Liebherr A309 Litronic Excavator Operators Service Repair Manual

PIN/Type – 717
Service Repair Manual: 2661 pages
Operators Manual: 217 pages
PIN/Type – 1035
Service Repair Manual: 3323 pages
Operators Manual: 258 pages
PIN/Type: 717 & 1035
Manuals: Operators Manual, Repair Manual

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)