Professional Documents
Culture Documents
Service manual
(20
Wheel loader
(10 points)
L506 - L510 Stereo
(10
en
Service manual
(20
Wheel loader
(10 points)
L506 - L510 Stereo
(10
Address
Address: LIEBHERR-WERK BISCHOFSHOFEN GMBH
Product identification
Manufacturer: LIEBHERR-WERK BISCHOFSHOFEN GMBH
Product group: Wheel loader
Type: L506 L507 L508 L509 L510
Construction number: 776 777 778 779 782
Serial number: 9099 9099 9099 9099 9099
Document identification
Order number: 1011 2640
Author: LBH / T-DOK department
Document version: 02
Manual number:
Owner:
Foreword
Target group This Service Manual has been written for those whose job it is to make sure
that the machines remain operational on a daily basis. This specifically
includes the mechanics and workshop specialists at Liebherr dealers and
Liebherr branch offices.
Contents In the first chapter you will find information about safety regulations as well
as specifications of the special tools needed for maintenance and repair.
Chapter 2 provides an overview of all important technical data for the entire
machine and the individual assemblies.
The following chapter, entitled Maintenance, contains the maintenance and
inspection schedule, inspection and setting logs, lubrication schedules and
filling quantity tables, a description of maintenance procedures and speci-
fications for prescribed lubricants and fuels.
The technical description of the machine in the following chapters is divided
into 15 functional groups. The design, function, and technical data for each
group, component and part are explained.
How to use this manual This manual describes a variety of types and finished forms. In general, this
information applies to the types and serial number groups specified in the
footnotes. One exception is that specific type and serial number data are
indicated at the beginning of each section (e.g. the technical specifications of
the components).
Whenever possible, parts and components are supplemented by indication
of the identification number in the heading.
This manual is available in German, English and French.
Working instructions It is imperative that safety regulations be observed with all tasks done on the
machine. You will find information on this in the General Information
chapter.
A complete set of tools in perfect condition is required for work on the
machine, along with any special tools that might be needed. Absolute
cleanliness must be observed with all tasks!
Sealing material such as O-rings and surface seals should be replaced
whenever repairs are carried out.
DVD edition We would particularly like to draw your attention to the fact that this book is
available not only in printed form, but also as an electronic document on
DVD (Lidos).
General information 1
Product description 2
Maintenance 3
Diesel engine 4
Cooling system 5
Travel hydraulics 6
Working hydraulics 7
Steering system 8
Brake system 9
Electrical system 10
Transfer gear 11
Axles, drive shafts 12
Machine frame, ballast weight 13
Central lubrication system 14
Covering, cab access 15
Cab, heating, air-conditioning 16
Lift arm, quick-change device 17
Attachments, accessories 18
Repair work, troubleshooting 19
Chapter contents
2 Product Description............................................................. 2.0-1
L506 - 776 / from 9099 L509 - 779 / from 9099 copyright by 2.0-1 of 2
L507 - 777 / from 9099 L510 - 782 / from 9099
L508 - 778 / from 9099 MJFCIFSS
Service Manual Product Description
Technical Data
L506 - 776 / from 9099 L509 - 779 / from 9099 copyright by 2.1-1 of 28
L507 - 777 / from 9099 L510 - 782 / from 9099
L508 - 778 / from 9099 MJFCIFSS
Product Description Service Manual
Technical Data
2.1-2 of 28 copyright by L506 - 776 / from 9099 L508 - 778 / from 9099
L507 - 777 / from 9099 L509 - 779 / from 9099
MJFCIFSS L510 - 782 / from 9099
Service Manual Product Description
Technical Data
L506 - 776 / from 9099 L509 - 779 / from 9099 copyright by 2.1-3 of 28
L507 - 777 / from 9099 L510 - 782 / from 9099
L508 - 778 / from 9099 MJFCIFSS
Product Description Service Manual
Technical Data
2.1-4 of 28 copyright by L506 - 776 / from 9099 L508 - 778 / from 9099
L507 - 777 / from 9099 L509 - 779 / from 9099
MJFCIFSS L510 - 782 / from 9099
Service Manual Product Description
Technical Data
L506 - 776 / from 9099 L509 - 779 / from 9099 copyright by 2.1-5 of 28
L507 - 777 / from 9099 L510 - 782 / from 9099
L508 - 778 / from 9099 MJFCIFSS
Product Description Service Manual
Technical Data
2.1-6 of 28 copyright by L506 - 776 / from 9099 L508 - 778 / from 9099
L507 - 777 / from 9099 L509 - 779 / from 9099
MJFCIFSS L510 - 782 / from 9099
Service Manual Product Description
Technical Data
L506 - 776 / from 9099 L509 - 779 / from 9099 copyright by 2.1-7 of 28
L507 - 777 / from 9099 L510 - 782 / from 9099
L508 - 778 / from 9099 MJFCIFSS
Product Description Service Manual
Technical Data
Diesel engine
Valid for: L506 - 776 / from 9099
Description Value Unit
Engine model D404T-00
Type / cylinders 4-cylinder inline
Combustion Four-stroke
direct injection
Capacity 2440 cm³
Rated power as per ISO 9249 42 / 57 kW / PS
Rated speed 2800 min-1
Maximum torque at 1680 min-1 209 Nm
Lower idle speed 850 50
min-1
Upper idle speed 3040 +80 min-1
Cylinder bore 86 mm
Stroke 105 mm
Compression ratio 18:1
Combustion pressure 24 - 28 bar
Injection nozzles / operating pressure 220 bar
Firing order 1-3-4-2
Inlet and outlet valve lash Hydraulic
adjustment
Injection pump Pump elements
Controller Mechanical
Turbocharger Constant
Longitudinal / traverse inclinability 30 °
Current / power consumption of starter 12 / 2.2 V / kW
Alternator voltage output 12 V
Alternator current output 65 A
Conversion factor 4.115
Frequency KL.W / engine speed
Coolant thermostat opening temperature 82.2 °C
2.1-8 of 28 copyright by L506 - 776 / from 9099 L508 - 778 / from 9099
L507 - 777 / from 9099 L509 - 779 / from 9099
MJFCIFSS L510 - 782 / from 9099
Service Manual Product Description
Technical Data
Valid for: L506 - 777 / from 9099; L508 - 778 / from 9099
Description Value Unit
Engine model D404T-01
Type / cylinders 4-cylinder inline
Combustion Four-stroke
direct injection
Capacity 2440 cm³
Rated power as per ISO 9249 46 / 63 kW / PS
Rated speed 2800 min-1
Maximum torque at 1680 min-1 227 Nm
Lower idle speed 850 50
min-1
Upper idle speed 3040 +80 min-1
Cylinder bore 86 mm
Stroke 105 mm
Compression ratio 18:1
Combustion pressure 24 - 28 bar
Injection nozzles / operating pressure 220 bar
Firing order 1-3-4-2
Inlet and outlet valve lash Hydraulic
adjustment
Injection pump Pump elements
Controller Mechanical
Turbocharger Constant
Longitudinal / traverse inclinability 30 °
Current / power consumption of starter 12 / 2.2 V / kW
Alternator voltage output 12 V
Alternator current output 65 A
Conversion factor 4.115
Frequency KL.W / engine speed
Coolant thermostat opening temperature 82.2 °C
Minimum pressure in cooling system after 0.7 bar
pump
Auxiliary drive transmission 1.03 i
Weight 232 kg
Emission thresholds comply with EU – RL 97/68 EC Stage II
L506 - 776 / from 9099 L509 - 779 / from 9099 copyright by 2.1-9 of 28
L507 - 777 / from 9099 L510 - 782 / from 9099
L508 - 778 / from 9099 MJFCIFSS
Product Description Service Manual
Technical Data
2.1-10 of 28 copyright by L506 - 776 / from 9099 L508 - 778 / from 9099
L507 - 777 / from 9099 L509 - 779 / from 9099
MJFCIFSS L510 - 782 / from 9099
Service Manual Product Description
Technical Data
Coupling
Description Value Unit
Type CF-K-100-10- -
64137
Tightening torque for elastic element fixing 40 Nm
bolts (8 pcs.)
Tightening torque for start coupling fixing 45+5 Nm
bolts (2 pcs.)
Fuel system
Description Value Unit
Tank capacity, FULL 80 l
Tank capacity, RESERVE 20 l
Fuel pre-filter
Description Value Unit
Type In-line filter -
Filtration grade 700 µ
L506 - 776 / from 9099 L509 - 779 / from 9099 copyright by 2.1-11 of 28
L507 - 777 / from 9099 L510 - 782 / from 9099
L508 - 778 / from 9099 MJFCIFSS
Product Description Service Manual
Technical Data
Vaccum switch
Description Value Unit
Air filter contamination vacuum switch 50 mbar
activation point
Pre-glow system
Description Value Unit
Resistance 1
Cooling system
Description Value Unit
Fan speed (depending on engine speed and 470 - 3100 min-1
temperature)
Operating pressure, fan speed at 1100 mA
Coolant up to 87 °C, Hydraulic oil up to 57 °C
At low idle: 6 ±3 bar
470 ±50 min-1
At high idle: 10 ±3 bar
580 ±50 min-1
Operating pressure, fan speed at 380 mA
Coolant 92 °C to 100 °C
Hydraulic oil 75 °C to 90 °C
At low idle: 20 ±3 bar
1000 ±100 min-1
At high idle: 140 ±10 bar
2600 ±100 min-1
Proportional pressure relief valve resistance 4,8
at 20 °C
Pressure relief valve 210 bar
Gear pump
Description Value Unit
Capacity 9 cm³
Flow rate (at rated speed) 26 l/min
2.1-12 of 28 copyright by L506 - 776 / from 9099 L508 - 778 / from 9099
L507 - 777 / from 9099 L509 - 779 / from 9099
MJFCIFSS L510 - 782 / from 9099
Service Manual Product Description
Technical Data
Gear motor
Description Value Unit
Displacement 8 cm³
Maximum pressure 210 bar
Valid for: L509 - 779 / from 9099; L510 - 782 / from 9099; ID 5717294
Description Value Unit
Control type DA
Maximum capacity 56 cm³
Flow rate at rated speed 154 l/min
Maximum swivel angle (both sides) 20 °
Speed (at rated speed) 2800 min-1
Power L508 41.5 kW
Power L509 48.5 kW
Power L510 52.2 kW
Replenishing pump capacity 11.6 cm³
Replenishing pump flow rate 29.5 l/min
L506 - 776 / from 9099 L509 - 779 / from 9099 copyright by 2.1-13 of 28
L507 - 777 / from 9099 L510 - 782 / from 9099
L508 - 778 / from 9099 MJFCIFSS
Product Description Service Manual
Technical Data
Valid for: L509 - 779 / from 9099; L510 - 782 / from 9099; ID 10023204
Description Value Unit
Type A6VM 107 DA
Maximum displacement 107 cm³
Minimum displacement 32.3 cm³
Maximum swivel angel 25 °
Minimum swivel angle 7.3 °
Maximum speed 4480 min-1
Torque ( p 400 bar) 681 Nm
Swivel restrictor (size) 0.45 mm
2.1-14 of 28 copyright by L506 - 776 / from 9099 L508 - 778 / from 9099
L507 - 777 / from 9099 L509 - 779 / from 9099
MJFCIFSS L510 - 782 / from 9099
Service Manual Product Description
Technical Data
Valid for: L508 - 778 / from 9099; L509 - 779 / from 9099; L510 - 782 / from 9099;
ID 10023228
Description Value Unit
Capacity 33 cm³
Flow rate at rated speed 92.4 l/min
Speed at rated speed 2800 min -1
Power L508, L509 29.3 KW
Power L510 33.8 KW
10
LS steering pressure relief valve 180 bar
Control block
Description Value Unit
Spool valve diameter 14 mm
Piston stroke, both sides 7.13 mm
5
Primary pressure relief valve L506, L507 230 bar
5
Primary pressure relief valve L508, L509 190 bar
5
Primary pressure relief valve L510 210 bar
Secondary pressure relief valve / lifting 5
220 bar
(+ 1 turn)
Secondary pressure relief valve / tilting in 5
220 bar
(+ 1 turn)
Secondary pressure relief valve / tilting out 5
170 bar
(+ 1 turn)
L506 - 776 / from 9099 L509 - 779 / from 9099 copyright by 2.1-15 of 28
L507 - 777 / from 9099 L510 - 782 / from 9099
L508 - 778 / from 9099 MJFCIFSS
Product Description Service Manual
Technical Data
Lift cylinder
Valid for: L506 - 776 / from 9099; L507 - 777 / from 9099
Description Value Unit
Piston diameter 80 mm
Rod diameter 40 mm
Stroke length 510 mm
Minimum installation length 835 mm
Lifting at rated load 4.9 sec
Lowering empty 4.2 sec
Piston rod bearing tightening torque WN 4122-026
Piston tightening torque 650 Nm
Weight 28.5 kg
Valid for: L508 - 778 / from 9099; L509 - 779 / from 9099; L510 - 782 / from 9099
Description Value Unit
Piston diameter 100 mm
Rod diameter 50 mm
Stroke length 510 mm
Minimum installation length 835 mm
Lifting at rated load 4.9 sec
Lowering empty 4.5 sec
Piston rod bearing tightening torque WN 4122-026
Piston tightening torque 650 Nm
Weight 36.8 kg
2.1-16 of 28 copyright by L506 - 776 / from 9099 L508 - 778 / from 9099
L507 - 777 / from 9099 L509 - 779 / from 9099
MJFCIFSS L510 - 782 / from 9099
Service Manual Product Description
Technical Data
Tilt cylinder
Valid for: L506 - 776 / from 9099; L507 - 777 / from 9099
Description Value Unit
Piston diameter 80 mm
Rod diameter 40 mm
Stroke length 450 mm
Minimum installation length 790 mm
Tilting out at rated load 1.5 sec
Piston rod bearing tightening torque WN 4122-026
Piston tightening torque 650 Nm
Weight 27.3 kg
Valid for: L509 - 779 / from 9099; L510 - 782 / from 9099
Description Value Unit
Piston diameter 100 mm
Rod diameter 50 mm
Stroke length 450 mm
Minimum installation length 875 mm
Tilting out at rated load 1.5 sec
Piston rod bearing tightening torque WN 4122-026
Piston tightening torque 650 Nm
Weight 35.5 kg
Hydraulic tank
Valid for: L506 - 776 / from 9099; L507 - 777 / from 9099; L508 - 778 / from 9099
Description Value Unit
Hydraulic tank capacity 55 l
Weight 145 kg
Valid for: L509 - 779 / from 9099; L510 - 782 / from 9099
Description Value Unit
Hydraulic tank capacity 75 l
Weight 200 kg
L506 - 776 / from 9099 L509 - 779 / from 9099 copyright by 2.1-17 of 28
L507 - 777 / from 9099 L510 - 782 / from 9099
L508 - 778 / from 9099 MJFCIFSS
Product Description Service Manual
Technical Data
Bleeder filter
Description Value Unit
Bleeder filtration grade 7 µm
Inlet opening pressure 0.03 bar
Outlet opening pressure 0.35 bar
Filler strainer filtration grade 800 µm
Steering cylinder
Description Value Unit
Piston diameter 70 mm
Rod diameter 30 mm
Stroke length 300 mm
Minimum installation length 552 mm
Piston rod bearing tightening torque WN 4122-011
Piston tightening torque 350 Nm
Weight 13.4 kg
2.1-18 of 28 copyright by L506 - 776 / from 9099 L508 - 778 / from 9099
L507 - 777 / from 9099 L509 - 779 / from 9099
MJFCIFSS L510 - 782 / from 9099
Service Manual Product Description
Technical Data
Drum brake
Description Value Unit
Drum diameter 203 mm
Brake pads with 60 mm
Equalising reservoir
Description Value Unit
Filling quantity 0.2 l
Oil specification Hydraulic oil HLPD -
SAE 10 W
Batteries
Description Value Unit
Number of batteries 1 Unit
Voltage 12 V
Capacity 100 Ah
Cold test current (at -18°C – EN 60095-1) 760 A
Transfer gear
Valid for: L506 - 776 / from 9099; L507 - 777 / from 9099; L508 - 778 / from 9099
Description Value Unit
Type 315 -
Transmission 2.23 -
Gear cover screw tightening torque 48 - 53 Nm
Drive flange cover screw tightening 52 - 58 Nm
torque
Input shaft screw tightening torque 250 - 270 Nm
L506 - 776 / from 9099 L509 - 779 / from 9099 copyright by 2.1-19 of 28
L507 - 777 / from 9099 L510 - 782 / from 9099
L508 - 778 / from 9099 MJFCIFSS
Product Description Service Manual
Technical Data
Valid for: L509 - 779 / from 9099; L510 - 782 / from 9099
Description Value Unit
Type 311 -
Transmission 2.28 -
Gear cover screw tightening torque 48 - 53 Nm
Drive flange cover screw 52 - 58 Nm
tightening torque
Input shaft screw tightening torque 250 - 270 Nm
Front axle
Valid for: L506 - 776 / from 9099; L507 - 777 / from 9099; L508 - 778 / from 9099
Description Value Unit
Type 111/70 -
Self-locking differential 45 %
Width 1486 mm
Overall transmission 21.75 i
Differential transmission 3.63 i
Wheel hub transmission 6.0 i
Wheel lug tightening torque 450 Nm
Wheel lug spanner size 30 mm
Service brake Drum -
Cardan shaft flange DIN 120 -
Flange size 1530 mm
Weight 212 kg
Valid for: L509 - 779 / from 9099; L510 - 782 / from 9099
Description Value Unit
Type 112/163 -
Self-locking differential 45 %
Width 1660 mm
Overall transmission 19.09 i
Differential transmission 3.18 i
Wheel hub transmission 6.0 i
Wheel lug tightening torque 450 Nm
Wheel lug spanner size 30 mm
Service brake Drum -
Cardan shaft flange DIN 120 -
Flange size 1660 mm
Weight 280 kg
2.1-20 of 28 copyright by L506 - 776 / from 9099 L508 - 778 / from 9099
L507 - 777 / from 9099 L509 - 779 / from 9099
MJFCIFSS L510 - 782 / from 9099
Service Manual Product Description
Technical Data
Rear axle
Valid for: L506 - 776 / from 9099; L507 - 777 / from 9099; L508 - 778 / from 9099
Description Value Unit
Type 315/211/164 -
Locking value 25 %
Width 1486 mm
Overall transmission 48.5 i
Differential transmission 3.44 i
Wheel hub transmission 6.0 i
Wheel lug tightening torque 450 Nm
Wheel lug spanner size 30 mm
Service brake Drum -
Cardan shaft flange DIN 120 -
Flange size 1530 mm
Swing angle 5 °
Weight 290 kg
Valid for: L509 - 779 / from 9099; L510 - 782 / from 9099
Description Value Unit
Type 311/212/113 -
Locking value 25 %
Width 1660 mm
Overall transmission 43.53 i
Differential transmission 3.18 i
Wheel hub transmission 6.0 i
Wheel lug tightening torque 450 Nm
Wheel lug spanner size 30 mm
Service brake Drum -
Cardan shaft flange DIN 120 -
Flange size 1660 mm
Swing angle 5 °
Weight 408 kg
Cardan shaft
Valid for: L506 - 776 / from 9099; L507 - 777 / from 9099; L508 - 778 / from 9099
Description Value Unit
Minimum length 1533 mm
Maximum length 1593 mm
Flange tightening torque 60 Nm
Weight 22 kg
Valid for: L509 - 779 / from 9099; L510 - 782 / from 9099
Description Value Unit
Minimum length 1505 mm
Maximum length 1565 mm
L506 - 776 / from 9099 L509 - 779 / from 9099 copyright by 2.1-21 of 28
L507 - 777 / from 9099 L510 - 782 / from 9099
L508 - 778 / from 9099 MJFCIFSS
Product Description Service Manual
Technical Data
Articulation bearing
Description Value Unit
Tightening torque of bolts 70 Nm
Valid for: L508 - 778 / from 9099; L509 - 779 / from 9099
Description Value Unit
Weight per ballast weight 408 kg
Material GG10 -
Valid for: L506 - 777 / from 9099; L508 - 778 / from 9099
Description Value Unit
Weight per ballast weight 335 kg
Material GG10 -
Valid for: L509 - 779 / from 9099; L510 - 782 / from 9099
Description Value Unit
Weight per ballast weight 484 kg
Material GG10 -
2.1-22 of 28 copyright by L506 - 776 / from 9099 L508 - 778 / from 9099
L507 - 777 / from 9099 L509 - 779 / from 9099
MJFCIFSS L510 - 782 / from 9099
Service Manual Product Description
Technical Data
Progressive distributor
MX-F
Description Value Unit
Maximum operating pressure at input 300 bar
Distributor temperature range min. -35 °C
(taking into account transfer medium) max. +100 °C
Transfer medium Greases up to
NLGI class 2
MX-F 25
Description Value Unit
Flow per outlet 25 mm³
Flow per element 50 mm³
Piston diameter 3 mm
MX-F 45
Description Value Unit
Flow per outlet 45 mm³
Flow per element 90 mm³
Piston diameter 4 mm
L506 - 776 / from 9099 L509 - 779 / from 9099 copyright by 2.1-23 of 28
L507 - 777 / from 9099 L510 - 782 / from 9099
L508 - 778 / from 9099 MJFCIFSS
Product Description Service Manual
Technical Data
MX-F 75
Description Value Unit
Flow per outlet 75 mm³
Flow per element 150 mm³
Piston diameter 5 mm
MX-F 105
Description Value Unit
Flow per outlet 105 mm³
Flow per element 210 mm³
Piston diameter 6 mm
Air-conditioning system
Description Value Unit
Refrigerant R134a
Coolant quantity 1400 g
Cooling power 6.4 kW
Coolant oil PAG ZXL 100PG
Coolant oil quantity 150 cm3
Pressure switch
Description Value Unit
Low pressure switch OFF 1.5 bar
Low pressure switch ON 2.9 bar
High pressure switch OFF 25.0 bar
High pressure switch ON 19.0 bar
2.1-24 of 28 copyright by L506 - 776 / from 9099 L508 - 778 / from 9099
L507 - 777 / from 9099 L509 - 779 / from 9099
MJFCIFSS L510 - 782 / from 9099
Service Manual Product Description
Technical Data
Temperature switch
Description Value Unit
Temperature switch adjustment range -1 to +14 °C
Temperature switch activation
5 ±1 °C
temperature
Temperature switch deactivation
1 ±1 °C
temperature
Lift arm
Valid for: L506 - 776 / from 9099; L507 - 777 / from 9099; L508 - 778 / from 9099
Description Value Unit
Lift arm length 2150 mm
Weight of complete lift arms (without 467 kg
cylinder)
Bucket arm weight 335 kg
Deflection lever weight 88 kg
Weight of complete connecting link 44 kg
Valid for: L509 - 779 / from 9099; L510 - 782 / from 9099
Description Value Unit
Lift arm length 2250 mm
Weight of complete lift arms 507 kg
(without cylinder)
Bucket arm weight 375 kg
Deflection lever weight 88 kg
Weight of complete connecting link 44 kg
Quick-change device
Description Value Unit
Additional control
Control, activation and operation -
lever
Lockout Changeover valve -
Lockout display Visual -
A - system connection size 852 mm
B - width 852 mm
H - height 382 mm
T - depth 119 mm
Weight 49 kg
L506 - 776 / from 9099 L509 - 779 / from 9099 copyright by 2.1-25 of 28
L507 - 777 / from 9099 L510 - 782 / from 9099
L508 - 778 / from 9099 MJFCIFSS
Product Description Service Manual
Technical Data
Standard bucket
2.1-26 of 28 copyright by L506 - 776 / from 9099 L508 - 778 / from 9099
L507 - 777 / from 9099 L509 - 779 / from 9099
MJFCIFSS L510 - 782 / from 9099
Service Manual Product Description
Technical Data
L506 - 776 / from 9099 L509 - 779 / from 9099 copyright by 2.1-27 of 28
L507 - 777 / from 9099 L510 - 782 / from 9099
L508 - 778 / from 9099 MJFCIFSS
Product Description Service Manual
Technical Data
Forklift
2.1-28 of 28 copyright by L506 - 776 / from 9099 L508 - 778 / from 9099
L507 - 777 / from 9099 L509 - 779 / from 9099
MJFCIFSS L510 - 782 / from 9099
3 Maintenance
3.0
Chapter contents
3 Maintenance........................................................................ 3.0-1
L506 - 776 / from 9099 L509 - 779 / from 9099 copyright by 3.0-1 of 4
L507 - 777 / from 9099 L510 - 782 / from 9099
L508 - 778 / from 9099 MJFCIFSS
Maintenance Service manual
3.0-2 of 4 copyright by L506 - 776 / from 9099 L508 - 778 / from 9099
L507 - 777 / from 9099 L509 - 779 / from 9099
MJFCIFSS L510 - 782 / from 9099
Service manual Maintenance
L506 - 776 / from 9099 L509 - 779 / from 9099 copyright by 3.0-3 of 4
L507 - 777 / from 9099 L510 - 782 / from 9099
L508 - 778 / from 9099 MJFCIFSS
Service manual Maintenance
Maintenance and inspection schedule
L506 - 776 / from 9099 L509 - 779 / from 9099 copyright by 3.1-1 of 4
L507 - 777 / from 9099 L510 - 782 / from 9099
L508 - 778 / from 9099 MJFCIFSS
Maintenance Service manual
Maintenance and inspection schedule
Customer: ............................................... Machine type: .................... Ser. no.: ............................. Service hours: .............. Date: ......................
Maintenance / inspection
after service hours Tasks to be performed
Complete machine
Have the driver lubricate the machine in accordance with the lubrication chart and instruct
him on proper maintenance
Instruct the driver in the operation of all functions
Check the machine for external damage
Check that all screw connections are tight
Seal any leaks
Check the hydraulic pressure according to the testing and adjustment plan
Diesel engine
Check the oil level in the diesel engine
Change the engine oil (NOTE: the operating hours stated here only apply to the
appropriate engine oil quality / for complicating factors see the lubricants and fuels
section)
Replace the oil filter
Check or replace the V-ribbed belt
Drain off condensate from the fuel fine filter
Change the fuel fine filter
Change the fuel pre-filter
Clean the service cap and dust extraction valve on the air filter
Check that the vacuum switch of the air filter works
Replace the air filter main element if indicated by the vacuum switch (replace the safety
element after having replaced the main element 3 times)
Check the air suction hoses for leaks and tight fitting
Check the exhaust system for leaks and tight fitting
Cooling system
Check the coolant level
Check the antifreeze concentration in the coolant
Replace the coolant and antifreeze (or every 2 years)
Clean the cooling system
Working hydraulics
Lubricate the pilot control device, universal joints and tappets
Check the oil level in the hydraulic tank
Change the hydraulic oil (take an oil sample every 500 hours for bio oil)
Change the return suction filter
Replace the bleeder filter on the hydraulic tank
Steering system
Check the steering
Lubricate the bearing points on the steering cylinders
3.1-2 of 4 copyright by L506 - 776 / from 9099 L508 - 778 / from 9099
L507 - 777 / from 9099 L509 - 779 / from 9099
MJFCIFSS L510 - 782 / from 9099
Service manual Maintenance
Maintenance and inspection schedule
Customer: ............................................... Machine type: .................... Ser. no.: ............................. Service hours: .............. Date: ......................
Maintenance / inspection
after service hours TASKS TO BE PERFORMED
Brake system
Check the service brake and parking brake
Check the oil level in the equalising reservoir of the brake system
Check the gap and wear on the brake linings
Electrical system
Check the indicator lamps and lighting
Check the batteries, fluid level and terminals
Transfer gear
Check the oil level in the transfer gear
Change the gear oil in the transfer gear
Axles and tyres
Check the tightness of the wheel lugs (once after 50, 100 and 250 h) (450Nm)
Check the tightening torque of the front axle fastening bolts (750 Nm)
Grease the lubricating points on the rear axle kingpin bearings
Check the axle oil levels
Change the axle gear oil
Check and lubricate the drive shaft
Check and adjust the tyre pressure
Machine frame and ballast weight
Lubricate the articulated oscillating bearing and the rear oscillating bearing
Check the tightening torque of the bolts on the pressure flange
Check that the taper connection of the steering rods is tight
Cab, heating and air-conditioning (optional)
Check the indicator beads in the dryer-collector unit (optional)
Check that the air-conditioning system is working (optional)
Lubricate the door hinges
Clean or replace the fresh air and recirculated air filter
Lift arms and quick-change device
Lubricate the lift arms and attachment
Lubricate the quick-change device
Check the bearing bushings on the lift arms
Check the lift arms and bucket stops
Check that the quick-change device is working properly
L506 - 776 / from 9099 L509 - 779 / from 9099 copyright by 3.1-3 of 4
L507 - 777 / from 9099 L510 - 782 / from 9099
L508 - 778 / from 9099 MJFCIFSS
Service manual Maintenance
Testing and adjustment plan
Customer: ……………………… Machine type: ………...… Ser. no.: ……....…… Service hours: …….…….…… Date: ………..…………
Maintenance / inspection
after service hours
TASKS TO BE PERFORMED
Diesel engine
Check the diesel engine speed
Cooling system
Check the pressure relief valve on the fan motor
Travel hydraulics
Check the replenishing pressure of the travel pump
Check the start of regulation of the travel pump
Check the output of the travel pump
Check the pressure relief and replenishing valve of the travel pump
Check the pressure cut-off of the travel pump
Check the variable displacement motor in the control range
Working hydraulics
Check the secondary pressure relief valves on the control block
Check the primary pressure relief valves on the control block
Steering system
Check the pressure relief valve of the steering system
Check the secondary pressure relief valves of the servostat
Brake system
Check the play of the inch/brake pedal
L506 - 776 / from 9099 L509 - 779 / from 9099 copyright by 3.2-1 of 2
L507 - 777 / from 9099 L510 - 782 / from 9099
L508 - 778 / from 9099 MJFCIFSS
Service manual Maintenance
Lubrication chart and filling quantities
L506 - 776 / from 9099 L509 - 779 / from 9099 copyright by 3.3-1 of 6
L507 - 777 / from 9099 L510 - 782 / from 9099
L508 - 778 / from 9099 MJFCIFSS
Costumer: L506, L507, L508 S/N: /
Operating hours:
Type of application:
Job site: Checked by:
Checked on date:
Value Test
Adjust. Value at Adjust.
Check / Adjustment Unit after
values check adjust.
point point 1
Diesel Engine
Diesel engine RPM
12 -1 50
Low idle RPM HZ 205 min 850 1
+20 -1 +80
High idle RPM HZ 740 min 3040 1
Cooling System
Cooling system (fan control)
Fan at high diesel engine RPM / bar 14010 P
Sensor unplugged
Driving Hydraulic
Replenishing pressure
At low idle RPM bar 292 2 G
At high idle RPM bar 312 2 G
Pressure cut-off
High pressure
Engine speed drop, max. difference
bar 4305 5 MA
-1
to high idle RPM HZ 15 min 60
= Blocked Machine
Working Hydraulic
Control valve block
5
Secondary pressure relief valve, lift 1) bar 220 2 P
5
Secondary press. relief valve, tilt in 1) bar 220 1 P
Secondary press. rel. valve, tilt out 1) bar 170 5 5 P
Ride control
Pressure relief valve bar 16010 10 P
plus ½ turn
Steering System
Priority-valve working hydraulic -
pump
Pressure relief valve - steering bar 18010 7
Servostat
Secondary pressure relief valves bar 26010 8
Brake System
Idle mouvement of the Brake-
inching pedal
Push the Inch- brake pedal softly by mm 5 9
hand
Check at running engine
Remarks: Signature:
1) Attention: The working hydraulic pump must not be loaded with more than 235 bar.
Turn out secondary relief valves by 1 turn
Adjust the secondary relief valves to the value in the table
After check / adjustment turn in secondary relief valves by 1 turn
Checking the secondary valves and the primary valve must be conducted at a diesel
engine speed of approx. 1000 rpm (242 Hz).
Operating hours:
Type of application:
Job site: Checked by:
Checked on date:
Value Test
Adjust. Value at Adjust.
Check / Adjustment Unit after
values check adjust.
point point 1
Diesel Engine
Diesel engine RPM
12 -1 50
Low idle RPM HZ 205 min 850 1
+20 -1 +80
High idle RPM HZ 740 min 3040 1
Cooling System
Cooling system (fan control)
Fan at high diesel engine RPM / bar 14010 P
Sensor unplugged
Driving Hydraulic
Replenishing pressure
At low idle RPM bar 282 2 G
At high idle RPM bar 302 2 G
Pressure cut-off
5
High pressure bar 460 5 MA
-1
Engine speed drop, max. difference min 60
to high idle RPM HZ 15
= Blocked Machine
Working Hydraulic
Control valve block
5
Secondary pressure relief valve, lift 1) bar 220 2 P
5
Secondary press. relief valve, tilt in 1) bar 220 1 P
Secondary press. rel. valve, tilt out 1) bar 170 5 5 P
Ride control
Pressure relief valve bar 16010 10 P
plus ½ turn
Steering System
Priority-valve working hydraulic -
pump
Pressure relief valve - steering bar 18010 7
Servostat
Secondary pressure relief valves bar 26010 8
Brake System
Idle mouvement of the Brake-
inching pedal
Push the Inch- brake pedal softly by mm 5 9
hand
Check at running engine
Remarks: Signature:
1) Attention: The working hydraulic pump must not be loaded with more than 235 bar.
Turn out relief valves by 1 turn
Adjust the secondary relief valves to the value in the table
After check / adjustment turn in secondary relief valves by 1 turn
Checking the secondary valves and the primary valve must be conducted at a diesel
engine speed of approx. 1000 rpm (242 Hz).
Valid for: L506 - 476 / from 9099; L507 - 477 / from 9099; L508 - 478 / from 9099;
Description Medium Dosage Unit
Diesel engine Engine oil 8.0 l
(with filter change) SAE 10W - 40
L506 - 776 / from 9099 L509 - 779 / from 9099 copyright by 3.4-1 of 4
L507 - 777 / from 9099 L510 - 782 / from 9099
L508 - 778 / from 9099 MJFCIFSS
Maintenance Service manual
Lubrication chart and filling quantities
Valid for: L509 - 779 / from 9099; L510 - 782 / from 9099
Description Medium Dosage Unit
Diesel engine Engine oil 11.25 l
(with filter change) SAE 10W - 40
3.4-2 of 4 copyright by L506 - 776 / from 9099 L508 - 778 / from 9099
L507 - 777 / from 9099 L509 - 779 / from 9099
MJFCIFSS L510 - 782 / from 9099
Service manual Maintenance
Lubrication chart and filling quantities
L506 - 776 / from 9099 L509 - 779 / from 9099 copyright by 3.4-3 of 4
L507 - 777 / from 9099 L510 - 782 / from 9099
L508 - 778 / from 9099 MJFCIFSS
Maintenance Service manual
Lubrication chart and filling quantities
Oil change
3.4-4 of 4 copyright by L506 - 776 / from 9099 L508 - 778 / from 9099
L507 - 777 / from 9099 L509 - 779 / from 9099
MJFCIFSS L510 - 782 / from 9099
Service manual Maintenance
Maintenance tasks
Visual contact
There is a risk of accidents for maintenance personnel!
Danger
The presence of unauthorised persons on the machine can place the
maintenance personnel in extreme danger.
! Never enter a dangerous area of the machine without making your pre-
sence known.
Make sure you can be clearly seen before entering one of the machine's
danger areas.
Secure the machine against rolling away with wheel wedges.
Wheel wedges
L506 - 776 / from 9099 L509 - 779 / from 9099 copyright by 3.5-1 of 26
L507 - 777 / from 9099 L510 - 782 / from 9099
L508 - 778 / from 9099 MJFCIFSS
Thank you very much
for your reading.
Please Click Here
Then Get More
Information.