Liebherr A309 Litronic Excavator Operators Service Repair Manual

Description

Table of Content – Service Repair Manual (A 309 – Type 1035)

• Book I Chapter 1-19 (Page 1)
  • Identification (Page 1)
  • Introduction (Page 3)
  • Main group directory (Page 5)
• 1 General Information (Page 15)
  • 1.02 Changes and modifications to series (Page 19)
  • 1.10 Safety instructions (Page 33)
  • 1.15 Tightening torques for screws in hydraulic flange connections (Page 45)
  • 1.20 Tightening torques (WN 4037 K) (Page 47)
  • 1.21 Tightening torques (Page 51)
  • 1.22 Assembly instruction for hydraulic cylinder WN 4121 C (Page 55)
  • 1.24 Assembly instruction for hydraulic cylinder WN 4122 B (Page 65)
  • 1.25 Tightening torques for piston rod bearing screws (Page 69)
  • 1.30 Angle-controlled screw tightening (Page 75)
  • 1.35 Hose installation Boom – Stick (Page 83)
  • 1.50 Fuels, lubricants and process chemicals (Page 89)
  • 1.55 TE_ML05 lubricant list (Page 105)
  • 1.56 TE_ML07 lubricant list (Page 121)
  • 1.60 Conservation guidelines (Page 133)
• 2 Tools (Page 139)
  • 2.01 Special tools – General information (Page 143)
  • 2.02 Special tools for diesel engine TCD 2012 (Page 151)
  • 2.03 Special tools for diesel engine TCD 2013 (Page 159)
  • 2.05 Special tools for hydraulic unit (Page 165)
  • 2.06 Special tools for electrical equipment (Page 169)
  • 2.07 Special tools for gears (Page 177)
  • 2.08 Special tools for axles (Page 179)
  • 2.12 Assembly tools for hydraulic cylinders (Page 183)
  • 2.13 Mounting device for piston rod bearing (Page 191)
  • 2.14 Slotted nut wrench for slewing gear (Page 193)
  • 2.15 Mounting device for slewing gear (Page 195)
  • 2.16 Mounting device for travel gear (Page 197)
• 3 Technical data / maintenance instructions (Page 199)
  • 3.09 Technical data A 309 LI TCD (Page 205)
  • 3.21 Inspection and maintenance schedule (Page 233)
  • 3.23 Inspection and maintenance schedule (Page 241)
  • 3.26 Maintenance- and inspection chart (Page 249)
  • 3.43 Adjustment protocol A 309 LI TCD (Page 255)
  • 3.75 Adjustment protocol (kits) (Page 393)
  • 3.84 Checking and adjusting tasks (Page 397)
  • 3.85 Checking and adjusting tasks (Page 441)
  • 3.87 Checking and adjusting tasks (Page 483)
  • 3.88 Checking and adjusting tasks (Page 519)
  • 3.100 Maintenance tasks (Page 553)
  • 3.101 Maintenance tasks for diesel engine (Page 557)
  • 3.102 Maintenance tasks for hydraulic system (Page 589)
  • 3.103 Maintenance tasks for electrical system (Page 607)
  • 3.104 Maintenance tasks for slewing gear mechanism (Page 613)
  • 3.105 Maintenance tasks for slewing ring (Page 615)
  • 3.106 Maintenance tasks for transmission (Page 617)
  • 3.107 Maintenance tasks for travel gear mechanism (Page 621)
  • 3.108 Maintenance tasks for axles (Page 625)
  • 3.109 Maintenance tasks for travel gear (Page 635)
  • 3.110 Maintenance tasks for steering system (Page 641)
  • 3.111 Maintenance tasks for oscillating axle support (Page 643)
  • 3.112 Maintenance tasks for brake system (Page 645)
  • 3.113 Maintenance tasks for operator’s cab and heating (Page 647)
  • 3.114 Maintenance tasks for air-conditioning system (Page 651)
  • 3.115 Maintenance tasks for uppercarriage, undercarriage and attachment (Page 657)
  • 3.116 Maintenance tasks for quick-change systems (Page 665)
• 4 Engine (Page 671)
  • 4.04 Technical data of diesel engines (Page 673)
  • 4.06 Technical data of diesel engines (Page 677)
  • 4.10 Technical data of diesel engines (Page 681)
  • 4.25 Installation and check list (Page 685)
  • 4.30 Liebherr diesel particle filter accessory kit (Page 691)
  • 4.40 Datalogger version 2.3.00 (Page 719)
  • 4.41 Datalogger software version 2.3.09 (Page 751)
• 5 Coupling / Splitterbox (Page 783)
  • 5.10 Coupling (Page 785)
• 6 Hydraulic system (Page 791)
  • 6.10 LSC system (Page 793)
  • 6.20 Design of hydraulic system (Page 801)
  • 6.25 Design of hydraulic system (Page 813)
  • 6.30 Design of hydraulic system (Page 825)
  • 6.40 Hydraulic system (Page 837)
  • 6.52 Hydraulic system (Page 845)
  • 6.54 Hydraulic unit with dozer blade (Page 853)
  • 6.60 Hydraulic system (Page 861)
  • 6.73 Hydraulic system with dozer blade (Page 925)
  • 6.76 Hydraulic system (Page 933)
  • 6.77 Hydraulic system (Page 941)
  • 6.78 Hydraulic system (Page 949)
• 7 Hydraulic components (Page 957)
  • 7.02 Hydraulic pumps – dismantling, installation and commissioning (Page 961)
  • 7.10 DPVO variable-displacement pump (Page 969)
  • 7.20 Cooling unit (Page 983)
  • 7.24 FMF hydraulic fixed displacement motor (Page 989)
  • 7.25 FMF hydraulic fixed displacement motor (Page 997)
  • 7.26 DMVA regulating motor (Page 1005)
  • 7.27 DMVA regulating motor (Page 1023)
  • 7.28 Regulating motor A6VE (Page 1041)
  • 7.29 Regulating motor A6VE (Page 1057)
  • 7.30 Hydraulic cylinder (Page 1075)
  • 7.32 Hydraulic double plunger cylinder (Page 1093)
  • 7.42 Control oil unit (Page 1107)
  • 7.45 Pilot control unit 4 x (Page 1113)
  • 7.46 4x pilot control unit for travel drive (Page 1121)
  • 7.47 Pilot control unit 2x (Page 1127)
  • 7.48 Pilot control valve 2 x (Page 1133)
  • 7.56 LSC control valve block (Page 1139)
  • 7.58 LSC control block (Page 1209)
  • 7.60 LSC control valve block (Page 1275)
  • 7.75 Rotary connection 1x (Page 1335)
  • 7.76 Rotary connection 6x (Page 1341)
  • 7.77 Rotary connection 5x (Page 1347)
  • 7.78 Rotary connection 7x (Page 1353)
  • 7.80 Double load holding valve (Page 1359)
  • 7.82 Support valve / double lowering brake valve (Page 1365)
  • 7.86 Double load-holding valve for regulating cylinder (Page 1371)
  • 7.95 Accumulator (Page 1379)
• 8 Electrical system (Page 1401)
  • 8.01 Overview of electrical symbols (Page 1405)
  • 8.02 Notes regarding the electrical system (Page 1417)
  • 8.10 Arrangement of components (Page 1421)
  • 8.20 Arrangement of components (Page 1441)
  • 8.30 Arrangement of components (Page 1461)
  • 8.40 Electrical system / basic machine (Page 1479)
  • 8.50 Electrical system (basic machine) (Page 1545)
  • 8.51 Electrical system / basic machine (Page 1611)
  • 8.56 Electrical system / basic machine (Page 1675)
  • 8.57 Electrical system / basic machine (Page 1741)
  • 8.60 Electrical system (basic machine) (Page 1807)
  • 8.61 Electrical system / basic machine (Page 1869)
  • 8.66 Electrical system / basic machine (Page 1933)
  • 8.70 UEC central control system (Page 1999)
  • 8.72 UEC central control system (Page 2011)
  • 8.74 UEC central control system (Page 2023)
  • 8.76 UEC error codes (Page 2035)
  • 8.80 Menu control (Page 2047)
  • 8.81 Menu control (Page 2077)
  • 8.86 Electronic travel drive control (Page 2133)
  • 8.90 Slip ring – rotary connection (Page 2143)
  • 8.100 Directory of electrical kits (Page 2149)
    • 8.101 Control system extension UEC 2 (Page 2151)
    • 8.102 Control system extension UEC 2 (Page 2173)
    • 8.103 Particle filter kit (Page 2200)
    • 8.104 Stroke limitation with proximity switches (Page 2210)
    • 8.105 Dozer blade (Page 2220)
    • 8.106 Overload warning system, switchable (Page 2226)
    • 8.107 Proportional control (Page 2238)
    • 8.108 Rear space camera monitoring system (Page 2256)
    • 8.109 Rear space and side camera monitoring system (Page 2258)
• 9 Slewing gear mechanism (Page 2260)
  • 9.10 Slewing gear mechanism (Page 2262)
  • 9.20 Slewing gear brake (Page 2274)
  • 9.24 Slewing gear brake (Page 2282)
• 10 Slewing ring (Page 2290)
  • 10.10 Slewing ring (Page 2292)
• 11 Two Speed Gear Box / Travel Gear (Page 2300)
  • 11.20 2 HL 270 / 290 transmission (Page 2302)
  • 11.32 HBGV block for 2 HL 270 / 290 (Page 2332)
  • 11.60 FAT 350 travel gear system (Page 2338)
  • 11.65 Travel brake (Page 2348)
• 12 Axles / Track Components (Page 2354)
  • 12.04 Steering axle 212 (Page 2356)
  • 12.06 Rigid axle 112 (Page 2370)
  • 12.08 Differential for axles 112 / 212 (Page 2382)
  • 12.12 Steering axle and steered rear axle 262 LD (Page 2394)
  • 12.14 Rigid axle 162 LD (Page 2408)
  • 12.16 Differential for axles 162 LD/262 LD (Page 2418)
  • 12.20 Steering axle 262 (Page 2430)
  • 12.22 Rigid axle 162 (Page 2442)
  • 12.24 Differential for 162 / 262 axles (Page 2452)
  • 12.30 MS – E 3050 / 3060 steering axle (Page 2462)
  • 12.32 MT – E 3050 / 3060 rigid axle (Page 2478)
  • 12.34 MS/MT – E 3050 / 3060 drive unit and differential (Page 2492)
  • 12.50 Tyres and tyre pressure (Page 2498)
  • 12.60 Chassis / drive (Page 2502)
  • 12.62 Technical data / tightening torques (Page 2508)
  • 12.64 Technical data / tightening torques (Page 2510)
  • 12.66 Wear of chassis parts (Page 2512)
  • 12.67 D4L wear limits (Page 2516)
  • 12.69 Wear limits – B60 (Page 2518)
  • 12.72 Chain (Page 2520)
  • 12.75 Tensioning unit (Page 2530)
  • 12.78 Idler (Page 2536)
  • 12.81 Running roller (Page 2540)
  • 12.82 Idler (Page 2542)
  • 12.84 Support roller (Page 2544)
  • 12.86 Slide ring seal (Page 2548)
• 13 Steering (Page 2550)
  • 13.10 Hydraulic steering system (Page 2552)
  • 13.20 Steering valve (Page 2558)
  • 13.25 Steering valve (Page 2566)
  • 13.32 Steering cylinders (Page 2574)
  • 13.35 Steering cylinder (Page 2580)
  • 13.50 Four-wheel steering (Page 2586)
• 14 Oscillating axle support (Page 2614)
  • 14.10 Oscillating axle support with automatic control (Page 2616)
  • 14.20 Support cylinders (Page 2626)
• 15 Brake system (Page 2634)
  • 15.05 Operating pressures of the brake system (Page 2636)
  • 15.10 Hydraulic brake system (Page 2638)
  • 15.20 Compact brake block (Page 2654)
• 16 Special equipment / accessory kits (Page 2660)
  • 16.03 Pipe fracture safety valve for boom cylinders (Page 2666)
  • 16.04 Pipe fracture safety valve for boom cylinders (Page 2680)
  • 16.06 Pipe fracture safety valve for stick cylinder (Page 2692)
  • 16.10 Pipe fracture safety valve for regulating cylinder (Page 2704)
  • 16.12 Overload warning system (Page 2714)
  • 16.14 Switchable overload warning system (Page 2724)
  • 16.16 Stroke limitation with proximity switches (Page 2738)
  • 16.18 Stroke limitation with angle sensors (Page 2752)
  • 16.20 Stroke limitation with angle sensors (Page 2766)
  • 16.22 Stick cylinder shut-down with proximity switch (Page 2786)
  • 16.32 Hydraulic quick change adapter (Page 2798)
  • 16.36 Hydraulic-electric LIKUFIX coupling system (Page 2808)
  • 16.42 Accessory kit AS1 (Page 2828)
  • 16.44 AS 1 proportional control (Page 2840)
  • 16.46 Accessory kit AHS 1 (Page 2860)
  • 16.52 AHS 11 accessory kit with Tool Control (Page 2868)
  • 16.53 Changeover of control for AHS 11 with Tool Control (Page 2898)
  • 16.54 Accessory kit AHS 11 with Tool Control plus (Page 2906)
  • 16.55 Changeover of control for AHS 11 with Tool Control plus (Page 2936)
  • 16.56 AHS 11 proportional control (Page 2944)
  • 16.60 AHS 12 accessory kit with Tool Control (Page 2980)
  • 16.61 Changeover of control for AHS 12 with Tool Control (Page 3018)
  • 16.62 Accessory kit AHS 12 with Tool Control plus (Page 3026)
  • 16.63 Changeover of control for AHS 12 with Tool Control plus (Page 3066)
  • 16.64 AHS 12 proportional control (Page 3074)
  • 16.70 Camera monitoring (Page 3112)
  • 16.80 Hydraulic cab elevation system (Page 3126)
  • 16.81 Hydraulic operator’s cab elevation system (Page 3144)
  • 16.84 Bypass filter – RT (Page 3162)
  • 16.86 Bypass filter – Liebherr (Page 3168)
  • 16.88 Bypass filter- KleenOil (Page 3176)
  • 16.90 Reversible fan drive (Page 3184)
  • 16.92 Generator drive accessory kit (Page 3198)
• 17 Cab / Heater / Air Conditioning System (Page 3210)
  • 17.30 Heating / air-conditioning system (Page 3212)
• 18 Undercarriage / Uppercarriage / Attachments (Page 3234)
  • 18.25 Semi-automatic central lubrication system (Page 3236)
  • 18.30 Automatic central lubrication system (Page 3248)
  • 18.34 Lubricant pump (Page 3262)
  • 18.38 SX-E progressive distributor (Page 3272)
  • 18.42 MX-F progressive distributor (Page 3284)
  • 18.46 Repair instructions for lubrication hoses (Page 3294)
• 19 Tank arrangement (Page 3296)
  • 19.10 Tank arrangement (Page 3298)
  • 19.20 Tank arrangement (Page 3312)