WH, ECU
voltage OOR high (157.03) LBH/Version 01/07.2007/en/lbhhae0/06.02.2013

Injector metering rail pressure

Warning, power loss, not Wiring, leak, dirt on
0x04009D00 157.04 #1 pressure: fuel pressure
running smoothly system WH, ECU
voltage OOR low (157.04)
Injector metering rail pressure
Warning, power loss, not Wiring, leak, dirt on
0x0A009D00 157.10 #1 pressure: rail pressure
running smoothly system WH, ECU
Drops Too Fast (157.10)
Injector metering rail pressure
Fuel supply, pressure
Warning, engine cannot #1 pressure: rail pressure not
0x11009D00 157.17 control valve, high
be started be flat developed during cranking
pressure pump
(157.17)
Battery potential (voltage),
0x11009E00 158.17 Warning, battery may switched: ECU cannot power ECU, faulty connections
Down (158.17)
Temperature sensor,
Fuel / return fuel temperature:
Engine power is reduced wiring, high pressure
0x0000AE00 174.00 fuel temperature high – most
to 40% pump, pressure relief
severe level (174.00)
valve, line

19.1-16 of 52 copyright by L524 - 659 / from 17890

L528 - 660 / from 17891
MJFCIFSS L538 - 433 / from 17893
L542 - 435 / from 17895
 Service code Service Codes, Diagnose
Malfunctions

ERROR Motor L524, L528 - This kind of malfunction is accompanied by a 1-second calculation error warning tone
Service Code
MURPHY Effect Cause Remedy
SCULI
Gage
Fuel / return fuel temperature:
Temperature sensor,
0x0300AE00 174.03 Warning fuel temperature voltage OOR
wiring, ECU
high (174.03)
Fuel / return fuel temperature:
0x0400AE00 174.04 Warning fuel temperature voltage OOR Wiring short circuit, ECU
low (174.04)
Fuel / return fuel temperature:
fuel temperature high –
0x1000AE00 174.16 Warning Wiring, fuel pressure
moderately severe level
(174.16)
Rated engine speed : a
e.g.: overheating. On the
Warning, engine speed condition exists which is
0x0000BD00 189.00 ECU; only in connection
reduction causing the engine to derate
with other DTC
(189.00)
Engine speed: engine speed
0x0000BE00 190.00 ENGINE STOP high – most severe level Mechanical problem; ECU
(190.00)
Warning; not running
Injector wiring: short to battery
0x03026300 611.03 smoothly; engine may not Wiring, injector, ECU
on the injector lines (611.03)
start
Warning; not running
Injector wiring: short to ground
0x04026300 611.04 smoothly; engine may not Wiring, injector, ECU
on the injector lines (611.04)
start
Power supply: battery voltage
Check battery, charging
0x12027300 627.18 Warning below normal level –
system, voltage
moderately critical condition
STOP; engine will not Controller #1 : ECU failure
0x0D027500 629.13 ECU or software
start (629.13)
Motor position sensor: noise Check wiring, sensor, ring
0x02027C00 636.02 Warning
detected gear
Engine position sensor (cam):
engine position sensor current Wiring, pump position
0x05027C00 636.05 Warning
below normal or open circuit sensor, ECU
(636.05)
Engine position sensor (cam):
engine position sensor current Wiring, pump position
LBH/Version 01/07.2007/en/lbhhae0/06.02.2013

0x06027C00 636.06 Warning

above normal or grounded sensor, ECU
circuit (636.06)
Motor position sensor
Pump position sensor:
0x08027C00 636.08 Warning (camshaft): motor position
check teeth, lines
sensor: no signal
Motor position sensor
(camshaft): motor position Pump position sensor:
0x0A027C00 636.10 Warning
sensor: sensor pattern error check lines, teeth
detected
Timing sensor (crankshaft):
0x02027D00 637.02 Warning Wiring, sensor, ring gear
timing sensor: noise detected
Timing sensor (crank): timing
Wiring, crankshaft position
0x05027D00 637.05 Warning sensor current below normal or
sensor, ECU
open circuit (637.05)
Timing sensor (crank): timing
Wiring, crankshaft position
0x06027D00 637.06 Warning sensor current above normal or
sensor, ECU
grounded circuit (637.06)

L524 - 659 / from 17890 copyright by 19.1-17 of 52

L528 - 660 / from 17891
L538 - 433 / from 17893 MJFCIFSS
L542 - 435 / from 17895
Service Codes, Diagnose Service code
Malfunctions

ERROR Motor L524, L528 - This kind of malfunction is accompanied by a 1-second calculation error warning tone
Service Code
MURPHY Effect Cause Remedy
SCULI
Gage
Timing sensor (crankshaft): Camshaft / crankshaft
0x07027D00 637.07 Warning timing sensor / position sensor sensor: check engine
do not match adjustment
Timing sensor (crankshaft): Camshaft sensor: check
0x08027D00 637.08 Warning
timing sensor: no signal lines, teeth
Timing sensor (crankshaft):
Camshaft sensor: check
0x0A027D00 637.10 Warning timing sensor: pattern fault
lines, teeth
detected
Enter part number with
Cylinder 1 injection element:
0x02028B00 651.02 Warning “Service Advisor” service
invalid part number
tool
Injector cylinder #1: the current
Warning, not running
0x05028B00 651.05 to the injector in cylinder is less Wiring, injector, ECU
smoothly
than expected (651.05)
Injector cylinder #1: the current
Warning, not running
0x06028B00 651.06 to the injector in cylinder Wiring, injector, ECU
smoothly
increases too rapidly (651.06)
Cylinder 1 injection element:
0x07028B00 651.07 Warning fuel flow in injection element on Injector: calibration
cylinder is less than expected
Cylinder 1 injection element:
Calibrate with “Service
0x0D028B00 651.13 Warning injection element: defective
Advisor” service tool
coding
Enter part number with
Cylinder 2 injection element:
0x02028C00 652.02 Warning “Service Advisor” service
invalid part number
tool
Injector cylinder #2: the current
Warning, not running
0x05028C00 652.05 to the injector in cylinder is less Wiring, injector, ECU
smoothly
than expected (652.05)
Injector cylinder #2: the current
Warning, not running
0x06028C00 652.06 to the injector in cylinder Wiring, injector, ECU
smoothly
increases too rapidly (652.06)
Cylinder 2 injection element:
0x07028C00 652.07 Warning fuel flow in injection element on Injector: calibration
cylinder is less than expected
Warning, not running Injector cylinder #2: injector QR Programming or
0x0D028C00 652.13
smoothly code string error (652.13) classification
LBH/Version 01/07.2007/en/lbhhae0/06.02.2013

Cylinder 3 injection element:

Warning, not running Calibrate with “Service
0x0D028C00 653.00 injection element restricted by
smoothly Advisor” service tool
max. pulse duration on cylinder
Enter part number with
Cylinder 3 injection element:
0x02028D00 653.02 Warning “Service Advisor” service
invalid part number
tool
Injector cylinder #3: the current
Warning, not running
0x05028D00 653.05 to the injector in cylinder is less Wiring, injector, ECU
smoothly
than expected (653.05)
Injector cylinder #3: the current
Warning, not running
0x06028D00 653.06 to the injector in cylinder Wiring, injector, ECU
smoothly
increases too rapidly (653.06)
Cylinder 3 injection element:
0x07028D00 653.07 Warning fuel flow in injection element on Injector: calibration
cylinder is less than expected.
Warning, not running Injector cylinder #3: injector QR Programming or
0x0D028D00 653.13
smoothly code string error (653.13) classification

19.1-18 of 52 copyright by L524 - 659 / from 17890

L528 - 660 / from 17891
MJFCIFSS L538 - 433 / from 17893
L542 - 435 / from 17895
 Service code Service Codes, Diagnose
Malfunctions

ERROR Motor L524, L528 - This kind of malfunction is accompanied by a 1-second calculation error warning tone
Service Code
MURPHY Effect Cause Remedy
SCULI
Gage
Cylinder 4 injection element:
Warning, not running Calibrate with “Service
0x0D028C00 654.00 injection element restricted by
smoothly Advisor” service tool
max. pulse duration on cylinder
Warning, not running Injector cylinder #4: part Programming or
0x02028E00 654.02
smoothly number is invalid (654.02) classification
Injector cylinder #4: the current
Warning, not running
0x05028E00 654.05 to the injector in cylinder is less Wiring, injector, ECU
smoothly
than expected (654.05)
Injector cylinder #4: the current
Warning, not running
0x06028E00 654.06 to the injector in cylinder Wiring, injector, ECU
smoothly
increases too rapidly (654.06)
Cylinder 4 injection element:
0x07028E00 654.07 Warning fuel flow in injection element on Injector: calibration
cylinder is less than expected
Cylinder 4 injection element:
Calibrate with “Service
0x0D028E00 654.13 Warning injection element: defective
Advisor” service tool
coding
Injector cylinder #5: the current
Warning, not running
0x05028F00 655.05 to the injector in cylinder is less Wiring, injector, ECU
smoothly
than expected (655.05)
Injector cylinder #5: the current
Warning, not running
0x06028F00 655.06 to the injector in cylinder Wiring, injector, ECU
smoothly
increases too rapidly (655.06)
ECU temperature: ECU
Control unit too hot
0x00047000 1136.00 Engine stop temperature too high – most
135 °C
critical condition
Fuel pump pressurizing
assembly #1: the circuit to
Warning, engine cannot Wiring, leak, dirt on
0x05054300 1347.05 pump solenoid #1 is open,
be started system WH
shorted to ground, or
overloaded (1347.05)
Fuel pump pressure
accumulator unit 1: rail
pressure control cannot adjust Pump: check lines, wiring
0x07054300 1347.07 Warning
the rail pressure to the required harness system
level. It may be too high or too
low
LBH/Version 01/07.2007/en/lbhhae0/06.02.2013

Load reduction to protect the

engine. A condition has arisen
0x1F062100 1569.31 Warning Emergency operation
which has caused the engine
load to be reduced.
Sensor supply voltage 1:
Rail pressure sensor;
0x030DB500 3509.03 Warning sensor supply voltage OOR
check supply voltage
high: range exceeded
Sensor supply voltage 1:
Rail pressure sensor;
0x040DB500 3509.04 Warning sensor supply voltage OOR
check supply voltage
low: fallen below range
Sensor supply voltage 2:
0x030DB600 3510.03 Warning sensor supply voltage OOR Check supply voltage
high: range exceeded
Sensor supply voltage 2:
0x040DB600 3510.04 Warning sensor supply voltage OOR Check supply voltage
low: fallen below range

L524 - 659 / from 17890 copyright by 19.1-19 of 52

L528 - 660 / from 17891
L538 - 433 / from 17893 MJFCIFSS
L542 - 435 / from 17895
Service Codes, Diagnose Service code
Malfunctions

ERROR Motor L524, L528 - This kind of malfunction is accompanied by a 1-second calculation error warning tone
Service Code
MURPHY Effect Cause Remedy
SCULI
Gage
Sensor supply voltage 3:
0x030DB700 3511.03 Warning sensor supply voltage OOR Check supply voltage
high: range exceeded
Sensor supply voltage 3:
0x040DB700 3511.04 Warning sensor supply voltage OOR Check supply voltage
low: fallen below range
Accelerator pedal position:
0x04001D00 3822.03 sensor 1 throttle voltage OOR
low (29.04)

LBH/Version 01/07.2007/en/lbhhae0/06.02.2013

19.1-20 of 52 copyright by L524 - 659 / from 17890

L528 - 660 / from 17891
MJFCIFSS L538 - 433 / from 17893
L542 - 435 / from 17895
 Service code Service Codes, Diagnose
Malfunctions

19.1.9 ERROR Motor service code L538, L542

Function
For “ERROR Motor” service codes, a replacement code (SUMMENFEHLER)
is generated on the display unit.
The actual error is not displayed, but is stored in the UEC3. The errors can
be read using the SCULI diagnosis software.

ERROR Motor This kind of malfunction is accompanied by a 1-second warning tone

Service code
Effect Cause Remedy
A700 UEC3
Construction machine CAN timeout
Emergency operation:
when requesting global process Check cables, plugs,
3006.00 E49638 engine running at lower
CAN bus connection problem or master
idle speed
master unit A15 defective
Construction machine CAN timeout
Emergency operation:
receiving total output data Check cables, plugs,
3006.01 E49639 engine running at lower
CAN bus connection problem or master
idle speed
master unit A15 defective
Construction machine CAN timeout
Emergency operation:
while sending messages Check cables, plugs,
3006.02 E4963A engine running at lower
CAN bus connection problem or master
idle speed
master unit A15 defective
Construction machine CAN
Emergency operation:
passive error Check cables, plugs,
3006.03 E4963B engine running at lower
CAN bus connection problem or master
idle speed
master unit A15 defective
Emergency operation: Construction machine CAN bus off
Check cables, plugs,
3006.04 E4963C engine running at lower CAN bus connection problem or
master
idle speed master unit A15 defective
CAN AMET timeout while requesting
Emergency operation:
global process Check cables, plugs,
3007.00 E4969C engine running at lower
CAN bus connection problem or master
idle speed
master unit A15 defective
CAN AMET timeout receiving total
Emergency operation:
output data Check cables, plugs,
3007.01 E4969D engine running at lower
CAN bus connection problem or master
idle speed
master unit A15 defective
CAN AMET timeout while sending
LBH/Version 01/07.2007/en/lbhhae0/06.02.2013

Emergency operation:
messages Check cables, plugs,
3007.02 E4969E engine running at lower
CAN bus connection problem or master
idle speed
master unit A15 defective
Emergency operation: CAN AMET passive error
Check cables, plugs,
3007.03 E4969F engine running at lower CAN bus connection problem or
master
idle speed master unit A15 defective
Emergency operation: CAN AMET bus off
Check cables, plugs,
3007.04 E496A0 engine running at lower CAN bus connection problem or
master
idle speed master unit A15 defective
CAN communication status CAN A
Check the ECU A700D
3009.00 E49764 No direct effect cannot connect at 125kB
engine control unit
CAN driver problem in ECU
CAN communication status CAN A
Check the ECU A700D
3009.01 E49765 No direct effect cannot connect at 250kB
engine control unit
CAN driver problem in ECU

L524 - 659 / from 17890 copyright by 19.1-21 of 52

L528 - 660 / from 17891
L538 - 433 / from 17893 MJFCIFSS
L542 - 435 / from 17895
Service Codes, Diagnose Service code
Malfunctions

ERROR Motor This kind of malfunction is accompanied by a 1-second warning tone

Service code
Effect Cause Remedy
A700 UEC3
CAN communication status CAN A
Check the ECU A700D
3009.02 E49766 No direct effect cannot connect at 500kB
engine control unit
CAN driver problem in ECU
CAN communication status CAN A
Check the ECU A700D
3009.03 E49767 No direct effect cannot connect at 1MB
engine control unit
CAN driver problem in ECU
CAN communication status CAN B
Check the ECU A700D
3009.04 E49768 No direct effect cannot connect at 125kB
engine control unit
CAN driver problem in ECU
CAN communication status CAN B
Check the ECU A700D
3009.05 E49769 No direct effect cannot connect at 250kB
engine control unit
CAN driver problem in ECU
CAN communication status CAN B
Check the ECU A700D
3009.06 E4976A No direct effect cannot connect at 500kB
engine control unit
CAN driver problem in ECU
CAN communication status CAN B
Check the ECU A700D
3009.07 E4976B No direct effect cannot connect at 1MB
engine control unit
CAN driver problem in ECU
CAN communication was
Check the ECU A700D
3009.08 E4976C No direct effect resynchronised
engine control unit
CAN driver problem in ECU
CAN communication timeout Check the ECU A700D
3009.09 E4976D No direct effect
CAN driver problem in ECU engine control unit
Check the ECU A700D
engine control unit
CAN communication – could not
3009.10 E4976E No direct effect Master unit A15
detect actual CAN A baud rate
Input module 1
Output module 1
Check the ECU A700D
engine control unit
CAN communication – could not
3009.11 E4976F No direct effect Master unit A15
detect actual CAN B baud rate
Input module 1
Output module 1
Turn the ignition off and on
Engine cannot be
Internal error – stack overflow again; if the problem
3010.00 E497C8 started, or engine shut
Internal engine control unit error persists, replace the ECU
down
LBH/Version 01/07.2007/en/lbhhae0/06.02.2013

A700D engine control unit.

Turn the ignition off and on
Engine cannot be
Internal error – exception again; if the problem
3010.01 E497C9 started, or engine shut
Internal engine control unit error persists, replace the ECU
down
A700D engine control unit.
Turn the ignition off and on
Engine cannot be
Internal error – program test again; if the problem
3010.02 E497CA started, or engine shut
Internal engine control unit error persists, replace the ECU
down
A700D engine control unit.
Turn the ignition off and on
Engine cannot be
Internal error – RAM test again; if the problem
3010.03 E497CB started, or engine shut
Internal engine control unit error persists, replace the ECU
down
A700D engine control unit.
Turn the ignition off and on
Internal error – error memory again; if the problem
3010.04 E497CC No direct effect
overflow persists, replace the ECU
A700D engine control unit.

19.1-22 of 52 copyright by L524 - 659 / from 17890

L528 - 660 / from 17891
MJFCIFSS L538 - 433 / from 17893
L542 - 435 / from 17895
 Service code Service Codes, Diagnose
Malfunctions

ERROR Motor This kind of malfunction is accompanied by a 1-second warning tone

Service code
Effect Cause Remedy
A700 UEC3
Turn the ignition off and on
again; if the problem
3010.05 E497CD No direct effect Internal error – computing time test
persists, replace the ECU
A700D engine control unit.
Turn the ignition off and on
The error that occurred again; if the problem
3010.06 E497CE Internal error – error index too high
cannot be displayed persists, replace the ECU
A700D engine control unit.
Turn the ignition off and on
Engine cannot be
Error accessing EEPROM again; if the problem
3011.00 E4982C started, or engine shut
Internal engine control unit error persists, replace the ECU
down
A700D engine control unit.
Turn the ignition off and on
Engine cannot be
Parameter memory check sum fault again; if the problem
3011.01 E4982D started, or engine shut
Internal engine control unit error persists, replace the ECU
down
A700D engine control unit.
Turn the ignition off and on
Engine cannot be Invalid parameter memory in
again; if the problem
3011.02 E4982E started, or engine shut EEPROM
persists, replace the ECU
down Internal engine control unit error
A700D engine control unit.
Turn the ignition off and on
ECU page check sum fault again; if the problem
3011.03 E4982F No direct effect
Internal engine control unit error persists, replace the ECU
A700D engine control unit.
Turn the ignition off and on
NMI page check sum fault again; if the problem
3011.04 E49830 No direct effect
Internal engine control unit error persists, replace the ECU
A700D engine control unit.
Turn the ignition off and on
Work data page check sum fault again; if the problem
3011.05 E49831 No direct effect
Internal engine control unit error persists, replace the ECU
A700D engine control unit.
Turn the ignition off and on
Load collective check sum fault again; if the problem
3011.06 E49832 No direct effect
Internal engine control unit error persists, replace the ECU
A700D engine control unit.
Turn the ignition off and on
Load collective structure value has
again; if the problem
3011.07 E49833 No direct effect changed
persists, replace the ECU
Internal engine control unit error
LBH/Version 01/07.2007/en/lbhhae0/06.02.2013

A700D engine control unit.

Turn the ignition off and on
EEPROM does not have enough
again; if the problem
3011.08 E49834 No direct effect space for the load collective
persists, replace the ECU
Internal engine control unit error
A700D engine control unit.
Turn the ignition off and on
again; if the problem
3011.09 E49835 No direct effect Permanent data check sum fault
persists, replace the ECU
A700D engine control unit.
Engine cannot be Check the on-board circuit
3012.00 E49890 started, or engine shut Supply voltage too low (<9V) (battery, alternator, wiring,
down connectors)
Engine cannot be
started, or engine shut
Check the on-board circuit
down
3012.01 E49891 Supply voltage too high (>33V) (battery, alternator, wiring,
Communication only
connectors)
possible with diagnostic
tools

L524 - 659 / from 17890 copyright by 19.1-23 of 52

L528 - 660 / from 17891
L538 - 433 / from 17893 MJFCIFSS
L542 - 435 / from 17895
Service Codes, Diagnose Service code
Malfunctions

ERROR Motor This kind of malfunction is accompanied by a 1-second warning tone

Service code
Effect Cause Remedy
A700 UEC3
Check the wiring and ECU
Engine shutdown A700D engine control unit
Digital output shorted to supply
Communication only If the problem cannot be
3012.02 E49892 voltage
possible with diagnostic rectified:
Defective line or component
tools Replace the ECU A700D
engine control unit
Check the wiring and ECU
A700D engine control unit
Engine shutdown Error releasing power outputs
If the problem cannot be
3012.03 E49893 All digital outputs Power outputs cannot be activated
rectified:
switched off or deactivated
Replace the ECU A700D
engine control unit
Check the on-board circuit
Engine cannot be Error on PS1
(battery, alternator, wiring,
3012.04 E49894 started, or engine shut Engine control unit supply voltage
connectors) with reference
down PS1 defective
to PS1
Engine shutdown Check the on-board circuit
12V reference fault: voltage too low
Communication only (battery, alternator, wiring,
3012.05 E49895 (<10V)
possible with diagnostic connectors) with reference
Defective line or component
tools to PS1
Engine shutdown Check the on-board circuit
12V reference fault: voltage too high
Communication only (battery, alternator, wiring,
3012.06 E49896 (>14V)
possible with diagnostic connectors) with reference
Defective line or component
tools to PS1
New data record or replace
Power curve internally Offset on full-load curve
3015.01 E499BD the ECU A700D engine
restricted Internal engine control unit error
control unit

Incorrect pump code (pump code is

Injector class 3 is used Check and modify pump
3015.03 E499BF wrong on at least one element)
as a replacement code
Internal engine control unit error

Speed recording error Check the ECU A700D

Maximum speed difference between wiring to the speed sensor
3019.00 E49B4C Higher speed is used
transmission and odometer is too and check the speed
high sensor
Insufficient alternator voltage when Check the wiring from the
engine is not running ECU A700D engine control
3020.00 E49BB0 No direct effect Defective wiring from engine control unit to the alternator and
LBH/Version 01/07.2007/en/lbhhae0/06.02.2013

unit to alternator, defective alternator check the ECU A700D

or broken V belt engine control unit
Excess alternator voltage when Check the wiring from the
engine is not running ECU A700D engine control
3020.01 E49BB1 No direct effect Defective wiring from engine control unit to the alternator and
unit to alternator, defective alternator check the ECU A700D
or broken V belt engine control unit
Insufficient alternator voltage when Check the wiring from the
engine is running ECU A700D engine control
3020.02 E49BB2 No direct effect Defective wiring from engine control unit to the alternator and
unit to alternator, defective alternator check the ECU A700D
or broken V belt engine control unit
Excess alternator voltage when Check the wiring from the
engine is running ECU A700D engine control
3020.03 E49BB3 No direct effect Defective wiring from engine control unit to the alternator and
unit to alternator, defective alternator check the ECU A700D
or broken V belt engine control unit

19.1-24 of 52 copyright by L524 - 659 / from 17890

L528 - 660 / from 17891
MJFCIFSS L538 - 433 / from 17893
L542 - 435 / from 17895
 Service code Service Codes, Diagnose
Malfunctions

ERROR Motor This kind of malfunction is accompanied by a 1-second warning tone

Service code
Effect Cause Remedy
A700 UEC3
Alternator voltage insufficiently Check the wiring from the
different to supply voltage ECU A700D engine control
3020.04 E49BB4 No direct effect Defective wiring from engine control unit to the alternator and
unit to alternator, defective alternator check the ECU A700D
or broken V belt engine control unit
Alternator voltage excessively Check the wiring from the
different to supply voltage ECU A700D engine control
3020.05 E49BB5 No direct effect Defective wiring from engine control unit to the alternator and
unit to alternator, defective alternator check the ECU A700D
or broken V belt engine control unit
Exhaust gas recirculation fault Check the wiring harness,
External exhaust gas
Short circuit to earth or cable rupture connectors, EGR valve,
3028.00 E49ED0 recirculation 1 not
Output and feedback values do ECU A700D engine control
activated
not match unit
Exhaust gas recirculation fault Check the wiring harness,
External exhaust gas
Shorted to supply voltage connectors, EGR valve,
3028.01 E49ED1 recirculation 1 not
Output and feedback values do ECU A700D engine control
activated
not match unit
Exhaust gas recirculation fault
External exhaust gas
Hardware fault Check the ECU A700D
3028.02 E49ED2 recirculation 1 not
Transistor status does not match engine control unit
activated
feedback value
Exhaust gas recirculation fault
Check the wiring harness,
External exhaust gas Negative control deviation
connectors, EGR valve,
3028.03 E49ED3 recirculation 1 not Target less than actual value,
ECU A700D engine control
activated controlled PWM goes
unit
towards minimum
Exhaust gas recirculation fault
Check the wiring harness,
External exhaust gas Positive control deviation
connectors, EGR valve,
3028.04 E49ED4 recirculation 1 not Target greater than actual value,
ECU A700D engine control
activated controlled PWM goes
unit
towards maximum
Exhaust gas recirculation fault
Current too high (switched off) –
Check the wiring harness,
External exhaust gas current higher than permitted
connectors, EGR valve,
3028.05 E49ED5 recirculation 1 not minimum value although
ECU A700D engine control
activated not energised
unit
Threshold violation when switched
off
LBH/Version 01/07.2007/en/lbhhae0/06.02.2013

Exhaust gas recirculation fault

Check the wiring harness,
External exhaust gas Current too low (activated state) –
connectors, EGR valve,
3028.06 E49ED6 recirculation 1 not current less than permitted
ECU A700D engine control
activated minimum value
unit
Threshold violation
Exhaust gas recirculation fault
Check the wiring harness,
External exhaust gas Current too high (activated state) –
connectors, EGR valve,
3028.07 E49ED7 recirculation 1 not current higher than permitted
ECU A700D engine control
activated maximum value
unit
Threshold violation
Exhaust gas recirculation fault Check the wiring harness,
External exhaust gas
EGR open without activation connectors, EGR valve,
3028.11 E49EDB recirculation 1 not
“Open” status is read even ECU A700D engine control
activated
without activation unit
Exhaust gas recirculation fault Check the wiring harness,
External exhaust gas
EGR closed without activation connectors, EGR valve,
3028.12 E49EDC recirculation 1 not
“Closed” status is read even ECU A700D engine control
activated
without activation unit

L524 - 659 / from 17890 copyright by 19.1-25 of 52

L528 - 660 / from 17891
L538 - 433 / from 17893 MJFCIFSS
L542 - 435 / from 17895
Service Codes, Diagnose Service code
Malfunctions

ERROR Motor This kind of malfunction is accompanied by a 1-second warning tone

Service code
Effect Cause Remedy
A700 UEC3
Air flap fault
Check the wiring harness,
Short circuit to earth or cable rupture
3029.00 E49F34 Air flap not activated connectors, air flap, ECU
Output and feedback values do
A700D engine control unit
not match
Air flap fault
Check the wiring harness,
Shorted to supply voltage
3029.01 E49F35 Air flap not activated connectors, air flap, ECU
Output and feedback values do
A700D engine control unit
not match
Air flap fault
Hardware fault Check the ECU A700D
3029.02 E49F36 Air flap not activated
Transistor status does not match engine control unit
feedback value
Air flap fault
Negative control deviation Check the wiring harness,
3029.03 E49F37 Air flap not activated Target less than actual value, connectors, air flap, ECU
controlled PWM goes A700D engine control unit
towards minimum
Air flap fault
Positive control deviation Check the wiring harness,
3029.04 E49F38 Air flap not activated Target greater than actual value, connectors, air flap, ECU
controlled PWM goes A700D engine control unit
towards maximum
Air flap fault
Current too high (switched off) –
current higher than permitted Check the wiring harness,
3029.05 E49F39 Air flap not activated minimum value although connectors, air flap, ECU
not energised A700D engine control unit
Threshold violation when switched
off
Air flap fault
Current too low (activated state) – Check the wiring harness,
3029.06 E49F3A Air flap not activated current less than permitted connectors, air flap, ECU
minimum value A700D engine control unit
Threshold violation
Air flap fault
Current too high (activated state) – Check the wiring harness,
3029.07 E49F3B Air flap not activated current higher than permitted connectors, air flap, ECU
maximum value A700D engine control unit
Threshold violation
Check the wiring harness,
LBH/Version 01/07.2007/en/lbhhae0/06.02.2013

Engine cannot be Starter fault

3032.00 E4A060 connectors, starter, ECU
started Short circuit to earth or cable rupture
A700D engine control unit
Check the wiring harness,
Engine cannot be Starter fault
3032.01 E4A061 connectors, starter, ECU
started Shorted to supply voltage
A700D engine control unit
Check the wiring harness,
Heating flange 1 fault
connectors, heating
Preglow and afterglow Short circuit to earth or cable rupture
3035.00 E4A18C flange/glow plug unit,
phases fail Output and feedback values do
external relay, ECU A700D
not match
engine control unit
Check the wiring harness,
Heating flange 1 fault
connectors, heating
Preglow and afterglow Shorted to supply voltage
3035.01 E4A18D flange/glow plug unit,
phases fail Output and feedback values do
external relay, ECU A700D
not match
engine control unit

19.1-26 of 52 copyright by L524 - 659 / from 17890

L528 - 660 / from 17891
MJFCIFSS L538 - 433 / from 17893
L542 - 435 / from 17895
 Service code Service Codes, Diagnose
Malfunctions

ERROR Motor This kind of malfunction is accompanied by a 1-second warning tone

Service code
Effect Cause Remedy
A700 UEC3
Heating flange 1 fault
Preglow and afterglow Hardware fault Check the ECU A700D
3035.02 E4A18E
phases fail Transistor status does not match engine control unit
feedback status
Heating flange 1 fault Check the wiring harness,
Negative control deviation connectors, heating
Preglow and afterglow
3035.03 E4A18F Target less than actual value, flange/glow plug unit,
phases fail
controlled PWM goes external relay, ECU A700D
towards minimum engine control unit
Heating flange 1 fault Check the wiring harness,
Positive control deviation connectors, heating
Preglow and afterglow
3035.04 E4A190 Target greater than actual value, flange/glow plug unit,
phases fail
controlled PWM goes external relay, ECU A700D
towards maximum engine control unit
Heating flange 1 fault
Current too high (switched off) – Check the wiring harness,
current higher than permitted connectors, heating
Preglow and afterglow
3035.05 E4A191 minimum value although flange/glow plug unit,
phases fail
not energised external relay, ECU A700D
Threshold violation when switched engine control unit
off
Heating flange 1 fault Check the wiring harness,
Current too low (activated state) – connectors, heating
Preglow and afterglow
3035.06 E4A192 current less than permitted flange/glow plug unit,
phases fail
minimum value external relay, ECU A700D
Threshold violation engine control unit
Heating flange 1 fault Check the wiring harness,
Current too high (activated state) – connectors, heating
Preglow and afterglow
3035.07 E4A193 current higher than permitted flange/glow plug unit,
phases fail
maximum value external relay, ECU A700D
Threshold violation engine control unit
Heating flange 1 fault Check the wiring harness,
No voltage in heating element connectors, heating
Preglow and afterglow
3035.11 E4A197 A low level is read despite activation flange/glow plug unit,
phases fail
– the external relay has not switched external relay, ECU A700D
correctly engine control unit
Heating flange 1 fault Check the wiring harness,
Voltage in heating element connectors, heating
Preglow and afterglow
3035.12 E4A198 A high level is read despite no flange/glow plug unit,
phases fail
activation – the external relay has external relay, ECU A700D
LBH/Version 01/07.2007/en/lbhhae0/06.02.2013

not switched correctly engine control unit

Check the wiring harness,
Heating flange 2 fault
connectors, heating
Preglow and afterglow Short circuit to earth or cable rupture
3036.00 E4A1F0 flange/glow plug unit,
phases fail Output and feedback values do
external relay, ECU A700D
not match
engine control unit
Check the wiring harness,
Heating flange 2 fault
connectors, heating
Preglow and afterglow Shorted to supply voltage
3036.01 E4A1F1 flange/glow plug unit,
phases fail Output and feedback values do
external relay, ECU A700D
not match
engine control unit
Heating flange 2 fault
Preglow and afterglow Hardware fault Check the ECU A700D
3036.02 E4A1F2
phases fail Transistor status does not match engine control unit
feedback status

L524 - 659 / from 17890 copyright by 19.1-27 of 52

L528 - 660 / from 17891
L538 - 433 / from 17893 MJFCIFSS
L542 - 435 / from 17895
Service Codes, Diagnose Service code
Malfunctions

ERROR Motor This kind of malfunction is accompanied by a 1-second warning tone

Service code
Effect Cause Remedy
A700 UEC3
Heating flange 2 fault Check the wiring harness,
Negative control deviation connectors, heating
Preglow and afterglow
3036.03 E4A1F3 Target less than actual value, flange/glow plug unit,
phases fail
controlled PWM goes external relay, ECU A700D
towards minimum engine control unit
Heating flange 2 fault Check the wiring harness,
Positive control deviation connectors, heating
Preglow and afterglow
3036.04 E4A1F4 Target greater than actual value, flange/glow plug unit,
phases fail
controlled PWM goes external relay, ECU A700D
towards maximum engine control unit
Heating flange 2 fault
Current too high (switched off) – Check the wiring harness,
current higher than permitted connectors, heating
Preglow and afterglow
3036.05 E4A1F5 minimum value although flange/glow plug unit,
phases fail
not energised external relay, ECU A700D
Threshold violation when switched engine control unit
off
Heating flange 2 fault Check the wiring harness,
Current too low (activated state) – connectors, heating
Preglow and afterglow
3036.06 E4A1F6 current less than permitted flange/glow plug unit,
phases fail
minimum value external relay, ECU A700D
Threshold violation engine control unit
Heating flange 2 fault Check the wiring harness,
Current too high (activated state) – connectors, heating
Preglow and afterglow
3036.07 E4A1F7 current higher than permitted flange/glow plug unit,
phases fail
maximum value external relay, ECU A700D
Threshold violation engine control unit
Heating flange 2 fault Check the wiring harness,
No voltage in heating element connectors, heating
Preglow and afterglow
3036.11 E4A1FB A low level is read despite activation flange/glow plug unit,
phases fail
– the external relay has not external relay, ECU A700D
switched correctly engine control unit
Heating flange 2 fault Check the wiring harness,
Voltage in heating element connectors, heating
Preglow and afterglow
3036.12 E4A1FC A high level is read despite no flange/glow plug unit,
phases fail
activation – the external relay has external relay, ECU A700D
not switched correctly engine control unit
Turbocharger fault Check the wiring harness,
Short circuit to earth or cable rupture connectors, turbocharger
3037.00 E4A254 Afterglow phase failure
Output and feedback values do solenoid valve, ECU
LBH/Version 01/07.2007/en/lbhhae0/06.02.2013

not match A700D engine control unit

Turbocharger fault Check the wiring harness,
Shorted to supply voltage connectors, turbocharger
3037.01 E4A255 Afterglow phase failure
Output and feedback values do solenoid valve, ECU
not match A700D engine control unit
Turbocharger fault
Hardware fault Check the ECU A700D
3037.02 E4A256 Afterglow phase failure
Transistor status does not match engine control unit
feedback status
Turbocharger fault
Check the wiring harness,
Negative control deviation
connectors, turbocharger
3037.03 E4A257 Afterglow phase failure Target less than actual value,
solenoid valve, ECU
controlled PWM goes
A700D engine control unit
towards minimum

19.1-28 of 52 copyright by L524 - 659 / from 17890

L528 - 660 / from 17891
MJFCIFSS L538 - 433 / from 17893
L542 - 435 / from 17895
 Service code Service Codes, Diagnose
Malfunctions

ERROR Motor This kind of malfunction is accompanied by a 1-second warning tone

Service code
Effect Cause Remedy
A700 UEC3
Turbocharger fault
Check the wiring harness,
Positive control deviation
connectors, turbocharger
3037.04 E4A258 Afterglow phase failure Target greater than actual value,
solenoid valve, ECU
controlled PWM goes
A700D engine control unit
towards maximum
Turbocharger fault
Current too high (switched off) –
Check the wiring harness,
current higher than permitted
connectors, turbocharger
3037.05 E4A259 Afterglow phase failure minimum value although
solenoid valve, ECU
not energised
A700D engine control unit
Threshold violation when switched
off
Turbocharger fault
Check the wiring harness,
Current too low (activated state) –
connectors, turbocharger
3037.06 E4A25A Afterglow phase failure current less than permitted
solenoid valve, ECU
minimum value
A700D engine control unit
Threshold violation
Turbocharger fault
Check the wiring harness,
Current too high (activated state) –
connectors, turbocharger
3037.07 E4A25B Afterglow phase failure current higher than permitted
solenoid valve, ECU
maximum value
A700D engine control unit
Threshold violation
Turbocharger fault Check the wiring harness,
Turbocharger is not Short circuit to earth or cable rupture connectors, turbocharger
3038.00 E4A2B8
activated Output and feedback values do solenoid valve, ECU
not match A700D engine control unit
Turbocharger fault Check the wiring harness,
Turbocharger is not Shorted to supply voltage connectors, turbocharger
3038.01 E4A2B9
activated Output and feedback values do solenoid valve, ECU
not match A700D engine control unit
Turbocharger fault
Turbocharger is not Hardware fault Check the ECU A700D
3038.02 E4A2BA
activated Transistor status does not match engine control unit
feedback status
Turbocharger fault
Check the wiring harness,
Negative control deviation
Turbocharger is not connectors, turbocharger
3038.03 E4A2BB Target less than actual value,
activated solenoid valve, ECU
controlled PWM goes
A700D engine control unit
towards minimum
Turbocharger fault
LBH/Version 01/07.2007/en/lbhhae0/06.02.2013

Check the wiring harness,

Positive control deviation
Turbocharger is not connectors, turbocharger
3038.04 E4A2BC Target greater than actual value,
activated solenoid valve, ECU
controlled PWM goes
A700D engine control unit
towards maximum
Turbocharger fault
Current too high (switched off) –
Check the wiring harness,
current higher than permitted
Turbocharger is not connectors, turbocharger
3038.05 E4A2BD minimum value although not
activated solenoid valve, ECU
energised
A700D engine control unit
Threshold violation when switched
off
Turbocharger fault
Check the wiring harness,
Current too low (activated state) –
Turbocharger is not connectors, turbocharger
3038.06 E4A2BE current less than permitted minimum
activated solenoid valve, ECU
value
A700D engine control unit
Threshold violation

L524 - 659 / from 17890 copyright by 19.1-29 of 52

L528 - 660 / from 17891
L538 - 433 / from 17893 MJFCIFSS
L542 - 435 / from 17895
Service Codes, Diagnose Service code
Malfunctions

ERROR Motor This kind of malfunction is accompanied by a 1-second warning tone

Service code
Effect Cause Remedy
A700 UEC3
Turbocharger fault
Check the wiring harness,
Current too high (activated state) –
Turbocharger is not connectors, turbocharger
3038.07 E4A2BF current higher than permitted
activated solenoid valve, ECU
maximum value
A700D engine control unit
Threshold violation
Exhaust gas recirculation fault Check the wiring harness,
External exhaust gas
Short circuit to earth or cable rupture connectors, EGR valve,
3039.00 E4A31C recirculation 2 not
Output and feedback values do not ECU A700D engine control
activated
match unit
Exhaust gas recirculation fault Check the wiring harness,
External exhaust gas
Shorted to supply voltage connectors, EGR valve,
3039.01 E4A31D recirculation 2 not
Output and feedback values do not ECU A700D engine control
activated
match unit
Exhaust gas recirculation fault
External exhaust gas
Hardware fault Check the ECU A700D
3039.02 E4A31E recirculation 2 not
Transistor status does not match engine control unit
activated
feedback value
Exhaust gas recirculation fault
Check the wiring harness,
External exhaust gas Negative control deviation
connectors, EGR valve,
3039.03 E4A31F recirculation 2 not Target less than actual value,
ECU A700D engine control
activated controlled PWM goes towards
unit
minimum
Exhaust gas recirculation fault
Check the wiring harness,
External exhaust gas Positive control deviation
connectors, EGR valve,
3039.04 E4A320 recirculation 2 not Target greater than actual value,
ECU A700D engine control
activated controlled PWM goes towards
unit
maximum
Exhaust gas recirculation fault
Current too high (switched off) –
Check the wiring harness,
External exhaust gas current higher than permitted
connectors, EGR valve,
3039.05 E4A321 recirculation 2 not minimum value although not
ECU A700D engine control
activated energised
unit
Threshold violation when switched
off
Exhaust gas recirculation fault
Check the wiring harness,
External exhaust gas Current too low (activated state) –
connectors, EGR valve,
3039.06 E4A322 recirculation 2 not current less than permitted minimum
ECU A700D engine control
activated value
unit
Threshold violation
LBH/Version 01/07.2007/en/lbhhae0/06.02.2013

Exhaust gas recirculation fault

Check the wiring harness,
External exhaust gas Current too high (activated state) –
connectors, EGR valve,
3039.07 E4A323 recirculation 2 not current higher than permitted
ECU A700D engine control
activated maximum value
unit
Threshold violation
Exhaust gas recirculation fault Check the wiring harness,
External exhaust gas
EGR open without activation connectors, EGR valve,
3039.11 E4A327 recirculation 2 not
"Open" status is read even without ECU A700D engine control
activated
activation unit
Exhaust gas recirculation fault Check the wiring harness,
External exhaust gas
EGR closed without activation connectors, EGR valve,
3039.12 E4A328 recirculation 2 not
“Closed” status is read even without ECU A700D engine control
activated
activation unit
Engine speed output fault
Check the wiring harness,
Short circuit to earth or cable rupture
3049.00 E4A704 No direct effect connectors, connected
Output and feedback values do not
module
match

19.1-30 of 52 copyright by L524 - 659 / from 17890

L528 - 660 / from 17891
MJFCIFSS L538 - 433 / from 17893
L542 - 435 / from 17895
 Service code Service Codes, Diagnose
Malfunctions

ERROR Motor This kind of malfunction is accompanied by a 1-second warning tone

Service code
Effect Cause Remedy
A700 UEC3
Engine speed output fault
Check the wiring harness,
Shorted to supply voltage
3049.01 E4A705 No direct effect connectors, connected
Output and feedback values do not
module
match
Check the wiring harness,
Cylinder A1 fault
connectors, solenoid valve,
3050.00 E4A768 No direct effect Incorrect current measurement or
ECU A700D engine control
cable rupture
unit
Check the wiring harness,
Cylinder A1 fault
connectors, solenoid valve,
3050.01 E4A769 No direct effect Excess low side current (earth
ECU A700D engine control
switch)
unit
Check the wiring harness,
Cylinder A1 fault
connectors, solenoid valve,
3050.02 E4A76A No direct effect Excess high side current (positive
ECU A700D engine control
switch)
unit
Check the wiring harness,
Cylinder A1 fault
connectors, solenoid valve,
3050.03 E4A76B No direct effect Excess high side current on free
ECU A700D engine control
wheel cylinder
unit
Cylinder A1 fault Replace the ECU A700D
3050.04 E4A76C No direct effect
No flight time measured engine control unit
Check the wiring harness,
Cylinder A1 fault connectors, solenoid valve,
3050.05 E4A76D No direct effect
Flight time too short ECU A700D engine control
unit
Check the wiring harness,
Cylinder A1 fault connectors, solenoid valve,
3050.06 E4A76E No direct effect
Flight time too long ECU A700D engine control
unit
Cylinder A1 fault Replace the ECU A700D
3050.07 E4A76F No direct effect
No rise time measured engine control unit
New data record or replace
Cylinder A1 fault
3050.08 E4A770 No direct effect the ECU A700D engine
Rise time too long
control unit
Check the wiring harness,
Cylinder A2 fault
connectors, solenoid valve,
3051.00 E4A7CC No direct effect Incorrect current measurement or
ECU A700D engine control
cable rupture
unit
LBH/Version 01/07.2007/en/lbhhae0/06.02.2013

Check the wiring harness,

Cylinder A2 fault
connectors, solenoid valve,
3051.01 E4A7CD No direct effect Excess low side current (earth
ECU A700D engine control
switch)
unit
Check the wiring harness,
Cylinder A2 fault
connectors, solenoid valve,
3051.02 E4A7CE No direct effect Excess high side current (positive
ECU A700D engine control
switch)
unit
Check the wiring harness,
Cylinder A2 fault
connectors, solenoid valve,
3051.03 E4A7CF No direct effect Excess high side current on free
ECU A700D engine control
wheel cylinder
unit
Cylinder A2 fault Replace the ECU A700D
3051.04 E4A7D0 No direct effect
No flight time measured engine control unit

L524 - 659 / from 17890 copyright by 19.1-31 of 52

L528 - 660 / from 17891
L538 - 433 / from 17893 MJFCIFSS
L542 - 435 / from 17895
Service Codes, Diagnose Service code
Malfunctions

ERROR Motor This kind of malfunction is accompanied by a 1-second warning tone

Service code
Effect Cause Remedy
A700 UEC3
Check the wiring harness,
Cylinder A2 fault connectors, solenoid valve,
3051.05 E4A7D1 No direct effect
Flight time too short ECU A700D engine control
unit
Check the wiring harness,
Cylinder A2 fault connectors, solenoid valve,
3051.06 E4A7D2 No direct effect
Flight time too long ECU A700D engine control
unit
Cylinder A2 fault Replace the ECU A700D
3051.07 E4A7D3 No direct effect
No rise time measured engine control unit
New data record or replace
Cylinder A2 fault
3051.08 E4A7D4 No direct effect the ECU A700D engine
Rise time too long
control unit
Check the wiring harness,
Cylinder A3 fault
connectors, solenoid valve,
3052.00 E4A830 No direct effect Incorrect current measurement or
ECU A700D engine control
cable rupture
unit
Check the wiring harness,
Cylinder A3 fault
connectors, solenoid valve,
3052.01 E4A831 No direct effect Excess low side current (earth
ECU A700D engine control
switch)
unit
Check the wiring harness,
Cylinder A3 fault
connectors, solenoid valve,
3052.02 E4A832 No direct effect Excess high side current (positive
ECU A700D engine control
switch)
unit
Check the wiring harness,
Cylinder A3 fault
connectors, solenoid valve,
3052.03 E4A833 No direct effect Excess high side current on free
ECU A700D engine control
wheel cylinder
unit
Cylinder A3 fault Replace the ECU A700D
3052.04 E4A834 No direct effect
No flight time measured engine control unit
Check the wiring harness,
Cylinder A3 fault connectors, solenoid valve,
3052.05 E4A835 No direct effect
Flight time too short ECU A700D engine control
unit
Check the wiring harness,
Cylinder A3 fault connectors, solenoid valve,
3052.06 E4A836 No direct effect
Flight time too long ECU A700D engine control
unit
LBH/Version 01/07.2007/en/lbhhae0/06.02.2013

Cylinder A3 fault Replace the ECU A700D

3052.07 E4A837 No direct effect
No rise time measured engine control unit
New data record or replace
Cylinder A3 fault
3052.08 E4A838 No direct effect the ECU A700D engine
Rise time too long
control unit
Check the wiring harness,
Cylinder A4 fault
connectors, solenoid valve,
3053.00 E4A894 No direct effect Incorrect current measurement or
ECU A700D engine control
cable rupture
unit
Check the wiring harness,
Cylinder A4 fault
connectors, solenoid valve,
3053.01 E4A895 No direct effect Excess low side current (earth
ECU A700D engine control
switch)
unit
Check the wiring harness,
Cylinder A4 fault
connectors, solenoid valve,
3053.02 E4A896 No direct effect Excess high side current (positive
ECU A700D engine control
switch)
unit

19.1-32 of 52 copyright by L524 - 659 / from 17890

L528 - 660 / from 17891
MJFCIFSS L538 - 433 / from 17893
L542 - 435 / from 17895
 Service code Service Codes, Diagnose
Malfunctions

ERROR Motor This kind of malfunction is accompanied by a 1-second warning tone

Service code
Effect Cause Remedy
A700 UEC3
Check the wiring harness,
Cylinder A4 fault
connectors, solenoid valve,
3053.03 E4A897 No direct effect Excess high side current on free
ECU A700D engine control
wheel cylinder
unit
Cylinder A4 fault Replace the ECU A700D
3053.04 E4A898 No direct effect
No flight time measured engine control unit
Check the wiring harness,
Cylinder A4 fault connectors, solenoid valve,
3053.05 E4A899 No direct effect
Flight time too short ECU A700D engine control
unit
Check the wiring harness,
Cylinder A4 fault connectors, solenoid valve,
3053.06 E4A89A No direct effect
Flight time too long ECU A700D engine control
unit
Cylinder A4 fault Replace the ECU A700D
3053.07 E4A89B No direct effect
No rise time measured engine control unit
New data record or replace
Cylinder A4 fault
3053.08 E4A89C No direct effect the ECU A700D engine
Rise time too long
control unit
Check the wiring harness,
Cylinder B1 fault
connectors, solenoid valve,
3058.00 E4AA88 No direct effect Incorrect current measurement or
ECU A700D engine control
cable rupture
unit
Check the wiring harness,
Cylinder B1 fault
connectors, solenoid valve,
3058.01 E4AA89 No direct effect Excess low side current (earth
ECU A700D engine control
switch)
unit
Check the wiring harness,
Cylinder B1 fault
connectors, solenoid valve,
3058.02 E4AA8A No direct effect Excess high side current (positive
ECU A700D engine control
switch)
unit
Check the wiring harness,
Cylinder B1 fault
connectors, solenoid valve,
3058.03 E4AA8B No direct effect Excess high side current on free
ECU A700D engine control
wheel cylinder
unit
Cylinder B1 fault Replace the ECU A700D
3058.04 E4AA8C No direct effect
No flight time measured engine control unit
Check the wiring harness,
Cylinder B1 fault connectors, solenoid valve,
LBH/Version 01/07.2007/en/lbhhae0/06.02.2013

3058.05 E4AA8D No direct effect

Flight time too short ECU A700D engine control
unit
Check the wiring harness,
Cylinder B1 fault connectors, solenoid valve,
3058.06 E4AA8E No direct effect
Flight time too long ECU A700D engine control
unit
Cylinder B1 fault Replace the ECU A700D
3058.07 E4AA8F No direct effect
No rise time measured engine control unit
New data record or replace
Cylinder B1 fault
3058.08 E4AA90 No direct effect the ECU A700D engine
Rise time too long
control unit
Check the wiring harness,
Cylinder B2 fault
connectors, solenoid valve,
3059.00 E4AAEC No direct effect Incorrect current measurement or
ECU A700D engine control
cable rupture
unit

L524 - 659 / from 17890 copyright by 19.1-33 of 52

L528 - 660 / from 17891
L538 - 433 / from 17893 MJFCIFSS
L542 - 435 / from 17895
Service Codes, Diagnose Service code
Malfunctions

ERROR Motor This kind of malfunction is accompanied by a 1-second warning tone

Service code
Effect Cause Remedy
A700 UEC3
Check the wiring harness,
Cylinder B2 fault
connectors, solenoid valve,
3059.01 E4AAED No direct effect Excess low side current (earth
ECU A700D engine control
switch)
unit
Check the wiring harness,
Cylinder B2 fault
connectors, solenoid valve,
3059.02 E4AAEE No direct effect Excess high side current (positive
ECU A700D engine control
switch)
unit
Check the wiring harness,
Cylinder B2 fault
connectors, solenoid valve,
3059.03 E4AAEF No direct effect Excess high side current on free
ECU A700D engine control
wheel cylinder
unit
Cylinder B2 fault Replace the ECU A700D
3059.04 E4AAF0 No direct effect
No flight time measured engine control unit
Check the wiring harness,
Cylinder B2 fault connectors, solenoid valve,
3059.05 E4AAF1 No direct effect
Flight time too short ECU A700D engine control
unit
Check the wiring harness,
Cylinder B2 fault connectors, solenoid valve,
3059.06 E4AAF2 No direct effect
Flight time too long ECU A700D engine control
unit
Cylinder B2 fault Replace the ECU A700D
3059.07 E4AAF3 No direct effect
No rise time measured engine control unit
New data record or replace
Cylinder B2 fault
3059.08 E4AAF4 No direct effect the ECU A700D engine
Rise time too long
control unit
Check the wiring harness,
Cylinder B3 fault
connectors, solenoid valve,
3060.00 E4AB50 No direct effect Incorrect current measurement or
ECU A700D engine control
cable rupture
unit
Check the wiring harness,
Cylinder B3 fault
connectors, solenoid valve,
3060.01 E4AB51 No direct effect Excess low side current (earth
ECU A700D engine control
switch)
unit
Check the wiring harness,
Cylinder B3 fault
connectors, solenoid valve,
3060.02 E4AB52 No direct effect Excess high side current (positive
ECU A700D engine control
switch)
unit
LBH/Version 01/07.2007/en/lbhhae0/06.02.2013

Check the wiring harness,

Cylinder B3 fault
connectors, solenoid valve,
3060.03 E4AB53 No direct effect Excess high side current on free
ECU A700D engine control
wheel cylinder
unit
Cylinder B3 fault Replace the ECU A700D
3060.04 E4AB54 No direct effect
No flight time measured engine control unit
Check the wiring harness,
Cylinder B3 fault connectors, solenoid valve,
3060.05 E4AB55 No direct effect
Flight time too short ECU A700D engine control
unit
Check the wiring harness,
Cylinder B3 fault connectors, solenoid valve,
3060.06 E4AB56 No direct effect
Flight time too long ECU A700D engine control
unit
Cylinder B3 fault Replace the ECU A700D
3060.07 E4AB57 No direct effect
No rise time measured engine control unit

19.1-34 of 52 copyright by L524 - 659 / from 17890

L528 - 660 / from 17891
MJFCIFSS L538 - 433 / from 17893
L542 - 435 / from 17895
 Service code Service Codes, Diagnose
Malfunctions

ERROR Motor This kind of malfunction is accompanied by a 1-second warning tone

Service code
Effect Cause Remedy
A700 UEC3
New data record or replace
Cylinder B3 fault
3060.08 E4AB58 No direct effect the ECU A700D engine
Rise time too long
control unit
Check the wiring harness,
Cylinder B4 fault
connectors, solenoid valve,
3061.00 E4ABB4 No direct effect Incorrect current measurement or
ECU A700D engine control
cable rupture
unit
Check the wiring harness,
Cylinder B4 fault
connectors, solenoid valve,
3061.01 E4ABB5 No direct effect Excess low side current (earth
ECU A700D engine control
switch)
unit
Check the wiring harness,
Cylinder B4 fault
connectors, solenoid valve,
3061.02 E4ABB6 No direct effect Excess high side current (positive
ECU A700D engine control
switch)
unit
Check the wiring harness,
Cylinder B4 fault
connectors, solenoid valve,
3061.03 E4ABB7 No direct effect Excess high side current on free
ECU A700D engine control
wheel cylinder
unit
Cylinder B4 fault Replace the ECU A700D
3061.04 E4ABB8 No direct effect
No flight time measured engine control unit
Check the wiring harness,
Cylinder B4 fault connectors, solenoid valve,
3061.05 E4ABB9 No direct effect
Flight time too short ECU A700D engine control
unit
Check the wiring harness,
Cylinder B4 fault connectors, solenoid valve,
3061.06 E4ABBA No direct effect
Flight time too long ECU A700D engine control
unit
Cylinder B4 fault Replace the ECU A700D
3061.07 E4ABBB No direct effect
No rise time measured engine control unit
New data record or replace
Cylinder B4 fault
3061.08 E4ABBC No direct effect the ECU A700D engine
Rise time too long
control unit
Injection system fault Check the wiring harness,
Cylinder fault connectors, solenoid valve,
3069.00 E4AED4 Engine shutdown
More than the permitted number of ECU A700D engine control
solenoid valves have failed unit
Injection system fault
LBH/Version 01/07.2007/en/lbhhae0/06.02.2013

Injection overlap to bank A

Check the start and
3069.01 E4AED5 Engine shutdown Distance between the current tooth
duration of injection
and the next tooth on bank A is
more than 540° crankshaft angle
Injection system fault
Injection overlap to bank B
Check the start and
3069.02 E4AED6 Engine shutdown Distance between the current tooth
duration of injection
and the next tooth on bank A is
more than 540° crankshaft angle
Injection system fault
Check the wiring harness,
High side short circuit to earth on
connectors, solenoid valve,
3069.03 E4AED7 No direct effect bank A
ECU A700D engine control
Excess high side PWM current on all
unit
injectors on bank A

L524 - 659 / from 17890 copyright by 19.1-35 of 52

L528 - 660 / from 17891
L538 - 433 / from 17893 MJFCIFSS
L542 - 435 / from 17895
Service Codes, Diagnose Service code
Malfunctions

ERROR Motor This kind of malfunction is accompanied by a 1-second warning tone

Service code
Effect Cause Remedy
A700 UEC3
Injection system fault
Check the wiring harness,
High side short circuit to earth on
connectors, solenoid valve,
3069.04 E4AED8 No direct effect bank B
ECU A700D engine control
Excess high side PWM current on all
unit
injectors on bank B
Injection system fault
Check the wiring harness,
High side short circuit to supply
connectors, solenoid valve,
3069.05 E4AED9 No direct effect voltage on bank A
ECU A700D engine control
Excess high side FREEcurrent on all
unit
injectors on bank A
Injection system fault
Check the wiring harness,
High side short circuit to supply
connectors, solenoid valve,
3069.06 E4AEDA No direct effect voltage on bank B
ECU A700D engine control
Excess high side FREEcurrent on all
unit
injectors on bank B
Injection system fault
Low side short circuit to earth on Check the wiring harness,
bank A connectors, solenoid valve,
3069.07 E4AEDB No direct effect
On at least one injector on bank A ECU A700D engine control
Rise time too long or cannot be unit
measured
Injection system fault
Low side short circuit to earth on Check the wiring harness,
bank B connectors, solenoid valve,
3069.08 E4AEDC No direct effect
On at least one injector on bank B ECU A700D engine control
Rise time too long or cannot be unit
measured
Injection system fault
Low side short circuit to supply
Check the wiring harness,
voltage on bank A
connectors, solenoid valve,
3069.09 E4AEDD No direct effect On at least one injector on bank A
ECU A700D engine control
Excess low side current, excess
unit
high side free current on all other
injectors in this bank
Injection system fault
Low side short circuit to supply
Check the wiring harness,
voltage on bank B
connectors, solenoid valve,
3069.11 E4AEDF No direct effect On at least one injector on bank B
ECU A700D engine control
Excess low side current, excess
unit
high side free current on all other
LBH/Version 01/07.2007/en/lbhhae0/06.02.2013

injectors in this bank

Check engine operation
Overspeed fault
(overspeed due to thrust
3069.39 E4AEFB Engine shutdown Overspeed from speed sensor 2 –
mode), check ECU A700D
safety limit exceeded
engine control unit
Check engine operation
Overspeed fault
(overspeed due to thrust
3070.00 E4AF38 No direct effect Overspeed from speed sensor 1 –
mode), check ECU A700D
warning limit exceeded
engine control unit
Check engine operation
Overspeed fault
(overspeed due to thrust
3070.01 E4AF39 No direct effect Overspeed from speed sensor 2 –
mode), check ECU A700D
warning limit exceeded
engine control unit
Check engine operation
Overspeed fault
(overspeed due to thrust
3070.02 E4AF3A Engine shutdown Overspeed from speed sensor 1 –
mode), check ECU A700D
safety limit exceeded
engine control unit

19.1-36 of 52 copyright by L524 - 659 / from 17890

L528 - 660 / from 17891
MJFCIFSS L538 - 433 / from 17893
L542 - 435 / from 17895
 Service code Service Codes, Diagnose
Malfunctions

ERROR Motor This kind of malfunction is accompanied by a 1-second warning tone

Service code
Effect Cause Remedy
A700 UEC3
Synchronisation error Turn the ignition off and on
Engine cannot be
3071.00 E4AF9C Synchronisation lost while engine again; check the engine
started
was running; gap not detected speed and phase sensor
Synchronisation error
Turn the ignition off and on
Engine cannot be Distance between gap (engine
3071.01 E4AF9D again; check the engine
started speed sensor) and phase sensor
speed and phase sensor
signal too great
Synchronisation error
Incorrect number of teeth – during Turn the ignition off and on
Engine cannot be
3071.02 E4AF9E the synchronisation phase, the again; check the engine
started
number of teeth measured between speed sensor
successive gaps is not as specified
Synchronisation error
Turn the ignition off and on
Engine cannot be Synchronisation not possible –
3071.03 E4AF9F again; check the engine
started speed too low during
speed and phase sensor
synchronisation phase
Synchronisation error
Faulty camshaft wheel index counter Turn the ignition off and on
Engine cannot be
3071.04 E4AFA0 – the additional tooth of the Bosch again; check the engine
started
camshaft wheel is not measured at speed and phase sensor
the right place
Emergency shutdown at Check distance of engine
the same time as speed sensor to flywheel
redundant sensor (1 or Engine speed sensor 1 fault (0.5 – 2.0 mm), check
3072.00 E4B000
2) fails; otherwise Signal from impulse recorder lost wiring to engine speed
engine speed recorded sensor, check engine
by redundant sensor speed sensor

Emergency shutdown at Check distance of engine

the same time as speed sensor to flywheel
Engine speed sensor 1 fault
redundant sensor (1 or (0.5 – 2.0 mm), check
3072.01 E4B001 Engine speed sensor does not
2) fails; otherwise wiring to engine speed
provide a signal
engine speed recorded sensor, check engine
by redundant sensor speed sensor

Emergency shutdown at Check distance of engine

the same time as Engine speed sensor 1 fault speed sensor to flywheel
redundant sensor (1 or Invalid signal difference – engine (0.5 – 2.0 mm), check
3072.02 E4B002
2) fails; otherwise speed measurement gradient too wiring to engine speed
LBH/Version 01/07.2007/en/lbhhae0/06.02.2013

engine speed recorded steep sensor, check engine

by redundant sensor speed sensor

Emergency shutdown at Check distance of engine

the same time as speed sensor to flywheel
Engine speed sensor 1 fault
redundant sensor (1 or (0.5 – 2.0 mm), check
3072.03 E4B003 Frequency too high (implausible
2) fails; otherwise wiring to engine speed
value)
engine speed recorded sensor, check engine
by redundant sensor speed sensor

Emergency shutdown at
Engine speed sensor 1 fault
the same time as Check the installation of
Impulse sensor polarity reversed –
redundant sensor (1 or the engine speed sensor;
3072.04 E4B004 engine speed sensor incorrectly
2) fails; otherwise check the ECU A700D
fitted or wrongly configured in the
engine speed recorded engine control unit
ECU A700D engine control unit
by redundant sensor

L524 - 659 / from 17890 copyright by 19.1-37 of 52

L528 - 660 / from 17891
L538 - 433 / from 17893 MJFCIFSS
L542 - 435 / from 17895
Service Codes, Diagnose Service code
Malfunctions

ERROR Motor This kind of malfunction is accompanied by a 1-second warning tone

Service code
Effect Cause Remedy
A700 UEC3
Emergency shutdown at
the same time as Check the installation of
Engine speed sensor 1 fault
redundant sensor (1 or the engine speed sensor;
3072.05 E4B005 Incorrect measurement (different
2) fails; otherwise check the ECU A700D
measurement to the other sensor)
engine speed recorded engine control unit
by redundant sensor

Emergency shutdown at Check distance of engine

the same time as speed sensor to flywheel
redundant sensor (1 or Engine speed sensor 2 fault (0.5 – 2.0 mm), check
3073.00 E4B064
2) fails; otherwise Signal from impulse recorder lost wiring to engine speed
engine speed recorded sensor, check engine
by redundant sensor speed sensor

Emergency shutdown at Check distance of engine

the same time as speed sensor to flywheel
Engine speed sensor 2 fault
redundant sensor (1 or (0.5 – 2.0 mm), check
3073.01 E4B065 Engine speed sensor does not
2) fails; otherwise wiring to engine speed
provide a signal
engine speed recorded sensor, check engine
by redundant sensor speed sensor

Emergency shutdown at Check distance of engine

the same time as Engine speed sensor 2 fault speed sensor to flywheel
redundant sensor (1 or Invalid signal difference – engine (0.5 – 2.0 mm), check
3073.02 E4B066
2) fails; otherwise speed measurement gradient too wiring to engine speed
engine speed recorded steep sensor, check engine
by redundant sensor speed sensor

Emergency shutdown at Check distance of engine

the same time as speed sensor to flywheel
Engine speed sensor 2 fault
redundant sensor (1 or (0.5 – 2.0 mm), check
3073.03 E4B067 Frequency too high (implausible
2) fails; otherwise wiring to engine speed
value)
engine speed recorded sensor, check engine
by redundant sensor speed sensor

Emergency shutdown at
Engine speed sensor 2 fault
the same time as Check the installation of
Impulse sensor polarity reversed –
redundant sensor (1 or the engine speed sensor;
3073.04 E4B068 engine speed sensor incorrectly
2) fails; otherwise check the ECU A700D
fitted or wrongly configured in the
engine speed recorded engine control unit
ECU A700D engine control unit
by redundant sensor
LBH/Version 01/07.2007/en/lbhhae0/06.02.2013

Emergency shutdown at
the same time as Check the installation of
Engine speed sensor 2 fault
redundant sensor (1 or the engine speed sensor;
3073.05 E4B069 Incorrect measurement (different
2) fails; otherwise check the ECU A700D
measurement to the other sensor)
engine speed recorded engine control unit
by redundant sensor
Check distance of phase
sensor to flywheel (0.5 –
No effect when engine Phase sensor fault
3074.00 E4B0C8 2.0 mm), check wiring to
is running Signal from impulse recorder lost
phase sensor, check
phase sensor
Phase sensor fault
Check the installation of
Phase sensor polarity reversed –
No effect when engine the engine speed sensor;
3074.04 E4B0CC phase sensor incorrectly fitted or
is running check the ECU A700D
wrongly configured in the ECU
engine control unit
A700D engine control unit

19.1-38 of 52 copyright by L524 - 659 / from 17890

L528 - 660 / from 17891
MJFCIFSS L538 - 433 / from 17893
L542 - 435 / from 17895
 Service code Service Codes, Diagnose
Malfunctions

ERROR Motor This kind of malfunction is accompanied by a 1-second warning tone

Service code
Effect Cause Remedy
A700 UEC3
Emergency shutdown at
the same time as Check the installation of
Phase sensor fault
redundant sensor (1 or the engine speed sensor;
3074.05 E4B0CD Incorrect measurement (different
2) fails; otherwise check the ECU A700D
measurement to the other sensor)
engine speed recorded engine control unit
by redundant sensor
Replacement sensor
value is used. The error Check the wiring and the
Coolant level sensor fault
3077.00 E4B1F4 disappears when the ECU A700D engine control
Short circuit to earth or cable rupture
measured value is in the unit / sensor
defined range
Replacement sensor
value is used. The error Coolant level sensor fault Check the wiring and the
3077.01 E4B1F5 disappears when the Sensor signal: shorted to supply ECU A700D engine control
measured value is in the voltage unit / sensor
defined range
Replacement sensor
value is used. The error Coolant level sensor fault Check the wiring and the
3077.02 E4B1F6 disappears when the Sensor supply voltage: cable rupture ECU A700D engine control
measured value is in the or shorted to earth unit / sensor
defined range
Replacement sensor
value is used. The error Coolant level sensor fault Check the wiring and the
3077.03 E4B1F7 disappears when the Sensor supply voltage: shorted to ECU A700D engine control
measured value is in the supply voltage unit / sensor
defined range
Reduced power or no
Coolant level sensor fault Check the medium for
reaction, depending on
3077.04 E4B1F8 Signal outside permitted range (limit range violation; repair any
the configuration and
1) mechanical problems
sensor
Reduced power or no
Coolant level sensor fault Check the medium for
reaction, depending on
3077.05 E4B1F9 Signal outside permitted range (limit range violation; repair any
the configuration and
2) mechanical problems
sensor
Replacement sensor
LBH/Version 01/07.2007/en/lbhhae0/06.02.2013

value is used. The error Check the wiring and the

Air filter pressure sensor 2 fault
3083.00 E4B44C disappears when the ECU A700D engine control
Short circuit to earth or cable rupture
measured value is in the unit / sensor
defined range
Replacement sensor
value is used. The error Air filter pressure sensor 2 fault Check the wiring and the
3083.01 E4B44D disappears when the Sensor signal: shorted to supply ECU A700D engine control
measured value is in the voltage unit / sensor
defined range
Replacement sensor
value is used. The error Air filter pressure sensor 2 fault Check the wiring and the
3083.02 E4B44E disappears when the Sensor supply voltage: cable rupture ECU A700D engine control
measured value is in the or shorted to earth unit / sensor
defined range

L524 - 659 / from 17890 copyright by 19.1-39 of 52

L528 - 660 / from 17891
L538 - 433 / from 17893 MJFCIFSS
L542 - 435 / from 17895
Service Codes, Diagnose Service code
Malfunctions

ERROR Motor This kind of malfunction is accompanied by a 1-second warning tone

Service code
Effect Cause Remedy
A700 UEC3
Replacement sensor
value is used. The error Air filter pressure sensor 2 fault Check the wiring and the
3083.03 E4B44F disappears when the Sensor supply voltage: shorted to ECU A700D engine control
measured value is in the supply voltage unit / sensor
defined range
Reduced power or no
Air filter pressure sensor 2 fault Check the medium for
reaction, depending on
3083.04 E4B450 Signal outside permitted range (limit range violation; repair any
the configuration and
1) mechanical problems
sensor
Reduced power or no
Air filter pressure sensor 2 fault Check the medium for
reaction, depending on
3083.05 E4B451 Signal outside permitted range (limit range violation; repair any
the configuration and
2) mechanical problems
sensor
Replacement sensor
value is used. The error Check the wiring and the
Charge air pressure sensor fault
3084.00 E4B4B0 disappears when the ECU A700D engine control
Short circuit to earth or cable rupture
measured value is in the unit / sensor
defined range
Replacement sensor
value is used. The error Charge air pressure sensor fault Check the wiring and the
3084.01 E4B4B1 disappears when the Sensor signal: shorted to supply ECU A700D engine control
measured value is in the voltage unit / sensor
defined range
Replacement sensor
value is used. The error Charge air pressure sensor fault Check the wiring and the
3084.02 E4B4B2 disappears when the Sensor supply voltage: cable rupture ECU A700D engine control
measured value is in the or shorted to earth unit / sensor
defined range
Replacement sensor
value is used. The error Charge air pressure sensor fault Check the wiring and the
3084.03 E4B4B3 disappears when the Sensor supply voltage: shorted to ECU A700D engine control
measured value is in the supply voltage unit / sensor
defined range
Reduced power or no
Charge air pressure sensor fault Check the medium for
reaction, depending on
3084.04 E4B4B4 Signal outside permitted range (limit range violation; repair any
LBH/Version 01/07.2007/en/lbhhae0/06.02.2013

the configuration and

1) mechanical problems
sensor
Reduced power or no
Charge air pressure sensor fault Check the medium for
reaction, depending on
3084.05 E4B4B5 Signal outside permitted range (limit range violation; repair any
the configuration and
2) mechanical problems
sensor
Replacement sensor
value is used. The error Check the wiring and the
Oil pressure sensor fault
3085.00 E4B514 disappears when the ECU A700D engine control
Short circuit to earth or cable rupture
measured value is in the unit / sensor
defined range
Replacement sensor
value is used. The error Oil pressure sensor fault Check the wiring and the
3085.01 E4B515 disappears when the Sensor signal: shorted to supply ECU A700D engine control
measured value is in the voltage unit / sensor
defined range

19.1-40 of 52 copyright by L524 - 659 / from 17890

L528 - 660 / from 17891
MJFCIFSS L538 - 433 / from 17893
L542 - 435 / from 17895
 Service code Service Codes, Diagnose
Malfunctions

ERROR Motor This kind of malfunction is accompanied by a 1-second warning tone

Service code
Effect Cause Remedy
A700 UEC3
Replacement sensor
value is used. The error Oil pressure sensor fault Check the wiring and the
3085.02 E4B516 disappears when the Sensor supply voltage: cable rupture ECU A700D engine control
measured value is in the or shorted to earth unit / sensor
defined range
Replacement sensor
value is used. The error Oil pressure sensor fault Check the wiring and the
3085.03 E4B517 disappears when the Sensor supply voltage: shorted to ECU A700D engine control
measured value is in the supply voltage unit / sensor
defined range
Reduced power or no
Oil pressure sensor fault Check the medium for
reaction, depending on
3085.04 E4B518 Signal outside permitted range (limit range violation; repair any
the configuration and
1) mechanical problems
sensor
Reduced power or no
Oil pressure sensor fault Check the medium for
reaction, depending on
3085.05 E4B519 Signal outside permitted range (limit range violation; repair any
the configuration and
2) mechanical problems
sensor
Replacement sensor
value is used. The error Check the wiring and the
Air filter pressure sensor 1 fault
3087.00 E4B5DC disappears when the ECU A700D engine control
Short circuit to earth or cable rupture
measured value is in the unit / sensor
defined range
Replacement sensor
value is used. The error Air filter pressure sensor 1 fault Check the wiring and the
3087.01 E4B5DD disappears when the Sensor signal: shorted to supply ECU A700D engine control
measured value is in the voltage unit / sensor
defined range
Replacement sensor
value is used. The error Air filter pressure sensor 1 fault Check the wiring and the
3087.02 E4B5DE disappears when the Sensor supply voltage: cable rupture ECU A700D engine control
measured value is in the or shorted to earth unit / sensor
defined range
Replacement sensor
value is used. The error Air filter pressure sensor 1 fault Check the wiring and the
LBH/Version 01/07.2007/en/lbhhae0/06.02.2013

3087.03 E4B5DF disappears when the Sensor supply voltage: shorted to ECU A700D engine control
measured value is in the supply voltage unit / sensor
defined range
Reduced power or no
Air filter pressure sensor 1 fault Check the medium for
reaction, depending on
3087.04 E4B5E0 Signal outside permitted range (limit range violation; repair any
the configuration and
1) mechanical problems
sensor
Reduced power or no
Air filter pressure sensor 1 fault Check the medium for
reaction, depending on
3087.05 E4B5E1 Signal outside permitted range (limit range violation; repair any
the configuration and
2) mechanical problems
sensor
Replacement sensor
value is used. The error Check the wiring and the
Ambient pressure sensor fault
3090.00 E4B708 disappears when the ECU A700D engine control
Short circuit to earth or cable rupture
measured value is in the unit / sensor
defined range

L524 - 659 / from 17890 copyright by 19.1-41 of 52

L528 - 660 / from 17891
L538 - 433 / from 17893 MJFCIFSS
L542 - 435 / from 17895
Service Codes, Diagnose Service code
Malfunctions

ERROR Motor This kind of malfunction is accompanied by a 1-second warning tone

Service code
Effect Cause Remedy
A700 UEC3
Replacement sensor
value is used. The error Ambient pressure sensor fault Check the wiring and the
3090.01 E4B709 disappears when the Sensor signal: shorted to supply ECU A700D engine control
measured value is in the voltage unit / sensor
defined range
Replacement sensor
value is used. The error Ambient pressure sensor fault Check the wiring and the
3090.02 E4B70A disappears when the Sensor supply voltage: cable rupture ECU A700D engine control
measured value is in the or shorted to earth unit / sensor
defined range
Replacement sensor
value is used. The error Ambient pressure sensor fault Check the wiring and the
3090.03 E4B70B disappears when the Sensor supply voltage: shorted to ECU A700D engine control
measured value is in the supply voltage unit / sensor
defined range
Reduced power or no
Ambient pressure sensor fault Check the medium for
reaction, depending on
3090.04 E4B70C Signal outside permitted range (limit range violation; repair any
the configuration and
1) mechanical problems
sensor
Reduced power or no
Ambient pressure sensor fault Check the medium for
reaction, depending on
3090.05 E4B70D Signal outside permitted range (limit range violation; repair any
the configuration and
2) mechanical problems
sensor
Replacement sensor
value is used. The error Check the wiring and the
Air filter pressure switch 2 fault
3091.00 E4B76C disappears when the ECU A700D engine control
Signal line shorted to earth
measured value is in the unit / sensor
defined range
Replacement sensor
value is used. The error Air filter pressure switch 2 fault Check the wiring and the
3091.01 E4B76D disappears when the Short circuit to supply voltage or ECU A700D engine control
measured value is in the signal line broken. unit / sensor
defined range
Replacement sensor
value is used. The error Check the wiring and the
Air filter pressure switch 2 fault
LBH/Version 01/07.2007/en/lbhhae0/06.02.2013

3091.02 E4B76E disappears when the ECU A700D engine control

Signal line shorted to supply line
measured value is in the unit / sensor
defined range
Replacement sensor
value is used. The error Check the wiring and the
Air filter pressure switch 2 fault,
3091.03 E4B76F disappears when the ECU A700D engine control
signal line shorted to supply line
measured value is in the unit / sensor
defined range
Reduced power or no Air filter pressure switch 2 fault
Check the medium for
reaction, depending on Monitoring threshold 1 exceeded or
3091.04 E4B770 range violation; repair any
the configuration and fallen below; medium no longer in
mechanical problems
sensor normal operating state
Reduced power or no Air filter pressure switch 2 fault
Check the medium for
reaction, depending on Monitoring threshold 2 exceeded or
3091.05 E4B771 range violation; repair any
the configuration and fallen below; medium no longer in
mechanical problems
sensor normal operating state

19.1-42 of 52 copyright by L524 - 659 / from 17890

L528 - 660 / from 17891
MJFCIFSS L538 - 433 / from 17893
L542 - 435 / from 17895
 Service code Service Codes, Diagnose
Malfunctions

ERROR Motor This kind of malfunction is accompanied by a 1-second warning tone

Service code
Effect Cause Remedy
A700 UEC3
Replacement sensor
value is used. The error Check the wiring and the
Air filter pressure switch 1 fault
3092.00 E4B7D0 disappears when the ECU A700D engine control
Signal line shorted to earth
measured value is in the unit / sensor
defined range
Replacement sensor
value is used. The error Air filter pressure switch 1 fault Check the wiring and the
3092.01 E4B7D1 disappears when the Short circuit to supply voltage or ECU A700D engine control
measured value is in the signal line broken. unit / sensor
defined range
Replacement sensor
value is used. The error Check the wiring and the
Air filter pressure switch 1 fault
3092.02 E4B7D2 disappears when the ECU A700D engine control
Signal line shorted to supply line
measured value is in the unit / sensor
defined range
Replacement sensor
value is used. The error Check the wiring and the
Air filter pressure switch 1 fault,
3092.03 E4B7D3 disappears when the ECU A700D engine control
signal line shorted to supply line
measured value is in the unit / sensor
defined range
Reduced power or no Air filter pressure switch 1 fault
Check the medium for
reaction, depending on Monitoring threshold 1 exceeded or
3092.04 E4B7D4 range violation; repair any
the configuration and fallen below; medium no longer in
mechanical problems
sensor normal operating state
Reduced power or no Air filter pressure switch 1 fault
Check the medium for
reaction, depending on Monitoring threshold 2 exceeded or
3092.05 E4B7D5 range violation; repair any
the configuration and fallen below; medium no longer in
mechanical problems
sensor normal operating state
Replacement sensor
value is used. The error Check the wiring and the
Water in fuel filter sensor
3093.00 E4B834 disappears when the ECU A700D engine control
Signal line shorted to earth
measured value is in the unit / sensor
defined range
Replacement sensor
value is used. The error Water in fuel filter sensor Check the wiring and the
LBH/Version 01/07.2007/en/lbhhae0/06.02.2013

3093.01 E4B835 disappears when the Short circuit to supply voltage or ECU A700D engine control
measured value is in the signal line broken unit / sensor
defined range
Replacement sensor
value is used. The error Check the wiring and the
Water in fuel filter sensor
3093.02 E4B836 disappears when the ECU A700D engine control
Signal line shorted to supply line
measured value is in the unit / sensor
defined range
Replacement sensor
value is used. The error Water in fuel filter sensor Check the wiring and the
3093.03 E4B837 disappears when the Signal line shorted to supply line ECU A700D engine control
measured value is in the voltage unit / sensor
defined range

L524 - 659 / from 17890 copyright by 19.1-43 of 52

L528 - 660 / from 17891
L538 - 433 / from 17893 MJFCIFSS
L542 - 435 / from 17895
Service Codes, Diagnose Service code
Malfunctions

ERROR Motor This kind of malfunction is accompanied by a 1-second warning tone

Service code
Effect Cause Remedy
A700 UEC3
Reduced power or no Water in fuel filter sensor
Check the medium for
reaction, depending on Monitoring threshold 1 exceeded or
3093.04 E4B838 range violation; repair any
the configuration and fallen below; medium no longer in
mechanical problems
sensor normal operating state
Reduced power or no Water in fuel filter sensor
Check the medium for
reaction, depending on Monitoring threshold 2 exceeded or
3093.05 E4B839 range violation; repair any
the configuration and fallen below; medium no longer in
mechanical problems
sensor normal operating state
Replacement sensor
value is used. The error Check the wiring and the
Exhaust temperature sensor fault
3094.00 E4B898 disappears when the ECU A700D engine control
Signal line shorted to earth
measured value is in the unit / sensor
defined range
Replacement sensor
value is used. The error Exhaust temperature sensor fault Check the wiring and the
3094.01 E4B899 disappears when the Short circuit to supply voltage or ECU A700D engine control
measured value is in the signal line broken. unit / sensor
defined range
Replacement sensor
value is used. The error Check the wiring and the
Exhaust temperature sensor fault
3094.02 E4B89A disappears when the ECU A700D engine control
Signal line shorted to supply line
measured value is in the unit / sensor
defined range
Replacement sensor
value is used. The error Exhaust temperature sensor fault Check the wiring and the
3094.03 E4B89B disappears when the Signal line shorted to supply line ECU A700D engine control
measured value is in the voltage unit / sensor
defined range
Reduced power or no Exhaust temperature sensor fault
Check the medium for
reaction, depending on Monitoring threshold 1 exceeded or
3094.04 E4B89C range violation; repair any
the configuration and fallen below; medium no longer in
mechanical problems
sensor normal operating state
Reduced power or no Exhaust temperature sensor fault
Check the medium for
reaction, depending on Monitoring threshold 2 exceeded or
3094.05 E4B89D range violation; repair any
the configuration and fallen below; medium no longer in
mechanical problems
LBH/Version 01/07.2007/en/lbhhae0/06.02.2013

sensor normal operating state

Replacement sensor
value is used. The error Check the wiring and the
Oil temperature sensor fault
3095.00 E4B8FC disappears when the ECU A700D engine control
Signal line shorted to earth
measured value is in the unit / sensor
defined range
Replacement sensor
value is used. The error Oil temperature sensor fault Check the wiring and the
3095.01 E4B8FD disappears when the Short circuit to supply voltage or ECU A700D engine control
measured value is in the signal line broken. unit / sensor
defined range
Replacement sensor
value is used. The error Check the wiring and the
Oil temperature sensor fault
3095.02 E4B8FE disappears when the ECU A700D engine control
Signal line shorted to supply line
measured value is in the unit / sensor
defined range

19.1-44 of 52 copyright by L524 - 659 / from 17890

L528 - 660 / from 17891
MJFCIFSS L538 - 433 / from 17893
L542 - 435 / from 17895
 Service code Service Codes, Diagnose
Malfunctions

ERROR Motor This kind of malfunction is accompanied by a 1-second warning tone

Service code
Effect Cause Remedy
A700 UEC3
Replacement sensor
value is used. The error Oil temperature sensor fault Check the wiring and the
3095.03 E4B8FF disappears when the Signal line shorted to supply line ECU A700D engine control
measured value is in the voltage unit / sensor
defined range
Reduced power or no Oil temperature sensor fault
Check the medium for
reaction, depending on Monitoring threshold 1 exceeded or
3095.04 E4B900 range violation; repair any
the configuration and fallen below; medium no longer in
mechanical problems
sensor normal operating state
Reduced power or no Oil temperature sensor fault
Check the medium for
reaction, depending on Monitoring threshold 2 exceeded or
3095.05 E4B901 range violation; repair any
the configuration and fallen below; medium no longer in
mechanical problems
sensor normal operating state
Replacement sensor
value is used. The error Check the wiring and the
Fuel temperature sensor fault
3096.00 E4B960 disappears when the ECU A700D engine control
Signal line shorted to earth
measured value is in the unit / sensor
defined range
Replacement sensor
value is used. The error Fuel temperature sensor fault Check the wiring and the
3096.01 E4B961 disappears when the Short circuit to supply voltage or ECU A700D engine control
measured value is in the signal line broken. unit / sensor
defined range
Replacement sensor
value is used. The error Check the wiring and the
Fuel temperature sensor fault
3096.02 E4B962 disappears when the ECU A700D engine control
Signal line shorted to supply line
measured value is in the unit / sensor
defined range
Replacement sensor
value is used. The error Fuel temperature sensor fault Check the wiring and the
3096.03 E4B963 disappears when the Signal line shorted to supply line ECU A700D engine control
measured value is in the voltage unit / sensor
defined range
Reduced power or no Fuel temperature sensor fault
Check the medium for
reaction, depending on Monitoring threshold 1 exceeded or
3096.04 E4B964 range violation; repair any
LBH/Version 01/07.2007/en/lbhhae0/06.02.2013

the configuration and fallen below; medium no longer in

mechanical problems
sensor normal operating state
Reduced power or no Fuel temperature sensor fault
Check the medium for
reaction, depending on Monitoring threshold 2 exceeded or
3096.05 E4B965 range violation; repair any
the configuration and fallen below; medium no longer in
mechanical problems
sensor normal operating state
Replacement sensor
value is used. The error Check the wiring and the
Charge air temperature sensor fault
3097.00 E4B9C4 disappears when the ECU A700D engine control
Signal line shorted to earth
measured value is in the unit / sensor
defined range
Replacement sensor
value is used. The error Charge air temperature sensor fault Check the wiring and the
3097.01 E4B9C5 disappears when the Short circuit to supply voltage or ECU A700D engine control
measured value is in the signal line broken unit / sensor
defined range

L524 - 659 / from 17890 copyright by 19.1-45 of 52

L528 - 660 / from 17891
L538 - 433 / from 17893 MJFCIFSS
L542 - 435 / from 17895
Service Codes, Diagnose Service code
Malfunctions

ERROR Motor This kind of malfunction is accompanied by a 1-second warning tone

Service code
Effect Cause Remedy
A700 UEC3
Replacement sensor
value is used. The error Check the wiring and the
Charge air temperature sensor fault
3097.02 E4B9C6 disappears when the ECU A700D engine control
Signal line shorted to supply line
measured value is in the unit / sensor
defined range
Replacement sensor
value is used. The error Charge air temperature sensor fault Check the wiring and the
3097.03 E4B9C7 disappears when the Signal line shorted to supply line ECU A700D engine control
measured value is in the voltage unit / sensor
defined range
Reduced power or no Charge air temperature sensor fault
Check the medium for
reaction, depending on Monitoring threshold 1 exceeded or
3097.04 E4B9C8 range violation; repair any
the configuration and fallen below; medium no longer in
mechanical problems
sensor normal operating state
Reduced power or no Charge air temperature sensor fault
Check the medium for
reaction, depending on Monitoring threshold 2 exceeded or
3097.05 E4B9C9 range violation; repair any
the configuration and fallen below; medium no longer in
mechanical problems
sensor normal operating state
Replacement sensor
value is used. The error Check the wiring and the
Coolant temperature sensor fault
3098.00 E4BA28 disappears when the ECU A700D engine control
Signal line shorted to earth
measured value is in the unit / sensor
defined range
Replacement sensor
value is used. The error Coolant temperature sensor fault Check the wiring and the
3098.01 E4BA29 disappears when the Short circuit to supply voltage or ECU A700D engine control
measured value is in the signal line broken. unit / sensor
defined range
Replacement sensor
value is used. The error Check the wiring and the
Coolant temperature sensor fault
3098.02 E4BA2A disappears when the ECU A700D engine control
Signal line shorted to supply line
measured value is in the unit / sensor
defined range
Replacement sensor
value is used. The error Coolant temperature sensor fault Check the wiring and the LBH/Version 01/07.2007/en/lbhhae0/06.02.2013

3098.03 E4BA2B disappears when the Signal line shorted to supply line ECU A700D engine control
measured value is in the voltage unit / sensor
defined range
Reduced power or no Coolant temperature sensor fault
Check the medium for
reaction, depending on Monitoring threshold 1 exceeded or
3098.04 E4BA2B range violation; repair any
the configuration and fallen below; medium no longer in
mechanical problems
sensor normal operating state
Reduced power or no Coolant temperature sensor fault
Check the medium for
reaction, depending on Monitoring threshold 2 exceeded or
3098.05 E4BA2C range violation; repair any
the configuration and fallen below; medium no longer in
mechanical problems
sensor normal operating state
Replacement sensor
value is used. The error Check the wiring and the
Internal temperature sensor fault
3099.00 E4BA8C disappears when the ECU A700D engine control
Signal line shorted to earth
measured value is in the unit / sensor
defined range

19.1-46 of 52 copyright by L524 - 659 / from 17890

L528 - 660 / from 17891
MJFCIFSS L538 - 433 / from 17893
L542 - 435 / from 17895
 Service code Service Codes, Diagnose
Malfunctions

ERROR Motor This kind of malfunction is accompanied by a 1-second warning tone

Service code
Effect Cause Remedy
A700 UEC3
Replacement sensor
value is used. The error Internal temperature sensor fault Check the wiring and the
3099.01 E4BA8D disappears when the Short circuit to supply voltage or ECU A700D engine control
measured value is in the signal line broken. unit / sensor
defined range
Replacement sensor
value is used. The error Check the wiring and the
Internal temperature sensor fault
3099.02 E4BA8E disappears when the ECU A700D engine control
Signal line shorted to supply line
measured value is in the unit / sensor
defined range
Replacement sensor
value is used. The error Internal temperature sensor fault Check the wiring and the
3099.03 E4BA8F disappears when the Signal line shorted to supply line ECU A700D engine control
measured value is in the voltage unit / sensor
defined range
Reduced power or no Internal temperature sensor fault
Check the medium for
reaction, depending on Monitoring threshold 1 exceeded or
3099.04 E4BA90 range violation; repair any
the configuration and fallen below; medium no longer in
mechanical problems
sensor normal operating state
Reduced power or no Internal temperature sensor fault
Check the medium for
reaction, depending on Monitoring threshold 2 exceeded or
3099.05 E4BA91 range violation; repair any
the configuration and fallen below; medium no longer in
mechanical problems
sensor normal operating state

4- and 6-cylinder engines - Cylinder description:

Cylinder description

19.1.10 WARNING service code L538, L542

LBH/Version 01/07.2007/en/lbhhae0/06.02.2013

Function
This is a fault in the on-board system voltage
WARNING diesel engine This kind of malfunction is accompanied by a 1-second warning tone
Service
Effect Cause Remedy
code
Batteries overheating,
Check alternator or engine
E6009 electrical components On-board voltage too high
electronics
may fail
Check battery, wiring or engine
E600A Engine difficult to start On-board voltage too low
electronics

L524 - 659 / from 17890 copyright by 19.1-47 of 52

L528 - 660 / from 17891
L538 - 433 / from 17893 MJFCIFSS
L542 - 435 / from 17895
Service Codes, Diagnose Service code
Malfunctions

19.1.11 Audible and visible warning symbols L524 – L528 Stage III
The following table contains the warning messages which are displayed only
visually, as well as those with an audible accompaniment; along with the
causes and remedies.
There are four different audible warning signals:
– Continuous tone
– Interval tone 1/10 (1 second tone followed by 10 second pause)
– Single 1 second beep
– Once-only warning tone 3/0.5 (3 x 0.5 seconds)

Warning signal Cause Remedy

Warning buzzer – three 0.5 second
beeps when Parking brake is engaged Release the parking brake
“preselecting the travel direction”

Air filter contaminated Replace the air filter

Air filter contamination symbol field Check the air filter system
(H7) lights up Check the air filter contamination
Fault in the air filter system or
Service code E6006 vacuum switch B4
electrical system
Switching point 50 mbar
Check the wiring

Coolant temperature symbol field

(H13) flashes
Service code E6000 Coolant temperature above 110°C Cleaning the cooling system
1/10 intermittent warning tone (T04) Check the fan speed
The output of the travel pump and
engine are reduced
Coolant temperature symbol field Coolant temperature above 113°C Cleaning the cooling system
(H13) flashes (T04) Check the fan speed
Service code E6000, E601F
Temperature sensor T04, check the
Continuous warning beep Fault in the cooling or electrical
wiring, at 20°C <> 3400
The output of the travel pump system
Check the engine thermostat
is reduced

Coolant temperature symbol field Coolant level too low

Check the coolant level
(H13) lights up (B13)
STOP symbol field lights up
Check coolant level contact sensor
Service code E6008 Fault in the electrical system
LBH/Version 01/07.2007/en/lbhhae0/06.02.2013

B13
Continuous warning beep
Hydraulic oil temperature above Cleaning the cooling system
95°C (B8) Check the fan speed
Hydraulic oil overheating symbol Check the temperature sensor B8
field (H23) lights up at 20°C <> 1112
Service code E2013 Check the wiring
1/10 intermittent warning tone Fault in the cooling / hydraulic / Check the working hydraulics pressure
The output of the travel pump electrical system relief valves (control block)
is reduced Check the travel hydraulics pressure
relief valves (variable displacement
pump)
Fuel level symbol field (H1) flashes
Drain water from fuel pre-filter
Service code E601C, E601D Water in the fuel
sight glass
Continuous warning beep
Emergency steering check symbol Emergency steering pump check not
Check the emergency steering pump
field (H24) lights up successfully completed (B3a)

19.1-48 of 52 copyright by L524 - 659 / from 17890

L528 - 660 / from 17891
MJFCIFSS L538 - 433 / from 17893
L542 - 435 / from 17895
 Service code Service Codes, Diagnose
Malfunctions

Warning signal Cause Remedy

STOP symbol field lights up, Check the pressure switch B3a
service code E2002 Error in the electrical / hydraulic Check the wiring
system Check the emergency steering
pump pressure
Emergency steering function
Emergency steering symbol activated due to failure of steering Check the steering pump:
field (H8) lights up pump (B3)
STOP symbol field lights up Check pressure switch B3
Error in the electrical / hydraulic
40 sec. warning tone Check the standby pressure of the
system
steering pump

With the ignition ON

Engine oil pressure symbol
field (H4) does not light up Engine oil pressure with stationary Check the pressure switch P04
Service code E2050 after engine Check the wiring
10 seconds
Single 1 second beep
While driving Engine oil pressure too low (P04) Check the oil level
Engine oil pressure symbol Error in the engine lubricating oil
field (H4) lights up Check the pressure relief valve
supply
Stop symbol field (H36) lights up
Service code E601D, E601C,
Check the pressure switch P04
E6004, E6025 Fault in the electrical system
Check the wiring
After 10 seconds continual warning
buzzer
Accumulator pressure symbol field Check the accumulator pressure
Brake accumulator pressure too low
(H19) lights up Service code E2016 Check accumulator charge valve
(B19)
No travel direction can be selected Check gear pump
After 1 minute continual warning Error in the electrical / hydraulic Check pressure switch B19
buzzer system Check the wiring
Torn V-belt Fit a new V-belt
Battery charge symbol field (H6)
Repair the alternator
lights up Defective alternator
Check the wiring to the main
Service code E 6016 Fault in the electrical system
electronics
Service code segment display (P7)
shows service code See the service code tables
Single 1 second beep
LBH/Version 01/07.2007/en/lbhhae0/06.02.2013

L524 - 659 / from 17890 copyright by 19.1-49 of 52

L528 - 660 / from 17891
L538 - 433 / from 17893 MJFCIFSS
L542 - 435 / from 17895
Service Codes, Diagnose Service code
Malfunctions

19.1.12 Audible and visible warning symbols L538 – L542 Stage III
The following table contains the warning messages which are displayed only
visually, as well as those with an audible accompaniment; along with the
causes and remedies.
There are four different audible warning signals:
– Continuous tone
– Interval tone 1/10 (1 second tone followed by 10 second pause)
– Single 1 second beep
– Once-only warning tone 3/0.5 (3 x 0.5 seconds)

Warning signal Cause Remedy

Warning buzzer – three 0.5 second
beeps when Parking brake is engaged Release the parking brake
“preselecting the travel direction”

Air filter contaminated Replace the air filter

Air filter contamination symbol field Check the air filter system
(H7) lights up Check the air filter contamination
Fault in the air filter system or
Service code E6006 vacuum switch B4
electrical system
Switching point 50 mbar
Check the wiring

Coolant temperature symbol field

(H13) flashes
Service code E6000, E6024 Coolant temperature above 100°C Cleaning the cooling system
1/10 intermittent warning tone (B708) Check the fan speed
The output of the travel pump and
engine are reduced
Coolant temperature symbol field Coolant temperature above 104°C Cleaning the cooling system
(H13) flashes (B708) Check the fan speed
Service code E6000, E6024, E601F
Check the temperature sensor B708
Continuous warning beep Fault in the cooling or electrical
at 20°C <> 2500
The output of the travel pump and system
Check the engine thermostat
engine are reduced
Coolant temperature symbol field Check the temperature sensor B708
Fault in the electrical system,
(H13) lights up at 20°C <> 2500
interruption or short circuit
Service code E6024 Check the wiring

Coolant temperature symbol field Coolant level too low

LBH/Version 01/07.2007/en/lbhhae0/06.02.2013

Check the coolant level

(H13) lights up (B13)
STOP symbol field lights up
Check coolant level contact sensor
Service code E6008, E6024 Fault in the electrical system
B13
Continuous warning beep
Hydraulic oil temperature above Cleaning the cooling system
95°C (B8) Check the fan speed
Hydraulic oil overheating symbol Check the temperature sensor B8
field (H23) lights up at 20°C <> 1112
Service code E2013 Check the wiring
1/10 intermittent warning tone Fault in the cooling / hydraulic / Check the working hydraulics pressure
The output of the travel pump electrical system relief valves (control block)
is reduced Check the travel hydraulics pressure
relief valves (variable displacement
pump)

19.1-50 of 52 copyright by L524 - 659 / from 17890

L528 - 660 / from 17891
MJFCIFSS L538 - 433 / from 17893
L542 - 435 / from 17895
 Service code Service Codes, Diagnose
Malfunctions

Warning signal Cause Remedy

Fuel level symbol field (H1) flashes
Drain water from fuel pre-filter sight
Service code E6024, E6003 Water in the fuel
glass
Continuous warning beep
Emergency steering pump check not
Check the emergency steering pump
Emergency steering check symbol successfully completed (B3a)
field (H24) lights up Check the pressure switch B3a
STOP symbol field lights up, Error in the electrical / hydraulic Check the wiring
service code E2002 system Check the emergency steering pump
pressure
Emergency steering function
Emergency steering symbol field activated due to failure of steering Check the steering pump:
(H8) lights up pump (B3)
STOP symbol field lights up Check pressure switch B3
Error in the electrical / hydraulic
40 sec. warning tone Check the standby pressure of the
system
steering pump

With the ignition ON

Engine oil pressure symbol
field (H4) does not light up Engine oil pressure with stationary Check the pressure switch P04
Service code E2050 after engine Check the wiring
10 seconds
Single 1 second beep
While driving Insufficient engine oil pressure
Check the oil level
Engine oil pressure symbol (B701)
field (H4) lights up Error in the engine lubricating oil
Stop symbol field (H36) lights up Check the pressure relief valve
supply
Service code E6024, E6025
Check pressure switch B701
After 10 seconds continual warning Fault in the electrical system
Check the wiring
buzzer
Accumulator pressure symbol field Check the accumulator pressure
Brake accumulator pressure too low
(H19) lights up Check accumulator charge valve
(B19)
Service code E2016 Check gear pump
No travel direction can be selected
Error in the electrical / hydraulic Check pressure switch B19
After 1 minute continual warning
system Check the wiring
buzzer
Torn V-belt Fit a new V-belt
Battery charge symbol field (H6)
Repair the alternator
lights up Defective alternator
Check the wiring to the main
Service code E 6016, E6024 Fault in the electrical system
electronics
LBH/Version 01/07.2007/en/lbhhae0/06.02.2013

Service code segment display (P7)

shows service code See the service code tables
Single 1 second beep

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L528 - 660 / from 17891
L538 - 433 / from 17893 MJFCIFSS
L542 - 435 / from 17895
Service Codes, Diagnose Service code
Malfunctions

LBH/Version 01/07.2007/en/lbhhae0/06.02.2013

19.1-52 of 52 copyright by L524 - 659 / from 17890

L528 - 660 / from 17891
MJFCIFSS L538 - 433 / from 17893
L542 - 435 / from 17895