Liebherr L550 - L580 2plus2 Wheel loader Repair Service Manual

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This complete service repair workshop manual PDF download for the Liebherr L550 - L580 2plus2 Wheel loader has easy to read text sections with top quality diagrams, pictures and illustrations. The step by step instructions show you how to fault find or complete any repair or overhaul, correctly and efficiently, saving time and avoiding costly mistakes. All specifications and tolerances are listed. Functions of components and systems are also explained.


APPLICABLE MODELS :

Type: L550 L556 L566 L576 L580
Production number: 456 454 460 457 459
Serial number: 16978 15653 14171 14171 14171


TABLE OF CONTENTS :

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


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Total Pages : 714


This service repair workshop manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same Repair Service manual your local dealer will use when doing a repair.

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.

All pages are printable, so run off what you need & take it with you into the garage or workshop. Save money $$ by doing your own repairs! These manuals make it easy for any skill level with these very easy to follow, step-by-step instructions! Instant download means no shipping cost or waiting for a CD to arrive in the mailyou will receive this manual today via instant download on completion of payment via our secure payment processor. We accept all major credit/debit cards/paypal.

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Service Manual Wheel loader L550 - L580 2plus2
Document ID
Preface
Index

1 General Informations
1.1 Safety regulations
1.1.1 Introduction
1.1.2 Overview of the safety regulations
1.2 Special tools for maintenance andrepair work
1.2.1 Special tools in general
1.2.2 Special tools for Liebherr diesel engines
1.2.3 Special tools for hydraulic cylinders
1.2.4 Special tools for electronics
1.2.5 Special tools for axles
1.2.6 Special tools for the transmission
1.2.7 Central lubrication system
1.2.8 Special tools for the air conditioning system
1.2.9 Special tools for cab windows

2 Production description
2.1 Technical data
2.1.1 Complete machine
2.1.2 Diesel engine and pump distributor gear
2.1.3 Cooling system
2.1.4 Travel hydraulics
2.1.5 Working hydraulics
2.1.6 Steering system
2.1.7 Brake system
2.1.8 Electrical system
2.1.9 Transmission
2.1.10 Axles and cardan shaft
2.1.11 Machine frame and ballast weight
2.1.12 Automatic central lubrication system
2.1.13 Cab, heating and air-conditioning
2.1.14 Lift arms and quick-change device
2.1.15 Equipment and accessories

3 Maintenance
3.1 Maintenance and inspection schedule
3.2 Testing and adjustment plan
3.3 Testing and adjustment checklists
L550 - L556 2plus2 - ab 15653
L566 - L580 2plus2 - ab 14171
3.4 Lubrication chart and filling quantities
3.4.1 Table of filling quantities
3.4.2 Lubrication charts
3.5 Maintenance tasks
3.5.1 Preparatory tasks for maintenance
3.5.2 Removing loose parts, dirt, ice and snow from the machine
3.5.3 Checking the machine for external damage
3.5.4 Making sure the bolted connections are tight
3.5.5 Sealing leaks
3.5.6 Checking the engine oil level
3.5.7 Changing the engine oil
3.5.8 Changing the diesel engine oil filter
3.5.9 Checking / replacing the V-ribbed belt
3.5.10 Checking / adjusting the engine valve play
3.5.11 Checking the diesel engine heating flange
3.5.12 Greasing the ring gear on the engine starter flywheel
3.5.13 Changing the engine oil separator filter insert
3.5.14 Checking the bearings and condition of the engine controlunits
3.5.15 Checking the state of sensors and cable connections
3.5.16 Changing the fuel pre-filter
3.5.17 Changing the fuel fine filter
3.5.18 Draining off condensate from the fuel pre-filter (thecorresponding service code appears)
3.5.19 Bleeding the fuel system
3.5.20 Draining off condensate and sediment from the fuel tank
3.5.21 Cleaning the air filter service cap and dust extraction valve
3.5.22 Testing the air filter vacuum switch
3.5.23 Changing the air filter primary element when indicated by thevacuum switch
3.5.24 Changing the air filter secondary element
3.5.25 Checking the air intake hoses for leaks and tight fitting
3.5.26 Checking the exhaust lines for leaks and tight fitting
3.5.27 Check the oil level in the pump distributor gear
3.5.28 Changing the splitter box oil
3.5.29 Checking the soot particle filter pressure monitor for function,leaks and blockages
3.5.30 Checking and draining the soot particle filter condensateseparator
3.5.31 Changing the soot particle filter condensate separator
3.5.32 Cleaning the soot particle filter
3.5.33 Checking the coolant antifreeze and corrosion inhibitorconcentration
3.5.34 Cleaning the cooling system
3.5.35 Changing the coolant
3.5.36 Checking the oil level in the hydraulic tank
3.5.37 Draining off condensate and sediment from the hydraulic tank
3.5.38 Changing the oil in the hydraulic tank and checking the returnstrainer
3.5.39 Checking and cleaning the magnetic rod on the hydraulic tank
3.5.40 Changing the hydraulic tank return suction filter
3.5.41 Changing the hydraulic tank bleeder filter
3.5.42 Lubricating the pilot control device solenoids, universal jointsand tappets
3.5.43 Testing the steering
3.5.44 Lubricating the bearing points on the steering cylinders
3.5.45 Testing the service brake and parking brake
3.5.46 Checking the gap and wear on the parking brake linings
3.5.47 Checking the indicator lamps and lighting
3.5.48 Checking the batteries, fluid level and terminals
3.5.49 Checking the transmission oil level
3.5.50 Changing the transmission oil
3.5.51 Changing the transmission oil filter
3.5.52 Checking the tightness of the wheels (once after 50, 100and 250 h)
3.5.53 Checking the axle oil level
3.5.54 Checking the axle oil level
3.5.55 Changing the axle oil
3.5.56 Changing the axle oil
3.5.57 Lubricating the bevel gear seal
3.5.58 Checking and lubricating the front drive shaft
3.5.59 Checking and lubricating the rear drive shaft
3.5.60 Testing and setting the tyre pressure for the machine's useand attachments
3.5.61 Lubricating the articulated bearing and the rear oscillatingbearing
3.5.62 Checking the lubrication system grease reservoir level
3.5.63 Checking the pipes, hoses and lubrication points of thelubrication system
3.5.64 Checking whether metered quantities are adequate at thebearing points (grease collars) of the central lubricationsystem
3.5.65 Lubricating the door hinges
3.5.66 Cleaning the fresh air and recirculated air filter
3.5.67 Changing the fresh air and recirculated air filter
3.5.68 Checking the indicator beads in the dryer-collector unit
3.5.69 Lubricating the lift arms and attachment
3.5.70 Checking the bucket bearing seals and the bearing bushingson the lift arms
3.5.71 Check the lift arms and bucket stops
3.5.72 Testing the quick-change device (optional)
3.6 Testing and adjustment tasks
3.6.1 Preparing for testing and adjustment
3.6.2 Safety precautions for testing and adjustment
3.6.3 Bringing the machine up to operating temperature
3.6.4 Checking the diesel engine speed
3.6.5 Check the fan motor and fan control pressure relief valve
3.6.6 Calibrating the pedals
3.6.7 Checking the replenishing pressure of the variabledisplacement pump
3.6.8 Checking the pressure relief and replenishing valve of thevariable displacement pump
3.6.9 Checking the pressure cut-off of the variable displacementpump
3.6.10 Calibrating the block curve
3.6.11 Calibrating the variable displacement motors
3.6.12 Checking the engine output
3.6.13 Checking the flow controller (delta p) of the workinghydraulics pump
3.6.14 Checking the flow controller (start of delivery) of the workinghydraulics pump
3.6.15 Checking the secondary pressure relief valves on the controlblock
3.6.16 Checking the primary pressure relief valves on the controlblock
3.6.17 Checking the LS pressure cut-off on the control block
3.6.18 Depressurising ride control and the hydro accumulators
3.6.19 Checking the cut-off pressure in the stabilisation module
3.6.20 Checking the nitrogen in the ride control hydro accumulator
3.6.21 Check the pressure cut-off of the steering pump
3.6.22 Checking the flow controller (delta p) of the steering pump
3.6.23 Checking the brake pressure of the compact brake valve
3.6.24 Checking the brake pressure at the axles
3.6.25 Checking the capacity of the brake accumulator
3.6.26 Checking the accumulator charge pressure
3.6.27 Checking the brake light pressure switch and brake lights
3.6.28 Checking the transmission shift pressure
3.6.29 Checking the nitrogen in the transmission hydro accumulator
3.7 Lubricants and fuels
3.7.1 Diesel fuels
3.7.2 Lubricating oils for diesel engines
3.7.3 Coolant for the diesel engine
3.7.4 Hydraulic oils
3.7.5 Lubricating oils for the transmission
3.7.6 Grease for general lubrication points

4 Diesel engine, Splitter box
4.1 Diesel engine
4.1.1 Electrical engine components
4.1.2 Crankshaft flywheel speed sensors – B711/B712
4.1.3 Camshaft speed sensor – B713
4.1.4 Coolant temperature sensor – B708Fuel temperature sensor – B709
4.1.5 Charge air temperature sensor – B707
4.1.6 Charge air pressure sensor – B703
4.1.7 Oil pressure sensor – B701
4.2 Fuel system
4.2.1 Fuel level sensor
4.2.2 Fuel pre-filter
4.2.3 Fuel fine filter
4.2.4 Refuelling pump (optional)
4.3 Air filter system
4.3.1 Air filter
4.3.2 Vacuum switch
4.4 Coupling
4.5 Splitter box

5 Cooling system
5.1 Gear pump
5.2 Gear motor
5.3 Temperature sensor

6 Travel Hydraulics
6.0.1 Travel hydraulics – L550, L556
6.0.2 Travel hydraulics – L566, L576, L580
6.1 Variable displacement pump
6.2 Variable displacement motors
6.2.1 Variable adjustment motor
6.2.2 Motor scavenging pump

7 Working hydraulics
7.0.1 Working hydraulics - L550, L556
7.0.2 Working hydraulics - L566, L576, L580
7.1 Working hydraulics pump
7.2 Control block
7.3 Pilot control unit
7.3.1 Pilot control unit
7.3.2 Pilot control solenoid valve
7.3.3 Pilot control hydro accumulator
7.3.4 Float position pressure switch
7.4 Ride control
7.4.1 Ride control – L550, L556
7.4.2 Ride control – L566, L576, L580
7.4.3 Stabilisation module
7.4.4 Hydro accumulator unit
7.4.5 Ride control pressure switch
7.5 Lift and tilt cylinders
7.5.1 Lift cylinder
7.5.2 Tilt cylinder
7.6 Hydraulic tank
7.6.1 Filter unit
7.6.2 Bleeder filter

8 Steering System
8.0 Steering system
8.1 Steering pump
8.2 Servostat
8.3 Steering cylinder
8.3.1 Steering damper hydro accumulator
8.4 Emergency steering
8.4.1 Emergency steering pump
8.4.2 Emergency steering pressure switch
8.4.3 Emergency steering check pressure switch
8.4.4 Valve block

9 Brake system
9.0.1 Brake system
9.1 Service brake
9.1.1 Brake system gear pump
9.1.2 Compact brake valve
9.1.3 Service brake hydro accumulator
9.1.4 Brake light pressure switch
9.1.5 Accumulator charge pressure switch
9.2 Parking brake
9.2.1 Disc brake
9.2.2 Parking brake hydro accumulator
9.3 Overspeed protection
9.3.1 Overspeed protection solenoid valve

10 Electrical system
10.0.1 Electrical system with circuit diagrams
SPL Id. Nr. 8920980
1 | OVERVIEW DIAGRAM ELECTRICAL SYSTEM ELECTRONICS
2 | TABLE OF CONTENTS
3 | TABLE OF CONTENTS
4 | KEY ; HANDOUT CONTAINING TYPE ; COUNTING NUMBER ; SYSTEM AND PLACE
5 | BMK-INDEX
6 | BMK-INDEX A - B
7 | BMK-INDEX B - E
8 | BMK-INDEX E - F
9 | BMK-INDEX F - H
10 | BMK-INDEX H - L
11 | BMK-INDEX L - M
12 | BMK-INDEX M - R
13 | BMK-INDEX R - S
14 | BMK-INDEX S - V
15 | BMK-INDEX V - X
16 | BMK-INDEX X
17 | BMK-INDEX X - Y
18 | BMK-INDEX Y
19 | IGNITION LOCK ; BATTERIES ; GENERATOR ; MAIN FUSES
20 | FUNCTION D+ PROFILE LIGHT; PARKING LIGHT
21 | TANK PIPE SENSOR ; TRANSMISSION- / HYDRAULIC OIL TEMPERATURE ;VENTILATOR ; COOLING WATER LEVEL , BRAKE ACCUMULATOR
22 | TANK PIPE SENSOR ; TRANSMISSION- / HYDRAULIC OIL TEMPERATURE ;VENTILATOR ; COOLING WATER LEVEL , BRAKE ACCUMULATOR
23 | EMERGENCY STEERING PUMP ; LFD ; AIR FILTER CONTAMINATION ; RIDE CONTROL
24 | EMERGENCY STEERING PUMP ; LFD ; AIR FILTER CONTAMINATION ; RIDE CONTROL
25 | STEERING COLUMN SWITCH ; STOP LIGHT ; LOW BEAM ; HIGH BEAM
26 | COUNTRY-SPECIFIC TYPE/EXECUTION
27 | HAZARD WARNING LIGHTS
28 | WINDSCREEN WASHER FRONT AND REAR ; HOOTER
29 | WINDSCREEN WASHER FRONT AND REAR ; HOOTER
30 | WORKING PROJECTOR FRONT CABIN XENON WORKING PROJECTOR
31 | WORKING PROJECTOR REAR REAR
32 | WORKING PROJECTOR REAR CABIN
33 | WARNING BEACON ; MIRROR- AND REAR WINDOW HEATER
34 | CIGARETTE LIGHTER ; ELECTRICAL SOCKET 12V ; RADIO ; LOUDSPEAKER
35 | DISPLAY UNIT CAN BUS 3
36 | DISPLAY UNIT CAN BUS 3
37 | CAN BUS 1
38 | CAN BUS 2
39 | SUPPLY KEYPADS
40 | SUPPLY MASTER SUPPLY DIAGNOSTIC PLUG
41 | SUPPLY INPUT MODULE 1 AND 2
42 | SUPPLY OUTPUT MODULE 1
43 | SUPPLY OUTPUT MODULE 1 AND 2
44 | SUPPLY OUTPUT MODULE 2
45 | OUTPUT MODULE 2; BACK-UP ALARM AND CAN BE SWITCHED OFF
46 | OUTPUT MODULE 2; BACK-UP ALARM AND CAN BE SWITCHED OFF
47 | MOTOR CONTROL ; AUTOMATIC RUN-OUT
48 | SUPPLY OUTPUT MODULE 3
49 | SUPPLY OUTPUT MODULE 3; AUTOMATIC LIGHTING SHUTDOWN
50 | SUPPLY INPUT MODULE 4; EP 3. AND 4. CONTROL CIRCUIT
51 | LH-CONTROL LEVER SWITCH COMFORT CONTROL ; 3 AND 4 CONTROL CIRCUIT
52 | ANGLE SENSOR INCH-/GAS PEDAL
53 | TRAVEL RANGES ; SWIVEL ANGLE HYDRO MOTORS OVERSPEED PROTECTION
54 | TRAVEL DIRECTIONS ; HYDRAULIC PUMP ; BUZZER ;PRESSURE HIGH PRESSURE TRAVEL PUMP
55 | BACK-UP ALARM; GEROTOR STEERING ; DIESEL PREHEATING
56 | FLOAT POSITION ; BUCKET RETURN-TO-DIG LIFT KICKOUT
57 | ADDITIONAL EQUIPMENT 1;2;3 AND 4 QUICKCHANGE
58 | ADDITIONAL EQUIPMENT 1;2 QUICKCHANGE
59 | FUNCTION WORKING BASKET
60 | EP 3. AND 4. CONTROL CIRCUIT
61 | CUTOFF TILT CYLINDER
62 | AIR CONDITIONING SYSTEM ;AMBIENT TEMPERATURE SENSOR ; SUN SENSOR
63 | AIR CONDITIONING SYSTEM ;AMBIENT TEMPERATURE SENSOR ; SUN SENSOR
64 | FAN MOTOR AND SENSOR ICE UP PROTECTION
65 | WATER VALVE VMC1 RECIRCULATED AIR FLAP VMC2
66 | FOOT FLAP VMC3 MIDDLE FLAP VMC4
67 | HEAD FLAP VMC5 TEMPERATURE SENSOR AUTOMATIC AIR CONDITIONING
68 | VENTILATOR CONDENSER INTEGRATED
69 | VENTILATOR CONDENSER RETROFIT KIT
70 | DIAGNOSTIC PLUG MOTOR CONTROL AND AIR CONDITIONING SYSTEM
71 | SUPPLY INPUT MODULE 3; JOYSTICK STEERING
72 | JOYSTICK STEERING
73 | SUPPLY INPUT MODULE 3; JOYSTICK STEERING
74 | JOYSTICK STEERING
75 | REVERSING OBSTACLE DETECTOR GROENEVELD
76 | REAR AREA MONITORING ÜBER MONITOR AND CAMERA
77 | CENTRAL LUBRICATION SYSTEM LIEBHERR
78 | PARKING BRAKE ; SPEED SENSOR CENTRAL LUBRICATION SYSTEM GROENEVELD
79 | ELECTRONIC IMMOBILISER
80 | AUXILIARY HEATER DBW 2010
81 | AUXILIARY HEATER THERMO 90
82 | DIESEL PREHEATING COLD WEATHER KIT -40°
83 | VERSION BATTERY WIRING HARNESSES -40°
84 | VERSION BATTERY WIRING HARNESSES L586
85 | GENERAL OUTLAY MASTER
86 | GENERAL OUTLAY INPUT MODULE 1
87 | GENERAL OUTLAY INPUT MODULE 2
88 | GENERAL OUTLAY INPUT MODULE 3
89 | GENERAL OUTLAY INPUT MODULE 4
90 | GENERAL OUTLAY OUTPUT MODULE 1
91 | GENERAL OUTLAY OUTPUT MODULE 2
92 | GENERAL OUTLAY OUTPUT MODULE 3
93 | GENERAL OUTLAY MOTOR CONTROL ENGINE SIDE
94 | GENERAL OUTLAY ELECTRIC KEYPAD
95 | GENERAL OUTLAY MAIN KEYPAD
96 | GENERAL OUTLAY HEAT- / AIR CONDITIONING SYSTEM
97 | GENERAL OUTLAY HEAT- / AIR CONDITIONING SYSTEM SYSTEM SIDE
98 | GENERAL OUTLAY OPTION KEYPAD
99 | GENERAL OUTLAY AIR CONDITIONING KEYPAD FLAP CONTROL
100 | GENERAL OUTLAY PROTECTIVE FOIL
101 | ELECTRICAL DIAGRAM DIESEL ENGINE 4 AND 6 CYLINDER
102 | STAND BY AM 6 CYLINDER ENGINE
103 | GENERAL OUTLAY SENSORS
104 | GENERAL OUTLAY MOTOR CONTROL 6 CYLINDER
105 | STARTER, GENERATOR
106 | CHARGE AIR COOLER ; OIL PRESSURE SWITCH, WATER DETECTOR
107 | FUEL TEMPERATURE SENSOR ; AKTIVE ; OSCILLATING
108 | ENGINE SPEED SENSOR 1, ENGINE SPEED SENSOR 2, PHASE SENSOR
109 | INJECTION PUMP CYLINDER 1-3
110 | INJECTION PUMP CYLINDER 4-6
111 | STAND BY AM 4 CYLINDER ENGINE
112 | GENERAL OUTLAY SENSORS
113 | GENERAL OUTLAY MOTOR CONTROL 4 CYLINDER
114 | KEY OF SYMBOLS DIN EN613461; DIN EN613462; DIN EN60617
10.1 Electrical components
10.1.1 Electrical components in the cab
10.1.2 Fuse and relay board A4
10.1.3 Main electronics (master) A15
10.1.4 Input modules (A16a, A16b, A16c)
10.1.5 Output modules (A17a, A17b, A17c)
10.1.6 Electrical components in the rear section
10.2 Battery installation
10.2.1 Batteries

11 Transmission
11.0 Transmission
11.1 Mechanical transmission
11.2 Electronic control unit
11.2.1 Main electronics (master)
11.2.2 Main wiring harness (including transmission)
11.2.3 Gear shifting solenoid valves
11.2.4 Speed sensor
11.3 Hydraulic control
11.3.1 Control valve block
11.3.2 Gear pump

12 Axles, Drive shafts
12.1 Axles – L550 - L576 2plus2
12.2 Axles – L580 2plus2
12.3 Drive shafts
12.3.1 Front drive shaft
12.3.2 Rear drive shaft

13 Machine frame, Ballastweight
13.1 Machine frame
13.2 Articulation bearing
13.3 Oscillating axle mount
13.4 Articulation lock
13.5 Ballast weight

14 Central lubrification system
14.1 Manual central lubrication
14.2 LIEBHERR automatic centrallubrication system (optional)
14.2.1 Central lubrication pump EP-1
14.2.2 Progressive distributor MX-F
14.2.3 Central lubrication pump controller EP-1 and operation

15 Covering, access
15.1 Covering
15.2 Cab access

16 Cab, heating, air conditioning
16.0.1 Cab, heating and air-conditioning
16.1 Instrument panel
16.1.1 Display unit A13
16.1.2 Control units A11, A18 and A22
16.1.3 Main function control unit (CAN bus) A11
16.1.4 Air conditioning control unit (CAN bus) A22
16.1.5 Option control unit (CAN bus) A19
16.1.6 Electrical control unit A18
16.1.7 LIEBHERR control lever
16.2 Heating, ventilation, air conditioning
16.2.1 Heating/air conditioning unit
16.2.2 Blower
16.3 Air conditioning system
16.3.1 Air conditioning compressor
16.3.2 Condenser
16.3.3 Dryer collector unit
16.3.4 Pressure switch
16.3.5 Evaporator

17 Lift arms and quick-changedevice
17.1 Lift arms
17.2 Pin bearing
17.2.1 Standard bearing
17.2.2 Bucket bearing
17.2.3 Removing the pin bearings
17.2.4 Changing the bushings
17.2.5 Assembling the bucket bearing
17.3 Quick change device (optional)

18 Equipment and accessories
18.1 Loading bucket
18.2 Forklift
18.3 Connection sizes – L550 / L556
18.3.1 Buckets - direct attachment
18.3.2 Buckets - quick-change device
18.3.3 Dimensions - Z kinematics, direct attachment
18.4 Connection sizes – L566 / L576 / L580
18.4.1 Buckets - direct attachment
18.4.2 Buckets - quick-change device
18.4.3 Dimensions - Z kinematics, direct attachment

19 Service Codes, Diagnose
19.0 Malfunctions
19.0.1 Service codes indicated on the display unit (A13)
19.0.2 Audible and visual warning signals

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