Liebherr L544-443 Wheel Loader Service Repair Manual SN 6190 To 7476 PDF

en
Service Manual
(20
Wheel loader
(10 points)
L544 - L554 2plus2
(10
en
Service Manual
(20
Wheel loader
(10 points)
L544 - L554 2plus2
(10
Address
Address: LIEBHERR-WERK BISCHOFSHOFEN GMBH
Dr. Hans Liebherr Straße 4

A 5500 BISCHOFSHOFEN, AUSTRIA
Product identification
Manufacturer: LIEBHERR-WERK BISCHOFSHOFEN GMBH
Product group: Wheel loader
Type: L 544 L 554
Construction number: 443 453
Serial number: 6190 - 7476 0501 - 7476
Document identification
Order number: 10022903
Author: LBH / TD - department
Document version: 01
Manual number:
Owner:
Foreword
Target group This Service Manual has been written for those whose job it is to ensure that
the machines remain operational on a daily basis. This includes the
mechanics and workshop specialists at Liebherr branch offices and Dealers.
Contents In the first chapter you will find information about safety regulations as well
as specifications for the special tools needed for maintenance and repair.
Chapter 2 provides an overview of important technical data for the entire
machine and the individual assemblies.
The following chapter, entitled Maintenance, contains the maintenance and
inspection schedule, testing and adjustment schedule, lubrication chart and
filling quantities, a description of maintenance procedures and specifications
for prescribed lubricants and fuels.
The technical description of the machine in the following chapters is divided
into 15 function groups. The design, function, and technical data for each
component and part are explained.
Chapter 19 is a new one and in it, you will find a list of available repair
manuals, troubleshooting hints, the service code table and a description of
the BODEM service software.
How to use this manual This manual describes a variety of machine types as well as optional
equipment. 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.
CD 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 CD.
General information 1
Product description 2
Maintenance 3
Diesel engine, splitter box 4
Cooling system 5
Travel hydraulics 6
Working hydraulics 7
Steering system 8
Brake system 9
Electrical system 10
Transmission 11
Axles, tyres 12
Machine frame, counterweight 13
Central lubrication system 14
Coverings, cab access 15
Cab, heating, air-conditioning 16
Lift arm, quick-coupling device 17
Attachments, accessories 18
Repairs, troubleshooting 19
1 General information
Chapter contents
1.1 Safety regulations 1.1 - 1
1.1.1 Introduction 1.1 1
1.1.2 Overview of safety regulations 1.1 2
1.2 Special tools for maintenance and repair work 1.2 - 1

1.2.1 Special tools, general information 1.2 1
1.2.2 Special tools for Liebherr diesel engines 1.2 1
1.2.3 Special tools for the hydraulic cylinders 1.2 2
1.2.4 Special electrical tools 1.2 2
1.2.5 Special tools for axles 1.2 3
1.2.6 Special tools for the transfer gear 1.2 4
1.2.7 Central lubrication system 1.2 4
1.2.8 Special tools for the air conditioning system 1.2 4
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Service Manual General Information
Safety regulations
1.1 Safety regulations

Working on the machine poses safety risks to the operator, driver or
maintenance technicians. Carefully reading and observing the various safety
instructions at regular intervals can considerably reduce the risk of accidents.
This is especially important for personnel who only occasionally work on the
machine, for example, carrying out repair or maintenance work. The safety
regulations listed below, if followed precisely, will ensure their 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 will be explained.
These are indicated by the headings Danger, Warning or Caution.
1.1.1. Introduction
1. The symbols below have the following meanings:
Danger
Warning that without appropriate precautions, certain operational procedures
could result in fatal accidents.
Warning
could result in severe physical injuries.
Caution
could result in minor physical injuries or damage to the machine.
2. Observance of these instructions does not relieve you of the
responsibility to observe other rules and guidelines!
The following should also be observed:
The safety rules enforced at the operating site
Legally enforced traffic regulations
Guidelines issued by trade associations
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General Information Service Manual
Safety regulations
1.1.2 Overview of safety regulations

1. A detailed description of these is included in the relevant section of the
"Safety regulations" chapter in the operator's manual.
The following sections are described in the operator's 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 welding on the machine
16 Instructions for working safely on machine attachments
17 Safety regulations when transporting the machine by crane
18 Safe maintenance of hydraulic hoses and hose lines
19 Attachments and accessories
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Special tools for maintenance and repair work
1.2 Special tools for maintenance and

repair work
1.2.1 Special tools, general information
Description ID no. Use Notes
Digital thermometer 7020372 All wheel loaders For taking temperature measurements
during adjustment work
DCA 4 coolant test kit 5608459 All wheel loaders For testing DCA 4 and antifreeze levels
For testing the acid concentration (battery
Anti-freeze and battery tester 7408922 All wheel loaders charge level) and testing the cooler anti-
freeze
24 Volt vacuum pump 7408148 All wheel loaders For preventing oil loss
Charging and testing device with 8145359 All wheel loaders For testing the hydro accumulators
case
0-40 bar pressure gauge 7361288 All wheel loaders For testing hydraulic pressures
Pressure gauge connection 7002436 All wheel loaders Connection for pressure gauge
1500 mm high-pressure tube 7002475 All wheel loaders High-pressure tube for pressure gauge
4000 mm high-pressure tube 7009134 All wheel loaders High-pressure tube for pressure gauge
Screw coupling M 10 x 1 5005180 All wheel loaders For testing hydraulic pressures
Oil drain hose 7005660 All wheel loaders For draining oil via an outlet valve
Outlet piece 7402657 All wheel loaders For the oil drain hose
Safety cap SW 10 7009315 All wheel loaders For securing the valves on the variable
displacement motor
Safety cap SW 13 7615515 All wheel loaders For securing the valves on the pumps
Safety cap SW 17 7622068 All wheel loaders For securing the valves on the control
valve block
Bodem data cable 10285174 L544 - L580 For adjusting the travel hydraulics, cooling
Software + dongle 69059 L544 - L580 system, joystick steering, and for reading
service codes
1.2.2 Special tools for Liebherr diesel engines

Compression tester 8008782 L544 - L580 diesel engine For testing compression levels
Injection nozzle tester 7361236 L544 - L580 diesel engine For testing injection nozzles
Adapter for compression tester 0524044 L544 - L580 diesel engine In place of the injection nozzle
High pressure hand pump with 7009318 L544 - L580 diesel engine For testing the delivery begin of the
accessories injection pump
Extracting device for injection 0524072 L544 - L580 diesel engine For removing injection nozzles
nozzles
Adapter for extracting device 0524029 L544 - L580 diesel engine For use with extracting device
Rotary angle extraction device 0524062 L544 - L580 diesel engine For cylinder head, main bearing, and
connection lug bearing screws
Krikit 2 V-belt gauge 8042829 L544 - L580 diesel engine For testing the V-belt tension
Engine turning tool 0524045 L544 - L580 diesel engine For turning the engine at the flywheel
Engine turning tool 9183785 L544 - L580 diesel engine For turning the engine via the crank
shaft
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1.2.3 Special tools for the hydraulic cylinders

80 mm installation sleeve 9227165 Steering cylinder L544, L554 For fitting the seals
90 mm installation sleeve 9227161 Steering cylinder L564, L574, For fitting the seals
L580
130 mm installation sleeve 9998624 Lift cylinder L544, L554 For fitting the seals
150 mm installation sleeve 9998622 Tilt cylinder L544, L554 For fitting the seals
Lift cylinder L564, L574, L580
170 mm installation sleeve 9107931 Tilt cylinder L564, L574, L580 For fitting the seals
80 mm expansion tube 9227166 Steering cylinder L544, L554 For fitting the seals
90 mm expansion tube 9227162 Steering cylinder L564, L574, For fitting the seals
L580
130 mm expansion tube 9110408 Lift cylinder L544, L554 For fitting the seals
150 mm expansion tube 9110410 Tilt cylinder L544, L554 For fitting the seals
Lift cylinder L564, L574, L580
170 mm expansion tube 9110412 Tilt cylinder L564, L574, L580 For fitting the seals
70/8 mm bearing head 9210219 Steering cylinder L544, L554 For fitting the bearing head
assembly wrench
75/12 mm bearing head 9239572 Steering cylinder L564, L574, For fitting the bearing head
assembly wrench L580
1.2.4 Special electrical tools

Digital multimeter 8502956 All wheel loaders For measuring electrical voltage, current,
resistance and frequency
Test pin red 884191214 All wheel loaders To measure in the DEUTSCH plug
Test pin black 884191114 All wheel loaders To measure in the DEUTSCH plug
Solenoid tester 8145743 All wheel loaders For checking solenoid valves
RS 232 interface 6905859 L544 - L554 For reading the service codes
Two SUB-D data cables 6905860 L544 - L554 For reading the service codes
Wire stripping and crimping tool 8460263 All wheel loaders For MATE-N-LOK connectors
0.5 6.0 mm²
Insertion tool 8145432 All wheel loaders For MATE-N-LOK connectors
Extraction tool 7366655 All wheel loaders For MATE-N-LOK connectors
Manual crimping tool 8503647 All wheel loaders For DEUTSCH connectors
Wedge extraction tool 7026267 All wheel loaders For DEUTSCH connectors
Size 12 extraction tool for pin and 8145674 All wheel loaders For DEUTSCH connectors
bushing
Size 16 extraction tool for pin and 8145673 All wheel loaders For DEUTSCH connectors
bushing
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1.2.5 Special tools for axles

Hand pump 8145835 Axles L544 - L580 For testing the disc brake seals
Clamping pliers 7009536 Axles L554 - L580 For locking or releasing the snap
ring
Spring hook 8145767 Axles L554 - L580 For locking or releasing the
return springs
260 mm slip bushing 7017559 Front axle L554 Installation aid for brake piston
Rear axle L554
Slip bushing M 90 x 1.5 7017558 Rear axle L554 Installation aid for ring gear
mm carrier
Slip bushing M 110 x 7017557 Front axle L554 Installation aid for ring gear
1.5 mm Rear axle L564, L574 carrier
Handle 7017566 Axles L544 - L580 Handle for installation tool
Handle 7011518 Axles L544 - L580 Handle for various installation
tools
Installation tool 7017563 Rear axle L554 For installation of grooved nuts
Installation tool 7017560 Front axle L554, L564, L574, 580 Installation aid for sealing ring
Rear axle L564, L574, L580 cartridge
Centring shackle 7013775 Axles L554 - L580 For grooved nut spanner
111 mm grooved nut 7009537 Rear axle L554 For installation of grooved nuts
spanner
140 mm grooved nut 7011251 Front axle L554 For installation of grooved nuts
spanner Rear axle L564, L574
M 16 x 1.5 gauge 7019556 Front axle L554 For measuring wear on the brake
Rear axle L554, L564, L574 discs
Clamping fork 7011522 Axles L554 - L580
Installation tool 7013922 Axles L554 - L580 Installation aid for shaft sealing
ring
84 mm grooved nut 7013773 Axles L554 - L580 For installation of grooved nuts
spanner on the axle drive
81 mm grooved nut 10017840 Axles L554 - L580 For installation of grooved nuts
spanner on the axle drive
Installation tool (used 7624271 Axles L544 AP-409, MT-L 3085 For fitting the axle input dust
with handle 7011518) guard
Installation tool 7624272 Axles L544 AP-409, MT-L 3085 For fitting the axle input shaft
sealing ring
Centring shackle 10008138 Axles L544 MT-L 3085 For removing the output
Socket spanner 10008139 Axles L544 MT-L 3085 For removing the output
Clamping fork 10008140 Axles L544 MT-L 3085 For removing the output
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1.2.6 Special tools for the transfer gear

Support tool 10016179 L544 L580 Stops the 1 st coupling shaft from moving
when tightening the grooved nut
Special socket 10016180 L544 L580 For tightening and loosening the grooved
nut on the 1st coupling shaft
Installation tool 10016181 L544 L580 For compressing the piston return springs
when fitting and removing the snap ring
1.2.7 Central lubrication system

Central lubrication BEKA MAX 10008427 All wheel loaders For testing the central lubrication system
data cable + software
Central lubrication 7624289 All wheel loaders For testing the central lubrication system
Groeneveld data cable
Groeneveld Plug Adapter 7624290 All wheel loaders For testing the central lubrication system
Central greasing system As below All wheel loaders For testing the central lubrication system
Groeneveld Software
The Groeneveld central greasing system software is ordered directly from

Groeneveld. The software is activated by means of an activation code.
Steps and necessary data:
Company name and department
The activation code consists of 6 digits (numbers supplied by user).
This data must be sent via E-Mail to the following address:
support@groeneveld.nl
1.2.8 Special tools for the air conditioning system

Vacuum pump 7027552 All wheel loaders For evacuating the air conditioning
system
4-valve test set 7027558 All wheel loaders For testing, evacuating and filling
the air conditioning system
Filling hose, blue 1500 mm 7027553 All wheel loaders For the test set
Filling hose, yellow 7027554 All wheel loaders For the test set
1500 mm
Filling hose, red 1500 mm 7027555 All wheel loaders For the test set
Car coupling 253a 7027556 All wheel loaders For the test set
Car coupling 254a 7027557 All wheel loaders For the test set
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2 Product description
Chapter contents
2 Product description 2.0 - 1
2.1 Technical data 2.1 - 1
2.1.1 Complete machine 2.1 - 1
2.1.2 Diesel engine, pump distributor gear 2.1 - 4
2.1.3 Cooling system 2.1 - 5
2.1.4 Travel hydraulics 2.1 - 5
2.1.5 Working hydraulics 2.1 - 6
2.1.6 Steering system 2.1 - 7
2.1.7 Brake system 2.1 - 8
2.1.8 Electrical system 2.1 - 9
2.1.9 Transfer gear 2.1 - 9
2.1.10 Axles, tyres 2.1 - 9
2.1.11 Machine frame, counterweight 2.1 - 10
2.1.12 Cab, heating, air-conditioning 2.1 - 11
2.1.13 Lift arm, quick-change device 2.1 - 11
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Service Manual Product description
Technical data
2.1 Technical data
2.1.1 Complete machine

Wheel loader with Z-bar lift arm Valid for: L544 - 443 / 6190 - 7476
The values stated refer to the standard version of the machine:
With Z-bar lift arm (2600 mm) without hydraulic quick-change device.
With 23.5 R25 Michelin XHA tyres.
The specified tipping loads and weights include all lubricants, full fuel
tank, ROPS/FOPS cab and operator.
Description Value Unit

Bucket capacity as per ISO 7546 3.0 m³
Bucket width 2700 mm
Specific material density 1.8 t/m³
A - Dump height at max. lift and 45° tilt- 2920 mm
out angle
B - Max. dumping height 3500 mm
C - Max. height of bucket base 3645 mm
D - Max. height of bucket pivot point 3915 mm
E - Max. height of bucket upper edge 5350 mm
F - Reach at max. lift and 45° tilt-out 1040 mm
angle
G - Digging depth 85 mm
H - Height of cab 3355 mm
I - Height of exhaust 3310 mm
J - Ground clearance 530 mm
K - Wheel base 3150 mm
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Product description Service Manual
Technical data

L - Overall length 7785 mm
Turning radius over bucket outer edge 6235 mm
Lifting force (SAE) 170 kN
Breakout force (SAE) 125 kN
Tipping load when straight 12020 kg
Tipping load, articulated 35° 10910 kg
Angle of articulation (to each side) 40 °
Operating weight 15300 kg
Tractive force 122.6 kN
Travel speed in travel range 1, forward 0 - 10 km/h
and reverse
and reverse
Travel speed in travel range A1-2 0 - 20 km/h
(automatic), forward and reverse
Sound pressure level in the cab L pA 73 dB
Wheel loader with Z-bar lift arm Valid for: L554 - 453 / 0501 - 7476
The values stated refer to the standard version of the machine:
With Z-bar lift arm (2750 mm) without hydraulic quick-change device.
With 23.5 R25 Michelin XHA tyres.
The specified tipping loads and weights include all lubricants, full fuel
tank, ROPS/FOPS cab and operator.
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Technical data

Bucket capacity as per ISO 7546 3.5 m³
Bucket width 2700 mm
Specific material density 1.8 t/m³
A - Dump height at max. lift and 45° tilt- 3085 mm
out angle
B - Max. dumping height 3700 mm
C - Max. height of bucket base 3920 mm
D - Max. height of bucket pivot point 4180 mm
E - Max. height of bucket upper edge 5740 mm
F - Reach at max. lift and 45° tilt-out 1070 mm
angle
G - Digging depth 110 mm
H - Height of cab 3355 mm
I - Height of exhaust 3310 mm
J - Ground clearance 530 mm
K - Wheel base 3150 mm
L - Overall length 8130 mm
Turning radius over bucket outer edge 6360 mm
Lifting force (SAE) 180 kN
Breakout force (SAE) 130 kN
Tipping load when straight 13925 kg
Angle of articulation (to each side) 40 °
Operating weight 17300 kg
Tractive force 136.4 kN
and reverse
and reverse
Sound pressure level in the cab L pA 73 dB
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Technical data
2.1.2 Diesel engine, pump distributor gear
Diesel engine Valid for: L544 - 443 / 6190 - 7476

Engine type D924T-E A2
Number of cylinders 4
Cylinder volume 6640 cm³
Rated power according to ISO 9249 121 / 165 kW / hp
Rated speed 2000 min-1
Max. torque at 1200 min-1 690 Nm
-1
Lower idling speed 800 50 min
Upper idling speed 2100 +80 min-1
Inlet valve play (cold) 0.25 mm
Outlet valve play (cold) 0.30 mm
Max. operating angle 45 °
Power consumption of starter 5.4 kW
Output voltage of alternator 28 V
Current output from alternator 55 A
Emission limit values comply with EU RL 97/68 EG level 1
Diesel engine Valid for: L554 - 453 / 0501 - 7476

Engine type D924T-E A2
Number of cylinders 4
Cylinder volume 6640 cm³
Rated power according to ISO 9249 137 / 186 kW / hp
Rated speed 2000 min-1
Max. torque at 1200 min-1 847 Nm
-1
Lower idling speed 800 50 min
Upper idling speed 2100 +80 min-1
Inlet valve play (cold) 0.25 mm
Outlet valve play (cold) 0.30 mm
Max. operating angle 45 °
Power consumption of starter 5.4 kW
Output voltage of alternator 28 V
Current output from alternator 55 A
Emission limit values comply with EU RL 97/68 EG level 1
Fuel system
Tank level FULL 260 l
Tank level RESERVE 45 l
Soot particle filter (optional) This equipment is optional, but is standard with the tunnel version of the
machine
Max. permissible exhaust gas counter- 0.2 bar
pressure
Additive mixing ratio in litres 1:1000
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Technical data
Refuelling pump (optional) This equipment is optional.

Flow rate 50 l/min
Max. duty cycle 15 minutes
Max. suction height 4 m
2.1.3 Cooling system
Gear pump
Displacement 14 cm³
RPM at rated engine speed 2550 min -1
Gear motor
Displacement of the gear motor 16 cm³
Pressure relief valve 175 10 bar
2.1.4 Travel hydraulics
Variable displacement pump Valid for: 544 - 443 / 6190 - 7476

Control type EZ
Max. displacement 90 cm³
Flow at rated engine speed 222 l/min
Power output 111 kW
Displacement of the replenishing pump 19.6 cm³
Weight 60 kg
Pressure cut-off 430 5 bar
Variable displacement pump Valid for: 554 - 453 / 0501 - 7476

Control type EZ
Power output 122 kW
Displacement of the replenishing pump 19.6 cm³
Weight 60 kg
Variable displacement motor 1

Control type EP
Max. speed 5900 min-1
Torque ( p 400 bar) 489 Nm
Weight 34 kg
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Technical data
Variable displacement motor 2 Valid for: L544 - 443 / 6190 - 7476

Control type EP
Weight 34 kg
Variable displacement motor 2 Valid for: L554 - 453 / 0501 - 7476

Control type EP
Weight 47 kg
Scavenging gear pump Variable

displacement motors 2
Displacement 8 cm³
2.1.5 Working hydraulics
Variable displacement pump

Control type LRDS
Power output 80 kW
Flow controller ( p) 22 2 bar
Power controller at regulation begin 180 10 bar
Control valve block Valid for: L544 - 443 / from 7477

Control piston diameter 25 mm
Control piston lift arm up / down flow rate 240 / 130 l/min
Control piston tilt in / out flow rate 130 / 130 l/min
Primary pressure relief valve 360 5 bar
Pilot control unit

Float position valve switching pressure 22 bar
Pilot control hydro accumulator 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

Cut-off valve 170 20 bar
Actuator cylinder switching point 260+20 bar
Safety valve 300+10 bar
LFD hydro accumulator

Number of hydraulic accumulators 5 Units
Preload pressure (nitrogen filling) 25 2 bar
Oil filling 150 cm³
Lift cylinder
Piston diameter 130 mm
Rod diameter 80 mm
Stroke length 745 mm
Tilt cylinder
Rod diameter 80 mm
Return suction filter Description Value Unit

Filtration grade 10 µm
Return strainer Description Value Unit

Breather filter Description Value Unit

Inlet opening pressure 0.03 bar
Outlet opening pressure 0.5 bar
2.1.6 Steering system
Steering pump
Type DFR
Power output 37 kW
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Technical data
Steering valve
Secondary pressure relief 285 10 bar
Flow amplification 1 : 1.6
Steering cylinder
Rod diameter 40 mm
Emergency steering pump Description Value Unit

Pressure relief valve 55 5 bar
Emergency steering pressure Description Value Unit

switch
Switch type N/O switch
Switching point 18 1 bar
Emergency steering check Description Value Unit

pressure switch
Switch type N/O switch
Switching point 5 1 bar
2.1.7 Brake system
Brake system gear pump Description Value Unit

Displacement 4 cm³
Compact brake valve Valid for: L544 - 443 / 6190 - 7476

Cut-off pressure for accumulator charging 185 5
Cut-in pressure for accumulator charging 155 5 bar
Max. brake pressure at pedal stop 73 5 bar
Compact brake valve Valid for: L554 - 453 / 0501 - 7476

Cut-off pressure for accumulator charging 185 5
Cut-in pressure for accumulator charging 155 5 bar
Max. brake pressure at pedal stop 65 5 bar
Brake hydro accumulator Valid for: L544 - 443 / 6190 - 7477

Number of hydraulic accumulators 4 Units
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Technical data
Brake hydro accumulator Valid for: L554 - 453 / 0501 - 7476
Number of hydro accumulators 2 units
Parking brake hydro accumulator Description Value Unit

2.1.8 Electrical system
Electrical system Description Value Unit

Power supply voltage 24 V
Battery voltage 12 V
Battery capacity 143 Ah
2.1.9 Transfer gear
Transfer gear Description Value Unit

Number of gears 3
1st gear ratio 6.103
2nd gear ratio 3.033
3rd gear ratio 1.342
Weight 285 kg
2.1.10 Axles, tyres
Front axle Valid for: L544 - 443 / 6190 - 7476

Differential ratio 3.89
Wheel hub ratio 6.0
Total gear ratio 23.33
Locking value of self-locking differential 45 %
Wheel base 2000 mm
Wheel lug tightening torque 650 Nm
Wheel lug spanner size 30 mm
Weight 816 kg
Front axle Valid for: L554 - 453 / 0501 - 7476

Wheel hub ratio 6.35
Wheel base 2000 mm
Weight 1054 kg
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Technical data
Rear axle Valid for: L544 - 443 / 6190 - 7476

Wheel hub ratio 6.0
Angle of swing 13 °
Wheel base 2000 mm
Weight 816 kg
Rear axle Valid for: L554 - 453 / 0501 - 7476

Wheel hub ratio 6.35
Angle of swing 13 °
Wheel base 2000 mm
Weight 700 kg
Front drive shaft Valid for: L544 - 443 / 6190 - 7476

Flange tightening torque 125 Nm
Front drive shaft Valid for: L554 - 453 / 0501 - 7476

Rear drive shaft Description Value Unit

2.1.11 Machine frame, counterweight
Counterweight Valid for: L544 - 443 / 6190 - 7476

Mass per counterweight 400 kg
Tightening torque for M24/10.9 bolts 960 Nm
Counterweight Valid for: L554 - 453 / 0501 - 7476

Mass per counterweight 800 kg
Tightening torque for M24/10.9 bolts 960 Nm
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Technical data
2.1.12 Cab, heating, air-conditioning system
Heating, Description Value Unit

ventilation
Number of blower speeds 4
Heat output 11.3 kW
Air-conditioning system Description Value Unit

Refrigerant R134a
Filling quantity 1800 g
Cooling output 5.6 10% kW
2.1.13 Lift arm, quick-change device
Z-bar kinematics lift arm Valid for: L544 - 443 / 6190 - 7476
L Length 2600 mm
Z-bar kinematics lift arm Valid for: L554 - 453 / 0501 - 7476
L Length 2750 mm
Quick-change device
A System connected dimensions 1000 mm
Weight 450 kg
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3 Maintenance
Chapter contents
3 Maintenance 3.0 - 1
3.1 Maintenance and inspection schedule 3.1 - 1
3.2 Testing and adjustment schedule 3.2 - 1
3.3 Testing and adjustment protocol 3.3 - 1
3.4 Lubricant chart, filling quantities 3.4 - 1
3.4.1 Table of filling quantities 3.4 - 1
3.4.5 Lubrication chart 3.4 - 5
3.5 Maintenance tasks 3.5 - 1
3.5.1 Preparatory tasks for maintenance 3.5 - 1
3.5.2 Checking the machine for external damage 3.5 - 7
3.5.3 Checking that all screw connections are tight 3.5 - 7
3.5.4 Sealing any leaks 3.5 - 7
3.5.5 Checking the oil level in the diesel engine 3.5 - 8
3.5.6 Changing the engine oil 3.5 - 9
3.5.7 Replacing the oil filters 3.5 - 9
3.5.8 Checking the V-ribbed belt 3.5 - 10
3.5.9 Checking the valve play 3.5 - 11
3.5.10 Lightly greasing the ring gear on the flywheel 3.5 - 12
3.5.11 Replacing the oil separator 3.5 - 12
3.5.12 Checking the flame glow system 3.5 - 12
3.5.13 Draining off water and sediment from the fuel tank 3.5 - 13
3.5.14 Changing the fine fuel filter 3.5 - 13
3.5.15 Draining off condensate from the fuel separator 3.5 - 14
3.5.16 Draining off condensate from the fine fuel filter 3.5 - 14
3.5.17 Replacing the filter insert in the fuel separator 3.5 - 14
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Service Manual Maintenance
3.5.18 Cleaning the service cap and dust extraction valve

on the air filter 3.5 - 15
3.5.19 Cleaning or replacing the air filter main element 3.5 - 16
3.5.20 Checking the air suction hoses for leaks and

tight fitting 3.5 - 17
3.5.21 Checking the oil level in the pump distributor gear 3.5 - 18
3.5.22 Changing the gear oil in the pump distributor gear 3.5 - 18
3.5.23 Checking the exhaust lines for leaks and tight fitting 3.5 - 19
3.5.24 Checking the coolant level 3.5 - 19
3.5.25 Replacing the coolant filter 3.5 - 20
3.5.26 Checking the anti-freeze and DCA-4

concentration in the coolant 3.5 - 21
3.5.27 Cleaning the cooling system 3.5 - 23
3.5.28 Replacing the coolant with anti-freeze and DCA-4 3.5 - 23
3.5.29 Lubricating the pilot control unit, cleaning the

magnets and lubricating the universal joints 3.5 - 24
3.5.30 Checking the oil level in the hydraulic tank 3.5 - 25
3.5.31 Draining water and sediment from the hydraulic tank 3.5 - 25
3.5.32 Changing the hydraulic oil and checking the return

strainer 3.5 - 25
3.5.33 Checking and cleaning the magnetic rod on the

hydraulic tank 3.5 - 26
3.5.34 Changing the return suction filter 3.5 - 27
3.5.35 Replacing the bleeder filter on the hydraulic tank 3.5 - 27
3.5.36 Checking the steering 3.5 - 28
3.5.37 Lubricating the bearing points on the steering

cylinders 3.5 - 28
3.5.38 Checking the service brake and parking brake 3.5 - 28
3.5.39 Checking the play and wear on the parking brake 3.5 - 29
3.5.40 Checking the indicator lamps and lighting 3.5 - 30
3.5.41 Checking the batteries, fluid level and terminals 3.5 - 30
3.5.42 Checking the oil level in the transfer gear 3.5 - 31
3.5.43 Changing the gear oil in the transfer gear 3.5 - 32
3.5.44 Changing the gear oil filter 3.5 - 32
3.5.45 Checking the tightness of the wheel lugs (once after

50, 100 and 250 h) 3.5 - 32
3.5.46 Checking the oil level and the axles 3.5 - 33
3.5.47 Checking the axle oil levels 3.5 - 33
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Maintenance Service Manual
3.5.48 Changing the gear oil in the axles L544 3.5 - 34
3.5.49 Changing the gear oil in the axles L554 3.5 - 34
3.5.50 Checking and lubricating the front drive shaft 3.5 - 35
3.5.51 Checking and lubricating the rear drive shaft 3.5 - 35
3.5.52 Setting the correct tyre pressure for the machine's

use and attachments 3.5 - 35
3.5.53 Lubricating the oscillating axle frame and

articulation bearing 3.5 - 36
3.5.54 Checking whether metered quantities (grease

collars) are adequate at the bearing points of the
central lubrication system 3.5 - 36
3.5.55 Checking the hose lines of the central lubrication

system (lubrication points, detached hoses, external
leakage) 3.5 - 37
3.5.56 Lubricating the door hinges 3.5 - 37
3.5.57 Cleaning or replacing the fresh air and re-circulated air

filter 3.5 - 37
3.5.58 Checking the indicator beads in the dryer-collector unit 3.5 - 37
3.5.59 Lubricating the lift arms and attachment 3.5 - 38
3.5.60 Check the bucket bearing seals and the bearing

bushings on the lift arms 3.5 - 39
3.5.61 Checking the lift arms and bucket stops 3.5 - 40
3.6 Testing and adjustment tasks 3.6 - 1
3.6.1 Preparatory tasks before checking and adjusting 3.6 - 1
3.6.2 Safety precautions before checking and adjusting 3.6 - 1
3.6.3 Warming up the machine to operating temperature 3.6 - 2
3.6.4 Checking the engine RPM 3.6 - 2
3.6.5 Checking the pressure relief valve of the fan motor and
the fan control 3.6 - 3
3.6.6 Calibrating the traction force potentiometer 3.6 - 5
3.6.7 Calibrating the inching pedal angle sensor 3.6 - 5
3.6.8 Calibrating the accelerator pedal angle sensor 3.6 - 6
3.6.9 Calibrating the engine characteristics 3.6 - 7
3.6.10 Checking the replenishing pressure of the variable

displacement pump 3.6 - 8
3.6.11 Calibrating the block curve 3.6 - 8
3.6.12 Checking the pressure relief/replenishing valves of the

variable displacement pump 3.6 - 9
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3.6.13 Checking the pressure cut-off of the variable

displacement pump 3.6 - 9
3.6.14 Checking the Q max of the variable displacement

motors 3.6 - 10
3.6.15 Checking the Q min of the variable displacement

motors 3.6 - 11
3.6.16 Check the power of the diesel engine 3.6 - 12
3.6.17 Checking the LS regulation (delta p) of the working

hydraulics pump 3.6 - 13
3.6.18 Checking the load-limit (regulation begin) of the

working hydraulics pump 3.6 - 14
3.6.19 Checking the secondary pressure relief valves of the

control valve block 3.6 - 14
3.6.20 Checking the primary pressure relief valve of the

control valve block 3.6 - 15
3.6.21 Checking the pressure cut-off of the working

hydraulics pump 3.6 - 16
3.6.22 Depressurising ride control and hydro accumulator 3.6 - 16
3.6.23 Checking the cut-off valve of the stabilisation module 3.6 - 17
3.6.24 Checking the nitrogen in the ride control hydro

accumulators 3.6 - 18
3.6.25 Check the pressure cut-off of the steering pump 3.6 - 18
3.6.26 Checking the flow controller (delta P) of the steering

pump 3.6 - 18
3.6.27 Checking the cut-off pressure at the compact brake valve 3.6 - 19
3.6.28 Checking the braking pressure at the axles 3.6 - 19
3.6.29 Checking the brake accumulator capacity 3.6 - 20
3.6.30 Checking the brake accumulator capacity 3.6 - 21
3.6.31 Checking the charged accumulator switching pressure 3.6 - 21
3.6.32 Checking the brake lights and brake light pressure switch 3.6 - 22
3.6.33 Checking the operating pressure of the transmission 3.6 - 22
3.6.34 Checking the nitrogen in the transmission hydro

accumulator 3.6 - 22
3.7 Lubricants and fuels 3.7 - 1
3.7.1 Handling lubricants and fuels 3.7 - 1
3.7.2 Lubricant and fuel specifications 3.7 - 2
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Maintenance and inspection schedule
3.1 Maintenance and inspection schedule

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
Here, the machine operator or his maintenance personnel are
responsible for carrying out maintenance tasks.
This affects the maintenance intervals every 10 and 50 service hours (h)
and non-scheduled intervals.
The symbols have the following meanings:

Table with blank circle, box or star, or service hours (h)
Here, authorised specialist technicians from LIEBHERR or its authorised
dealers must perform or direct maintenance and inspection work.
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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Customer: .............................................. Machine type: .................... Ser. no.: ............................. Oper. hours: .............. Date: ......................
Maintenance/inspection at
operating hours WORK TO BE PERFORMED
By maintenance personnel By authorised qualified personnel
One-off activity One-off activity
Repetition interval Repetition interval
If necessary If necessary
Annually at the start of the cold season
Have the operator lubricate the machine in accordance with the lubrication chart and
instruct him on proper maintenance
Instruct the operator in the operation of all functions
Check the machine for external damage
Check that all nuts and bolts are tight
Seal any leaks
Check the hydraulic pressure according to the testing and adjustment schedule
Diesel engine, pump distributor gear
Check the oil level in the diesel engine
Change the engine oil (once after 500 h, then every 250 h or 500 h, depending on oil
250h
specifications)
Replace the oil filters
Check and replace the ribbed V- belt
Check the valve play
Lightly grease the ring gear on the flywheel
3000h Replace the oil separator (minimum of every 2 years)
Check the flame glow system
Drain off water and sediment from the fuel tank
Replace the fuel fine filter
Drain off condensate from the fuel separator
Replace the filter insert in the fuel separator
Clean the service cap and dust extraction valve on the air filter
Clean or replace the air filter main element (replace the safety element after having
replaced the main element 3 times)
Check the air suction hoses for leaks and tight fitting
Check the oil level in the pump distributor gear
Change the oil in the pump distributor gear
Check the exhaust lines for leaks and tight fitting
Cooling system
Check the coolant level
Replace the coolant filter
Check the anti-freeze protection and DCA-4 concentration in the coolant
Clean the cooling system
3000h Replace the coolant with anti-freeze protection and DCA-4 (at least every 2 years)
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Working hydraulics
Lubricate the pilot control unit, clean the magnets and lubricate the universal joints
Check the oil level in the hydraulic tank
Drain water and sediment from the hydraulic tank
Change the hydraulic oil and check the return strainer
250h Check and clean the magnetic rod on the hydraulic tank
Change the return suction filter
Replace the breather filter on the hydraulic tank
Steering system
Check the steering
Lubricate the bearing points on the steering cylinders
Brake system
Check the service brake and parking brake
Check the play and wear on the parking brake
Electrical system
Check the indicator lamps and lighting
Check the batteries, fluid level and terminals
Transmission
Check the oil level in the transmission
Change the oil in the transmission
Change the oil filter
Axles, tyres
Check the tightness of the wheel lugs (once after 50, 100 and 250 h)
Check the axle oil levels
Change the axle gear oil
Check and lubricate the front drive shaft
Check and lubricate the rear drive shaft
Set the correct tyre pressure for the machine's use and attachments
Machine frame, counterweight
Lubricate the oscillating axle frame and articulation bearing
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Central lubrication system
Check whether the metered quantities from the central lubrication system are adequate for
all bearing points
Check the hose lines of the central lubrication system (lubrication points, detached hoses,
external leakage)
Cab, heating, air-conditioning system
Lubricate the door hinges
Clean or replace the fresh air and re-circulating air filters
Check the indicator beads in the dryer unit
Lift arm, quick-change device
Lubricate the lift arms and attachment
Check the bucket bearing seals and the bearing bushings on the lift arms
Check the lift arms and bucket stops
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Testing and adjustment schedule
3.2 Testing and adjustment schedule

Only LIEBHERR trained, personnel may perform the tasks listed in the
testing and adjustment schedule.
For a short description of how to perform the adjustments and inspection
tasks, see the testing and adjustment protocol section.
For a detailed description of how to perform these tasks, see the section on
testing and adjustment tasks.
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Testing and adjustment schedule
By authorised qualified personnel

One-off activity
Repetition interval
If necessary
Diesel engine
Check the speed on the diesel engine
Cooling system
Check the pressure relief valve of the fan motor and the fan control
Travel hydraulics
Calibrate the tractive force rotary switch
Calibrate the inching pedal angle sensor
Calibrate the accelerator pedal angle sensor
Record the engine characteristics
Check the replenishing pressure of the variable displacement pump
Check the pressure relief / replenishing valves of the variable displacement pump
Check the pressure cut-off of the variable displacement pump
Calibrate the block curve
Check the Q max of the variable displacement motors
Check the Q min of the variable displacement motors
Check the power of the diesel engine
Working hydraulics
Check the flow controller ( P) on the working hydraulics pump
Check the power controller (regulation begin) of the working hydraulics pump
Check the secondary pressure relief valves on the control valve block
Check the primary pressure relief valve on the control valve block
Check the pressure cut-off of working hydraulics pump
Check the cut-off valve on the stabilisation module
Check the nitrogen in the ride control hydro accumulator
Steering system
Check the pressure cut-off of the steering pump
Check the flow controller ( P) of the steering pump
Brake system
Check the cut-in and cut-off pressure at the compact brake valve
Check the brake pressure at the axles
Check the brake accumulator capacity
Check the charged accumulator switching pressure
Check the brake lights and brake light pressure switch
Transmission
Check the operating pressure of the transmission
Check the nitrogen in the transmission hydro accumulator
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Testing and adjustment protocol
3.3 Testing and adjustment protocol

The testing and adjustment protocol lists all the activities to be performed
during testing and adjustment. You will find information that is more detailed
in the section testing and adjustment tasks.
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Thank you very much
for your reading.
Please Click Here
Then Get More
Information.

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en

Dr. Hans Liebherr  Straße 4

1.1.2 Overview of safety regulations 1.1  2

1.2 Special tools for maintenance and repair work 1.2 - 1

1.2.2 Special tools for Liebherr diesel engines 1.2  1

1.2.3 Special tools for the hydraulic cylinders 1.2  2

1.2.4 Special electrical tools 1.2  2

1.2.5 Special tools for axles 1.2  3

1.2.6 Special tools for the transfer gear 1.2  4

1.2.7 Central lubrication system 1.2  4

1.2.8 Special tools for the air conditioning system 1.2  4

L544 - 443 / 6190 - 7476 ! 1.0 - 1 of 2

1.1 Safety regulations

1. The symbols below have the following meanings:

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1.1.2 Overview of safety regulations

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1.2 Special tools for maintenance and

1.2.2 Special tools for Liebherr diesel engines

L544 - 443 / 6190 - 7476 ! 1.2 - 1 of 4

1.2.3 Special tools for the hydraulic cylinders

1.2.4 Special electrical tools

1.2 - 2 of 4! ! L544 - 443 / 6190 - 7476

1.2.5 Special tools for axles

Description ID no. Use Notes

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1.2.6 Special tools for the transfer gear

1.2.7 Central lubrication system

The Groeneveld central greasing system software is ordered directly from

1.2.8 Special tools for the air conditioning system

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2 Product description 2.0 - 1

2.1 Technical data 2.1 - 1

2.1.1 Complete machine 2.1 - 1

2.1.2 Diesel engine, pump distributor gear 2.1 - 4

2.1.3 Cooling system 2.1 - 5

2.1.4 Travel hydraulics 2.1 - 5

2.1.5 Working hydraulics 2.1 - 6

2.1.6 Steering system 2.1 - 7

2.1.7 Brake system 2.1 - 8

2.1.8 Electrical system 2.1 - 9

2.1.9 Transfer gear 2.1 - 9

2.1.10 Axles, tyres 2.1 - 9

2.1.11 Machine frame, counterweight 2.1 - 10

2.1.12 Cab, heating, air-conditioning 2.1 - 11

2.1.13 Lift arm, quick-change device 2.1 - 11

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2.1 Technical data

2.1.1 Complete machine

Description Value Unit

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Description Value Unit

2.1 - 2 of 12! ! L544 - 443 / 6190 - 7476

Description Value Unit

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2.1.2 Diesel engine, pump distributor gear

Diesel engine Valid for: L544 - 443 / 6190 - 7476

Diesel engine Valid for: L554 - 453 / 0501 - 7476

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Refuelling pump (optional) This equipment is optional.

2.1.3 Cooling system

2.1.4 Travel hydraulics

Variable displacement pump Valid for: 544 - 443 / 6190 - 7476

Dr. Hans Liebherr Straße 4

1.1.2 Overview of safety regulations 1.1 2

1.2.2 Special tools for Liebherr diesel engines 1.2 1

1.2.3 Special tools for the hydraulic cylinders 1.2 2

1.2.4 Special electrical tools 1.2 2

1.2.5 Special tools for axles 1.2 3

1.2.6 Special tools for the transfer gear 1.2 4

1.2.7 Central lubrication system 1.2 4

1.2.8 Special tools for the air conditioning system 1.2 4