Liebherr Hydraulic excavator A 309 Litronic Operating instructions Manual 26392

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Operating instructions Hydraulic excavator A 309 Litronic from serial number 26392

Document identification Id. number:

8720354

Edition:

10 / 2005

Valid for:

A 309 Litronic from serial number 26392

Author:

LHB - Technical documentation department

Product identification Manufacturer:

LIEBHERR Hydraulikbagger GmbH

Type:

A 309 Litronic

Type no.:

717

Conformity:

CE

Address Liebherr Hydraulikbagger GmbH Liebherr-Straße 12 88457 Kirchdorf / Iller, Germany

Operating instructions

Machine data Please fill in the following data when you receive your machine.

This will also be helpful when ordering spare parts.

Vehicle Id. No.: WLHZ . . . . . ZK . . . . . .

Year of manufacture: . . . .

Delivery date: . . / . . / . .

MJFCIFSS

A 309 Litronic / 8720354

Foreword

This operating manual has been written for the machine operator and for the maintenance personnel of the machine.

It contains: regulations.

Before initial operation and at regular subsequent intervals, the operating manual must be carefully read and observed by all persons who carry out work with or on the machine.

Working with or on the machine includes, for example: Operation including setting up or equipping, rectifying malfunctions during the course of work, resolving output reductions, care, disposal of operating and service materials.

Service, including maintenance, inspection and repair work.

Transportationor loading of the machine.

The operating manual allows the machine operator to familiarize himself with the machine more easily and prevents problems due to improper operation.

The observance of the operating and maintenance instructions by maintenance personnel:

The operating manual is part of the machine. Place a copy in the document compartment in the cab for easy access.

The operating and maintenance manual should also incorporate information regarding current national regulations for accident prevention and protection. In addition to the operating instructions and the legally binding regulations on accident prevention valid in the user country and the job site, the recognized specialized technical regulations for safe and correct working procedures must also be observed.

This operating and maintenance manual contains all the necessary information to operate and maintain your machine. l may depict details and working devices, which differ from your machine. protective devices and covers have been removed in the interests of better presentation. on our machines, may result in changes to your machine, which are not yet indicated in this operating manual.

However, should you require further explanation or information, LIEBHERR's Technical Documentation, Sales Training and Service departments are available for your convenience.

Operating instructions

You will appreciate that LIEBHERR cannot honor any warranty claims made on the basis of improper operation, insufficient maintenance, use of unauthorized service fluids or non-adherence to safety regulations.

LIEBHERR will void any and all obligations incurred by LIEBHERR and / or its dealers, such as guarantee commitments, service contracts etc. without prior notice in the event that replacement parts other than original LIEBHERR parts or spare parts purchased from LIEBHERR are used for maintenance or repairs.

Modifications, conditions, copyright We reserve the right to make modifications without prior notice in the course of technical progress.

The information and illustrations contained in this manual may neither be copied and distributed nor used for competitive purposes. All rights are expressly reserved in accordance with copyright laws.

The warranty and liability c not be expanded by the above information.

1-2

MJFCIFSS

al business conditions will

A 309 Litronic / 8720354

Operating instructions

Table of contents 1

Product description ....................................................................................................................................... 1-1 1.1

1.2 2

Safety information, signs .............................................................................................................................. 2-1 2.1 2.2 2.3

2.4

2.5 3

Assembly - Overview ............................................................................................................................. 1-1 1.1.1 Machine and construction equipment....................................................................................... 1-1 1.1.2 Uppercarriage........................................................................................................................... 1-2 1.1.3 Undercarriage........................................................................................................................... 1-3 Technical data ....................................................................................................................................... 1-3

Symbols in the operating instructions .................................................................................................... 2-1 Use in accordance with the regulations ................................................................................................. 2-2 Safety instructions ................................................................................................................................. 2-2 2.3.1 General Safety instructions ...................................................................................................... 2-2 2.3.2 Crushing and burn prevention .................................................................................................. 2-3 2.3.3 Fire and explosion prevention .................................................................................................. 2-4 Signs on the machine ............................................................................................................................ 2-4 2.4.1 Introduction............................................................................................................................... 2-4 2.4.2 Arrangement of signs ............................................................................................................... 2-5 2.4.3 Explanation of signs ................................................................................................................. 2-6 Identification tags on the machine ....................................................................................................... 2-11

Control, operation.......................................................................................................................................... 3-1 3.1

3.2

3.3

3.4

Operating and control elements............................................................................................................. 3-1 .. 3-1 3.1.2 Arrangement of joysticks .......................................................................................................... 3-3 3.1.3 Overview of control console, right ............................................................................................ 3-4 3.1.4 Control console functions ......................................................................................................... 3-6 Operation ............................................................................................................................................. 3-13 3-13 3.2.2 Safety lever ............................................................................................................................ 3-15 ............ 3-16 3.2.4 Adjusting the steering column ................................................................................................ 3-20 3.2.5 Front windshield ..................................................................................................................... 3-20 3.2.6 Sun visor ................................................................................................................................ 3-21 dow ............................................................................................... 3-21 3.2.8 Interior illumination ................................................................................................................. 3-22 3.2.9 Fire extinguisher (option)* ...................................................................................................... 3-22 3.2.10 Windshield wiper .................................................................................................................... 3-22 3.2.11 Lighting................................................................................................................................... 3-24 3.2.12 Heating system / heating and air conditioning system (option) .............................................. 3-25 Operation ............................................................................................................................................. 3-29 3.3.1 Safety instructions .................................................................................................................. 3-29 3.3.2 Starting / shutting down the machine ..................................................................................... 3-30 3.3.3 Jump start procedure ............................................................................................................. 3-35 3.3.4 Travel operation ..................................................................................................................... 3-36 3.3.5 All wheel steering, crab steering (option) ............................................................................... 3-38 3.3.6 Travelling on public roads ...................................................................................................... 3-40 3.3.7 Towing the machine ............................................................................................................... 3-42 3.3.8 Oscillating axle lock ................................................................................................................ 3-44 3.3.9 Support................................................................................................................................... 3-45 Working with the machine.................................................................................................................... 3-47 3.4.1 Working with the machine safely ............................................................................................ 3-47 3.4.2 Sensor controlled low idle automatic ...................................................................................... 3-51 3.4.3 Operating the swing gear ....................................................................................................... 3-51 3.4.4 Locking the superstructure ..................................................................................................... 3-53

A 309 Litronic / 8720354

MJFCIFSS

Operating instructions

3.5

3.6

3.7

4

Malfunctions ................................................................................................................................................... 4-1 4.1

4.2

5

3.4.5 Working position ..................................................................................................................... 3-54 3.4.6 Joystick functions ................................................................................................................... 3-55 3.4.7 Lowering the attachment when the engine is not running ...................................................... 3-57 3.4.8 Turning, rotating, locking and unlocking the attachments ...................................................... 3-58 3.4.9 Accessory kit AHS 12 (option) ................................................................................................ 3-59 3.4.10 Overload warning device ........................................................................................................ 3-60 Installation and removal of attachment parts ....................................................................................... 3-62 3.5.1 Safe installation and removal of attachment parts.................................................................. 3-62 3.5.2 Safe removal and installation of attachment pins ................................................................... 3-62 3.5.3 Installation and removal of digging tool .................................................................................. 3-63 3.5.4 Installation and removal of grapple on stick ........................................................................... 3-65 3.5.5 Fitting/removing the Passfix bolts ........................................................................................... 3-67 3.5.6 Mechanical quick change adapter (option) ............................................................................. 3-68 3.5.7 Hydraulic quick change adapter (option) ................................................................................ 3-73 3.5.8 LIKUFIX Hydraulic coupling system (option) ......................................................................... 3-80 General working methods .................................................................................................................... 3-82 3.6.1 Guidelines for minimum impact working methods .................................................................. 3-82 3.6.2 Preparatory activities .............................................................................................................. 3-82 3.6.3 Working with the backhoe bucket ........................................................................................... 3-84 3.6.4 Loading the transport vehicle ................................................................................................. 3-85 3.6.5 Working with the hydraulic hammer........................................................................................ 3-85 3.6.6 Grading ................................................................................................................................... 3-87 3.6.7 Working with the grab ............................................................................................................. 3-88 3.6.8 Load lifting work...................................................................................................................... 3-90 Transport.............................................................................................................................................. 3-91 3.7.1 Transporting the machine safely ............................................................................................ 3-91 3.7.2 Transporting the machine on a flatbed trailer ......................................................................... 3-92 3.7.3 Loading the machine with a crane .......................................................................................... 3-94

Problems and remedies ......................................................................................................................... 4-2 4.1.1 Diesel engine and fuel system.................................................................................................. 4-2 4.1.2 Hydraulic system ...................................................................................................................... 4-3 4.1.3 Travel gear ............................................................................................................................... 4-4 4.1.4 Electrical system....................................................................................................................... 4-4 4.1.5 Heating and Air conditioning system ........................................................................................ 4-5 4.1.6 Work attachment ...................................................................................................................... 4-5 Fuses and relays.................................................................................................................................... 4-5 4.2.1 Fuse box E50 ........................................................................................................................... 4-6 4.2.2 Panel ignition switch ................................................................................................................. 4-6 4.2.3 Panel, cab................................................................................................................................. 4-7 4.2.4 Distributor plate ........................................................................................................................ 4-8

Maintenance ................................................................................................................................................... 5-1 5.1

5.2

Maintaining the machine safely.............................................................................................................. 5-1 5.1.1 General Safety instructions ...................................................................................................... 5-1 5.1.2 Cleaning ................................................................................................................................... 5-1 5.1.3 Crack inspection ....................................................................................................................... 5-2 5.1.4 Welding..................................................................................................................................... 5-3 5.1.5 Operating and service fluids ..................................................................................................... 5-3 5.1.6 Repair ....................................................................................................................................... 5-3 5.1.7 Electrical system....................................................................................................................... 5-4 5.1.8 Pressure accumulator............................................................................................................... 5-4 5.1.9 Hydraulic hoses and lines......................................................................................................... 5-5 Maintenance access doors .................................................................................................................... 5-6 5.2.1 Overview of access doors ........................................................................................................ 5-6 5.2.2 Door lock .................................................................................................................................. 5-7

MJFCIFSS

A 309 Litronic / 8720354

Operating instructions

5.3

5.4

5.5

5.6

5.7

5.8

5.9

5.10

5.11

5.13

5.14

5.2.3 Engine hood release ................................................................................................................ 5-8 Tires....................................................................................................................................................... 5-8 5.3.1 Checking the tire pressure ....................................................................................................... 5-9 5.3.2 Filling with foam...................................................................................................................... 5-10 Lubricants and operating fluids............................................................................................................ 5-10 5.4.1 General information to change lubricants and operating fluids .............................................. 5-10 5.4.2 Lubrication chart ..................................................................................................................... 5-12 5.4.3 Lubrication chart ..................................................................................................................... 5-14 5.4.4 Operating fluid chart ............................................................................................................... 5-15 Lubricant and operating fluid specifications......................................................................................... 5-15 5.5.1 Lube oil for the Diesel engine ................................................................................................. 5-15 5.5.2 Fuel ........................................................................................................................................ 5-16 5.5.3 Hydraulic oil ............................................................................................................................ 5-17 5.5.4 Gear oil................................................................................................................................... 5-20 5.5.5 Lubricating grease and other lubricants ................................................................................. 5-21 5.5.6 Coolant ................................................................................................................................... 5-21 Diesel engine ....................................................................................................................................... 5-24 5.6.1 Check oil level ........................................................................................................................ 5-24 5.6.2 Changing the oil ..................................................................................................................... 5-25 Cooling system .................................................................................................................................... 5-25 5.7.1 Checking and cleaning the cooling system ............................................................................ 5-25 5.7.2 Checking the coolant level ..................................................................................................... 5-26 5.7.3 Anti-corrosion fluid and antifreeze.......................................................................................... 5-26 5.7.4 Changing water filters............................................................................................................. 5-27 5.7.5 Changing the coolant ............................................................................................................. 5-27 Fuel system ......................................................................................................................................... 5-29 5.8.1 Refuelling ............................................................................................................................... 5-29 5.8.2 Draining the water from the fuel tank ..................................................................................... 5-30 5.8.3 Emptying and cleaning the fuel tank ...................................................................................... 5-31 5.8.4 Draining off water at the preliminary fuel filter ........................................................................ 5-31 5.8.5 Replacing the fuel prefilter cartridge....................................................................................... 5-31 5.8.6 Replacing the fuel filter cartridge (fine filter) ........................................................................... 5-32 Dry air filter .......................................................................................................................................... 5-32 5.9.1 Replace filter elements. .......................................................................................................... 5-33 5.9.2 Monitoring the filtered air line ................................................................................................. 5-35 Hydraulic system ................................................................................................................................. 5-35 5.10.1 Checking the oil level in the hydraulic tank ............................................................................ 5-36 5.10.2 Relieving the pressure in the hydraulic system ...................................................................... 5-37 5.10.3 Emptying and refilling the hydraulic tank ................................................................................ 5-38 5.10.4 Return filter ............................................................................................................................. 5-39 5.10.5 Servo oil filter.......................................................................................................................... 5-40 5.10.6 Servo circuit............................................................................................................................ 5-41 5.10.7 Bleeding the hydraulic pump .................................................................................................. 5-41 5.10.8 Servicing the hydraulic cylinder.............................................................................................. 5-42 5.10.9 Replacing hydraulic hoses ..................................................................................................... 5-43 Changing the oil on components ......................................................................................................... 5-43 5.11.1 General notes......................................................................................................................... 5-43 5.11.2 Swin gear - oil change............................................................................................................ 5-44 5.11.3 Transmission - oil change ...................................................................................................... 5-45 5.11.4 Steering and rigid axle - oil change ........................................................................................ 5-45 ...... 5-46 .......... 5-46 Electrical system.................................................................................................................................. 5-47 5.13.1 Notes for electrical system ..................................................................................................... 5-47 5.13.2 Battery master switch ............................................................................................................. 5-47 5.13.3 Battery care ............................................................................................................................ 5-48 5.13.4 Slip ring assembly (option) ..................................................................................................... 5-49 Heating system / heating and air conditioning system (option) ........................................................... 5-50

A 309 Litronic / 8720354

MJFCIFSS

Operating instructions

5.15

5.16

5.17 5.18

5.19

5.14.1 Fresh air filter.......................................................................................................................... 5-50 5.14.2 Heating system ....................................................................................................................... 5-51 5.14.3 Air conditioning system (option) ............................................................................................. 5-51 Lubricating the machine....................................................................................................................... 5-54 5.15.1 Lubricating the swing gear...................................................................................................... 5-54 5.15.2 Lubricating the attachment ..................................................................................................... 5-55 5.15.3 Lubricating the axles............................................................................................................... 5-55 5.15.4 Lubricating the digging tool / bucket tilt device ....................................................................... 5-56 5.15.5 Lubricating the grapple (option) .............................................................................................. 5-56 Quick change systems......................................................................................................................... 5-57 5.16.1 Lubricate the mechanical quick change adapter (option) ....................................................... 5-57 5.16.2 Hydraulic quick change adapter (option) ................................................................................ 5-58 5.16.3 LIKUFIX (option) ..................................................................................................................... 5-59 Parking and swing gear brake ............................................................................................................. 5-60 General Maintenance points ................................................................................................................ 5-60 5.18.1 Replacing wear parts .............................................................................................................. 5-60 5.18.2 Replacing the teeth on the digging tool .................................................................................. 5-60 5.18.3 Welding work on the machine ................................................................................................ 5-61 Inspection and maintenance schedule................................................................................................. 5-62

MJFCIFSS

A 309 Litronic / 8720354

1 Product description 1.1 Assembly - Overview This section contains an overview of the machine and descriptions of the components shown.

1.1.1

Machine and construction equipment

Fig. 1-1

Machine and construction equipment

100

Uppercarriage

320

Hoist cylinder

360

Stick

200 300

Undercarriage Swing bearing

330 340

Adjusting cylinder Boom

370 380

Bucket cylinder Digging tool

310

Basic boom

350

Stick cylinder

Product description

Operating instructions

Assembly - Overview

1.1.2

Uppercarriage

Fig. 1-2

Uppercarriage

500

Diesel engine

7100 Hydraulic tank

530 560

Dry air filter Radiator

7300 Hydraulic pump 7600 Control valve block

700 Swing gear 6000

1-2

MJFCIFSS

8700 Operator's cab 9300 Fuel tank

A 309 Litronic / 8720354

Operating instructions

Product description Technical data

1.1.3

Undercarriage

Fig. 1-3

Undercarriage

600 Transmission 1000 Rotary connection

4000 Steering axle 4100 Rigid axle

1500 Outrigger support 1700 Dozer blade

9680 Step with toolbox 9690 Step

1.2 Technical data Please refer to the accompanying technical description.

A 309 Litronic / 8720354

MJFCIFSS

1-3

Product description

Operating instructions

Technical data

1-4

MJFCIFSS

A 309 Litronic / 8720354

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Ô·»¾¸»®®óا¼®¿«´·µ¾¿¹¹»® Ù³¾Ø Üóèèìëé Õ·®½¸¼±®ºñ×´´»® õìç øð÷éíëì èðóðô Ú¿¨ õìç øð÷éíëì èðóéî çì ©©©ò´·»¾¸»®®ò½±³ô ÛóÓ¿·´æ ·²º±à´¸¾ò´·»¾¸»®®ò½±³

2 Safety information, signs Working with the machine holds dangers to which you as the owner, machine operator or maintenance expert could be exposed. If you regularly read and note the safety information, you can prevent dangers and accidents. This applies especially to persons, who are working on the machine only occasionally, such as for maintenance work. The following information comprises safety regulations which, if followed conscientiously, will guarantee your safety and that of other persons, as well as avoid damage to the machine.

Following these regulations does not release you from the responsibility to follow all safety regulations and guidelines valid for the jobsite, as required by law or issued by trade associations.

For EU countries, guideline 89/655/EEC contains the minimum safety information applicable to the operator.

2.1 Symbols in the operating instructions Work processes and actions that could cause danger are accompanied by safety information in these operating instructions. This safety information describes various dangers which are emphasized by the terms Danger, Caution and Note.

These terms are identified by symbols in the operating instructions and have the following significance: Danger!

Warning relating to a danger that carries a high risk of death or serious injury if the appropriate preventative measures are not taken.

Caution!

Warning relating to dangers that could result in physical injury and/or damage to the machine if the appropriate preventative measures are not taken.

Note!

This symbol is used to identify user tips as well as operating and maintenance procedures, which should be followed to keep your machine operational and to insure long service life and / or to facilitate certain operating or working procedures.

This symbol signifies the following: The machine operator or the maintenance personnel must first fulfill the given prerequisite, i. e. the machine must be brought into a particular work position in order to be able to carry out the actions subsequently described.

Safety information, signs

Operating instructions

Use in accordance with the regulations

This symbol identifies an action.

The machine operator or the maintenance personnel should be active at this location and carry out the action described.

This symbol means "Carry out an activity".

If the machine operator or maintenance personnel have carried out the activities described in an action, the result of this action will be described here.

Following these notes does not relieve you of the responsibility for following additional rules and guidelines!

Additional points that should be observed are:

2.2 Use in accordance with the regulations ple, bucket ) designed to loosen, take on, transport and dump soil, rocks and other materials, where the load is predominantly transported without moving the machine. Moving the machine when it is carrying a load must be carried out by observing the appropriate safety measures (see section "Notes for machine operating safety").

quires special equipment and may also require special safety devices. These attachments (e.g. log grapple, demolition hammer, concrete cutter etc.) may only be attached and used with approval and in accordance with the basic machine manufacturer. intended use. The manufacturer is not liable for damage resulting from this action. The risk must be assumed solely by the user. and the inspection / maintenance instructions is also deemed to be appropriate and destined use in accordance with regulations.

2.3 Safety instructions 2.3.1

General Safety instructions ating instructions before starting the machine. tions relating to special accessories for the machine. perate, maintain or repair the machine.

The legal minimum age must be observed.

2-2

MJFCIFSS

A 309 Litronic / 8720354

Operating instructions

Safety information, signs Safety instructions

Clearly define who is responsible for the operation or set up, maintenance and repair. Allow personnel to refuse unsafe instructions given by a third person. This also applies to traffic regulations. should only operate or work on the machine under the constant supervision and guidance of an experienced person. ically if they observe safety instructions and guidelines given in the Operating manual. wearing rings, watches, ties, scarves, open jackets or loose clothing. There is a danger of injury, as these items could get caught or be pulled in. s, safety boots, work gloves, reflective vests, ear protection etc. are required. r special safety instructions and regulations.

el or the joysticks as handholds. Inadvertent movements, which could cause accidents, should be touched off. vided to climb off or on the machine. h the emergency exit through the front window.

ground,

h the ignition key in contact position, move all servo controls (joysticks and pedals) in all directions to relieve the servo pressure and the remaining pressures in the working circuits. Then relieve the pressure in the tank, as described in this operating manual. walk around inspection. Check if all warning signs are on the machine and if they are all legible. difications on the machine, which could affect the safety, without obtaining explicit approval from the manufacturer. This also applies to the installation and adjustment of safety devices and safety valves as well as to any welding on load carrying parts.

2.3.2

Crushing and burn prevention long as it is not safely resting on the ground or properly supported.

a suitable alignment tool. fans will swirl and throw out objects, which can damage the fan.

A 309 Litronic / 8720354

MJFCIFSS

2-3

Safety information, signs

Operating instructions

Signs on the machine

pressure. Avoid contact with any components containing coolant. Danger of severe burns. diator cap on the expansion tank is cool enough to touch. Turn the cap carefully to relieve the pressure. ine and the hydraulic oil are hot. Do not allow your skin to come into contact with hot oil or components containing hot oil. sparks and open flames.

cured with the appropriate supports to prevent them from closing inadvertently. raised with the attachment, without being properly supported from below with hardwood beams.

2.3.3

Fire and explosion prevention

aged wires or cables must be repaired immediately by an electrician or especially trained personnel. ine except in appropriate storage tanks.

vent vibration, rubbing and heat build up. ciently ventilated areas. to start Diesel engines with preheat system or flame glow systems. DANGER OF EXPLOSION! location and use of fire extinguishers on the machine as well as the local fire reporting procedures and fire fighting possibilities.

2.4 Signs on the machine 2.4.1

Introduction The machine displays several types of signs: Safety plates provide warnings relating to dangers of accidents which could result in serious injury or death.

Information plates indicate specific points relating to the operation, maintenance and characteristics of the machine.

2-4

MJFCIFSS

A 309 Litronic / 8720354

Operating instructions

Safety information, signs Signs on the machine

Nameplates are attached to components for which the machine number must be provided when ordering spare parts.

Danger!

Non-observance of safety plates can result in serious injury or death.

Check warning plates regularly to ensure that they are complete and clearly legible.

Replace missing or illegible safety and information plates immediately.

2.4.2

Arrangement of signs

Fig. 2-1

Arrangement of signs on the machine

4

Identification tag

51

Warning sign Danger zone

15

Lubrication chart

52

Warning sign Engine shut down

20

Prohibition sign

60

Information sign Acoustic sound output level Lwa

22

Sign Operating symbols

65

Load chart

30

Lubrication chart, engine

66

Warning sign Accident prevention, safety lever, attachments

32/62 Speed sign (Germany) 35 40

A 309 Litronic / 8720354

Information sign Loading and anchoring points Information sign Latch points

MJFCIFSS

67

Warning sign Operating brake, parking brake 80-1 Information sign Safety belt 80-2 Warning sign Operating brake

2-5

Safety information, signs

Operating instructions

Signs on the machine

45

2.4.3

85

47

Information sign Tackle - lifting point Information sign Jump starting

50

Warning sign Danger zone

250

90

Information sign Engine hood release Information sign Engine cleaning Information sign Emergency exit rear window

Explanation of signs Sign 4: Machine identification tag The identification tag displays the following information:

Sign 15: Lubrication chart Displays the relevant filling capacities as well as the change intervals, grease quality, filling and lube point.

Sign 20: Prohibition sign Entering the marked area is prohibited.

Sign 22: Operating symbols Describes the functions of the operating devices which are not labelled.

2-6

MJFCIFSS

A 309 Litronic / 8720354

Operating instructions

Safety information, signs Signs on the machine

Sign 30: Lubrication chart, engine Refers to the maintenance intervals for the Diesel engine.

Sign 32/62: Speed sign 16, 20 km/hr. (only for Germany) Displays the construction-dependent top speed of the machine.

Sign 35: Loading and anchoring points Identifies the positions of the loading and anchoring points, as well as the relevant weight of the machine.

Sign 40: Latch point

Sign 45: Tackle lifting point

A 309 Litronic / 8720354

MJFCIFSS

2-7

Safety information, signs

Operating instructions

Signs on the machine

Sign 47: Jump starting The information in the operating instructions must be carefully observed when jump starting the machine.

Sign 50: Danger zone It is prohibited for anyone to remain in the danger zone.

Sign 52: Engine shut-down The engine hood may only be opened when the engine is shut off.

Sign 60: Acoustic sound output level Lwa Indicates the sound output level of the machine to the environment in dB(A). *XX = The applicable value for the machi

Sign 65: Load chart Shows the permissible loads at the end of the stick, depending on the radius.

2-8

MJFCIFSS

A 309 Litronic / 8720354

Operating instructions

Safety information, signs Signs on the machine

Sign 66, Part 1: Accident prevention The accident prevention regulations given in the operating instructions must be strictly observed when operating the machine.

Sign 66, Part 2: Safety lever

Sign 66, Part 3: Attachments The attachment reaches as far as the cab! Caution when attachment is retracted.

Sign 67: Operating brake / parking brake It is not permitted to apply the operating and parking brakes simultaneously when the machine is operating.

The operating brake may only be applied when the machine is operating. The operating brake may not be used as a parking brake when leaving the machine.

A 309 Litronic / 8720354

MJFCIFSS

2-9

Safety information, signs

Operating instructions

Signs on the machine

Sign 80-1: Safety belt The safety belt must be fastened before starting the machine.

Sign 80-2: Operating brake (only applicable for Germany) The operating brake may only be applied when the machine is operating. The operating brake may not be used as a parking brake when leaving the machine.

Sign 85: Hood release Indicates remote control release of the engine hood.

Sign 90: Engine cleaning The engine compartment may only be cleaned when the Diesel engine is shut down.

Before cleaning with water or steam, cover / tape off all openings whose safety and function could be affected by infiltration of water or steam.

The rubber weather strip can be loosened and removed and the rear window pushed out by pulling the tab on the inside of the rear window.

2 - 10

MJFCIFSS

A 309 Litronic / 8720354

Operating instructions

Safety information, signs Identification tags on the machine

2.5 Identification tags on the machine

Fig. 2-2

A 309 Litronic / 8720354

Important identification tags on the machine

1

Control valve block

5

Axles

2

Diesel engine

6

Swing gear

3

Heating /air conditioning unit

7

Travel gear with oil motor

4

Hydraulic pump

MJFCIFSS

2 - 11

Safety information, signs

Operating instructions

Identification tags on the machine

2 - 12

MJFCIFSS

A 309 Litronic / 8720354

3 Control, operation 3.1 Operating and control elements 3.1.1

Overview of the

Fig. 3-1

Operator's platform

1

Safety lever servo control

18

Heater

6

Operating brake

20

Fuse box

7

Accelerator pedal

21

Radio*

8

Air vent for heater

P5

Operating hours counter

9

Attachment control*

S4

Horn

10

Positioning swing brake*

* Optional extras

Control, operation

Operating instructions

Operating and control elements

Fig. 3-2 A

Control panel A

S1

Ignition switch

B

Control panel B

S5

C

Control panel C

S32

Turn / slew add-on unit pushbuttons* Indicator lever

3 4

Joystick, right Joystick, left

S44 S63

Hazard warning system switch Drag bearing switch

5

Outrigger control

S75

Full floating axle switch

14

Various installation kits*

S263 Turn-indicator switch

* Optional extras

3-2

MJFCIFSS

A 309 Litronic / 8720354

Operating instructions

Control, operation Operating and control elements

3.1.2

Arrangement of joysticks

Fig. 3-3

Joystick, right ( 3) and left (4)

Caution!

The machine is delivered in series with standard control.

On request, the machine can be equipped with a control system that deviates from the norm (e.g. with LIEBHERR control). In this case, the additional operating instructions for this control system must be observed.

PCSA controls The left joystick (4) controls the stick or swing movements: a and b: The stick is moved in or out. c and d: The uppercarriage is turned to the left or to the right.

The right joystick (3) controls the boom or bucket and grapple movements: e and f: The bucket will be tilted in or out, the grapple will be closed or opened. g and h: The boom will be raised or lowered.

A 309 Litronic / 8720354

MJFCIFSS

3-3

Control, operation

Operating instructions

Operating and control elements

3.1.3 3.1.3.1

Overview of control console, right Control panel A

Fig. 3-4

Control panel A

Display instruments

3-4

P6

Coolant temperature display

P7

Fuel level display

MJFCIFSS

P50

Clock

A 309 Litronic / 8720354

Operating instructions

Control, operation Operating and control elements

Indicator lights H7 H11

Engine oil pressure Preheat

H26 Quick-change adapter* H167 Direction of travel forwards

H12 Battery charging

H168 Direction of travel backwards

H13

Air filter contamination

H175 Engine overheating

H15

Hydraulic oil temperature

H176 Automatic full floating axle

H16

Overload warning device*

H186 Drag bearing

H18

Coolant level

H196 Scrap cutter / sorting grab*

H19 H20

Turn signals Indicator light, parking brake

H311 Full floating axle locking H336 Water in fuel filter

H23

Accumulator charge pressure (Operating brake)

* Optional extras

Operation R75

Speed adjustment

S47

Quick-change adapter*

S18 S19

Overload warning device* Rotary grab actuator

S241 Hydraulic hammer* S335 Switching supports

S21

Crawling speed

S360 Acknowledge quick-change adapter buzzer*

S42

First gear

S422 Radio mute

* Optional extras

3.1.3.2

Control panel B

Fig. 3-5

A 309 Litronic / 8720354

Control panel B

S20

Automatic idling

13

Heating system / heating and air conditioning system*

S74

Immobilizer*

S16

Parking brake

MJFCIFSS

3-5

Control, operation

Operating instructions

Operating and control elements

S318 Air-conditioning system*

S35

Servo control

S398 Reversing switch for fan * Optional extras

3.1.3.3

Control panel C

Fig. 3-6

Control panel C

S8 S11

Rotating beacon* Windscreen washing system

S61 Headlights S218 Roof windscreen wiper*

S14 S22

Windscreen wiper Work headlight, front, roof headlight, front*

E8 19

Cigarette lighter Ashtray

21

Fuse box

S22-1 Roof headlight, rear* * Optional extras

3.1.4 3.1.4.1

Control console functions Display instruments P5 - Operating hours counter display Displays the operating hours.

Serves as the basis for timely adherence to the maintenance chart.

Displays the engine coolant temperature.

3-6

MJFCIFSS

A 309 Litronic / 8720354

Operating instructions

Control, operation Operating and control elements

Displays the available quantity of fuel in the fuel tank.

To reduce the formation of condensate, always keep the fuel level as high as possible.

P50 - Clock Displays the current time.

3.1.4.2

Indicator lights

The indicator light illuminates if the engine oil pressure drops below 0.5 bar while the machine is operating.

The buzzer in the cab sounds simultaneously.

Bring the diesel engine to low idle immediately.

Allow the engine to idle for approximately 5 seconds.

Shut down the diesel engine.

The indicator light is illuminated while a preheating procedure is underway. When the preheating procedure is completed, the indicator light turns off and the diesel engine can be started.

The indicator light illuminates if the ignition key is placed in the contact position.

The indicator light turns off as soon as the desel engine is started.

While the machine is operating, this indicator light illuminates if the V-belt alternator or the electrical charging system is defective.

Bring the diesel engine to low idle immediately.

Allow the engine to idle for approximately 5 seconds.

Shut down the diesel engine.

Rectify the error.

If the air filter is heavily contaminated, the indicator light illuminates.

Bring the diesel engine to low idle immediately.

Allow the engine to idle for approximately 5 seconds.

Shut down the diesel engine.

If necessary, replace the filter element.

A 309 Litronic / 8720354

MJFCIFSS

3-7

Control, operation

Operating instructions

Operating and control elements

The indicator light illuminates if the hydraulic oil temperature in the tank exceeds 98 °C. Bring the diesel engine to low idle immediately.

Shut down the desel engine as quickly as possible.

Locate and rectify the error (radiator dirty etc.).

H16 - indicator light, overload warning (red)* The indicator light illuminates if the maximum permissible load carrying capacity of the machine is reached and the overload warning device S18 is switched on.

The buzzer in the cab sounds simultaneously.

Avoid increasing the load any further.

Reduce the load on the machine.

The indicator light illuminates if the coolant level drops below a specified level.

Bring the diesel engine to low idle immediately.

Shut down the desel engine as quickly as possible.

Locate the leak and carry out repairs.

Caution!

This monitoring device acts as an increased level of security in case of larger amounts of water loss (e.g. hose rupture). It does not relieve the operator or maintenance personnel from the responsibility of regularly checking the coolant level in the equalizing reservoir.

H19 - indicator light, turn signal The indicator light illuminates after the direction indicator turn signal switch has been operated and when the hazard warning system is operating.

H20 - Indicator light, parking brake The indicator light illuminates if the parking brake is engaged (S16) or if the parking brake's release pressure is too low.

H23 - Indicator light, accumulator charge pressure - operating brake (red)* The indicator light lights up if the accumulator charge pressure is too low. The brake function is endangered.

Bring the machine to a stop.

Bring the diesel engine to low idle immediately.

Push the safety lever up.

Check the brake system.

H26 - indicator light, quick-change adapter (red)* The indicator light illuminates during an unlocking procedure or when the locking pins are retracted.

3-8

MJFCIFSS

A 309 Litronic / 8720354

Operating instructions

Control, operation Operating and control elements

H167 - indicator light, drive forwards (green) Illuminates when direction of travel is selected.

H168 - indicator light, reverse (green) Illuminates when direction of travel is selected.

H175 - indicator light, engine overheating (red) The indicator light illuminates if the coolant overheats.

The buzzer in the cab sounds simultaneously.

Bring the diesel engine to low idle immediately.

Shut down the desel engine as quickly as possible.

Rectify the error.

Note!

If the ribbed V-belt breaks or the loading system is defective, the buzzer will not function.

H176 - indicator light, automatic full floating axle (green)

H186 - indicator light, drag bearing (green) The indicator light lights up after changing over to the drag bearing.

H196 - indicator light, grab / hydraulic hammer (green)* The indicator light illuminates on switch S241 in position 1 (centre position).

H311 - indicator light, full floating axle locking (green)

H336 - indicator light, water in fuel filter Illuminates if the fuel pre-filter has collected too much water.

Drain water from the fuel filter.

3.1.4.3

Switches

Press switch down.

The rotating beacon flashes.

Indicator light in the switch illuminates.

Press switch up.

The rotating beacon is switched off.

Indicator light in the switch goes out.

A 309 Litronic / 8720354

MJFCIFSS

3-9

Control, operation

Operating instructions

Operating and control elements

S11 - Windscreen washing system (green) Press and hold button down.

Washing water will be sprayed onto the windscreen through the outlet nozzles.

The windscreen washer runs continuously.

Release the button.

Washing water will be stopped.

Windscreen washer will run continuously for approx. 3 more seconds.

S14 - Windscreen wiper (green) This switch has two settings: Push the switch down to position 1 (centre position).

Continuous operation is activated.

Push the switch down to position 2 (final position).

Intermittent setting is activated.

S16 - Parking brake (green) Press switch down.

Parking brake is engaged.

Indicator light in the switch illuminates.

Press switch up.

Parking brake is released.

Indicator light in the switch goes out.

S18 - Overload warning device (red)* Press switch down.

Overload warning device is activated.

Indicator light in the switch illuminates.

Press switch up.

Overload warning device is deactivated.

Indicator light in the switch goes out.

S19 - Rotary grab actuator (green)* Press switch down.

The rotary grab actuator is activated.

Indicator light in the switch illuminates.

Press switch up.

The rotary grab actuator is deactivated.

Indicator light in the switch goes out.

Press switch down.

Automatic idling is activated.

Indicator light in the switch illuminates.

Press switch up.

Automatic idling is deactivated.

Indicator light in the switch goes out.

3 - 10

MJFCIFSS

A 309 Litronic / 8720354

Operating instructions

Control, operation Operating and control elements

Press switch down.

Crawling speed is activated.

Indicator light in the switch illuminates.

Press switch up.

Crawling speed is deactivated.

Indicator light in the switch goes out.

S22 - Work headlight, front / roof headlight, front (green)* This switch has three settings: Neutral (0), Position 1 and 2.: Push the switch down to position 1 (centre position).

The front work headlight is switched on.

Push the switch down to position 2 (final position).

The front work headlight is switched on.

The rear roof headlight is switched on.

This switch has three settings: Neutral (0), Position 1 and 2.

Push the switch down to position 1 (centre position).

No function.

Push the switch down to position 2 (final position).

The rear work headlight is switched on.

The rear roof headlight is switched on.

S35 - Servo control (green) Press switch down.

Left and right joysticks are ready to operate.

Indicator light in the switch illuminates.

Press switch up.

Left and right joysticks no longer operate.

Indicator light in the switch goes out.

Press and hold button down.

The hydraulic quick-change adapter is activated.

Indicator light in the switch illuminates.

Release the button.

The hydraulic quick-change adapter is deactivated.

Indicator light in the switch goes out.

This switch has three settings: Neutral (0), Position 1 and 2.

Push the switch down to position 1 (centre position).

Sidelight is activated.

Push the switch down to position 2 (final position).

Driving light is activated.

The switch can also function if the ignition key is in position 0 or P.

A 309 Litronic / 8720354

MJFCIFSS

3 - 11

Control, operation

Operating instructions

Operating and control elements

This switch has three settings: Neutral (0), Position 1 and 2.

Push the switch down to position 1 (centre position).

Continuous operation is activated.

Push the switch down to position 2 and hold (final position).

Washing water will be sprayed on the windscreen.

The windscreen washer runs continuously.

This switch has three settings: Neutral (0), Position 1 and 2.

Push the switch down to position 1 (centre position).

The high pressure auxiliary consumer (eg. sorting grab, scrap cutter) is activated.

Indicator light H196 illuminates.

Push the switch down to position 2 (final position).

The reduced pressure auxiliary consumer (eg. hydraulic hammer, ram) is activated.

Indicator light H196 goes out.

Indicator light in the switch illuminates.

S318 - Air-conditioning system (green)* Press switch down.

The air-conditioning system is switched on.

Indicator light in the switch illuminates.

Press switch up.

The air-conditioning system is switched off.

Indicator light in the switch goes out.

S335 - Switching supports (yellow) Press the switch.

Indicator light in the switch illuminates.

The split shield / claw support is activated.

Press switch again.

Indicator light in the switch goes out.

Shield support is activated.

The button is available if the machine is equipped with an overload warning device.

Press switch down.

The quick-change adapter buzzer is deactivated.

Press switch down.

The air flow will be transferred from outlet nozzles 8c (head area) to outlet nozzles 8a (foot area) and 8b (windscreen).

Indicator light in the switch illuminates.

Press switch up.

The air flow will be transferred from outlet nozzles 8a (foot area) and 8b (windscreen) to outlet nozzles 8c (head area).

Indicator light in the switch goes out.

3 - 12

MJFCIFSS

A 309 Litronic / 8720354

Operating instructions

Control, operation Operation

S422 - Radio mute Press switch down.

The radio is muted Indicator light in the switch illuminates.

Press switch up.

Radio plays again at original volume.

Indicator light in the switch goes out.

3.2 Operation 3.2.1 3.2.1.1

Entering or leavi Entering Caution!

Ensure that the safety lever is always in its uppermost position when entering or leaving the cab.

Always use the handholds provided for this purpose when entering or leaving the machine.

Do not use the control levers as handholds.

Never jump off the machine.

Fig. 3-7

A 309 Litronic / 8720354

Climb up using the handholds

MJFCIFSS

3 - 13

Control, operation

Operating instructions

Operation

3.2.1.2

Getting in

Fig. 3-8 1

Door - exterior

Door handle

2

Latch

11 Door lock

Press the door lock 11 on the door handle 1 and open the door.

If the door is to remain open during operations, swing the door back by 180° and secure in latch 2.

Climb in facing the machine and Adjust the seat and steering column if necessary.

3.2.1.3

Getting out

Fig. 3-9 3

Door - interior

Door handle on door lock

4

Lever for the latch

Shut down the machine and raise the safety lever.

Push the door handle 3 on the lock down.

Open the door fully and secure it in latch 2.

Climb out facing the machine.

3 - 14

MJFCIFSS

A 309 Litronic / 8720354

Operating instructions

Control, operation Operation

To release the door latch: The door is secured in latch 2.

Move the lever 4 next to the cab frame outward.

The door is now unlocked.

Close the door.

3.2.2

Safety lever

Fig. 3-10

Safety lever

For safety purposes, the left-hand control desk is provided with a safety lever.

Caution!

The safety lever must always be pushed up into its highest position (see arrow) when entering or exiting the cab.

When the safety lever is pushed up, the pilot control pressure is interrupted. This means that: stick or foot pedals, are operated. e (indicator light in switch S17 illuminates).

S17.

By moving the safety lever to its lowest position, the original switching states of the slewing gear brake and its switch S17 will be recreated and the pilot control devices are active.

Before starting work from the operator's seat, the safety lever must be pushed to its lowest position.

A 309 Litronic / 8720354

MJFCIFSS

3 - 15

Control, operation

Operating instructions

Operation

Fig. 3-11 tion) 1

Upper horizontal adjustment

4b Rear seat incline adjustment

7

Lumbar support adjustment

2

Lower horizontal adjustment

5

Seat suspension adjustment

8

Seat heater

3

Armrest adjustment

6

Lumbar support adjustment

10 Backrest adjustment

4a Front seat incline adjustment

This will avoid unexpected movements of the machine.

3.2.3.1

Adjusting the armrests

Fig. 3-12

Adjusting the armrests

Turn the knurled screw 3 on the armrest in direction a.

The armrests incline upwards.

Turn the knurled screw 3 on the armrest in direction b.

The armrests incline downward.

3 - 16

MJFCIFSS

A 309 Litronic / 8720354

Operating instructions

Control, operation Operation

3.2.3.2

Adjusting the seat and backrest

Fig. 3-13

Adjusting the seat and backrest

Rear seat incline: Pull lever 4a up, set the incline and release the lever.

Front seat incline: Pull lever 4b up, set the incline and release the lever.

Backrest: Pull lever 10 up, set the incline and release the lever.

3.2.3.3

Adjusting the horizontal seat position

Fig. 3-14

Horizontal seat adjustment

Pull up the lever 1 to push the operator's seat in the horizontal direction.

Pull up the lever 2 to push the operator's seat including the control panels in the horizontal direction.

A 309 Litronic / 8720354

MJFCIFSS

3 - 17

Control, operation

Operating instructions

Operation

3.2.3.4

Adjusting the seat suspension

Fig. 3-15

Adjusting the seat suspension

Use the turning knob 5 to adjust the seat suspension to match the body weight.

3.2.3.5

Adjustments on switch arrangement (air- cushioned opera-

Fig. 3-16 To adjust the vibration damper: Press button 5 (+ or -) and set the vibration system according to body weight.

To adjust the lumbar support: Press button 6 (+ or -) to inflate or deflate the lower lumbar chamber.

Press button 7 (+ or -) to inflate or deflate the upper lumbar chamber.

To turn on the seat heater: Use switch 8 to turn the seat heater on or off.

The seat heater turns off automatically when the proper temperature is reached.

3 - 18

MJFCIFSS

A 309 Litronic / 8720354

Operating instructions

Control, operation Operation

3.2.3.6

Putting on / releasing the safety belt

Fig. 3-17

Safety belt

The safety belt is automatic. It is not necessary to adjust the length of the belt.

Pull the belt and buckle 2 from the roller mount 1.

If pulled out of the roller mount jerky, the belt may lock.

Push the buckle into the belt lock 3 until it is properly engaged.

Danger!

The safety belt is designed to protect the operator.

Before starting the machine, always fasten the safety belt.

Ensure that the safety belt is not twisted when it is fastened.

To ensure your safety, check the condition, function and fastening of the belt regularly and replace any damaged parts immediately.

To open the lock 4, push the belt lock down using your thumb.

The safety belt will slide automatically back into the roller mount 1.

3.2.3.7

Vibration damper The seat complies with ISO 7096.

If the machine is used in accordance with regulations, the values of the vibration tation vibration for the relevant machine class in accordance with ISO 7096.

The values for vibration accelerations a zw, measured in accordance with ISO 26311, therefore comply with the requirements for protection against whole body vibration according to EN 474-1.

A 309 Litronic / 8720354

MJFCIFSS

3 - 19

Control, operation

Operating instructions

Operation

3.2.4

Adjusting the steering column

Fig. 3-18

Steering column

By adjusting the steering column, the position of the steering wheel to the body can be set.

Press the release lever 2 down with the foot.

Set the desired position by pulling or pushing the steering wheel.

Take the foot off the release lever 2; the steering column is locked in the desired position.

3.2.5

Front windshield

Fig. 3-19

Front windshield

The front windshield can be locked in two positions. a: Window closed. b: Window fully opened (locked in place on the roof of the cab).

Pull pin 1 in and down.

The window is unlocked.

Move the windshield with bracket 2, secure in one of the two window positions (a or b) and relock with the pin 1.

3 - 20

MJFCIFSS

A 309 Litronic / 8720354

Operating instructions

Control, operation Operation

3.2.6

Sun visor

Fig. 3-20

Sun visor, front windshield and cab roof

The cab is provided with two sun visors on the front windshield and on the window pane in the cab roof.

Front windshield Pull the sun visor down on the cross bar 1.

The sun visor can be adjusted as desired.

Press button 2 (red).

The sun visor rolls up by itself.

Cab roof Pull out the sun visor and secure it in the retainers designed for this purpose.

To retract the sun visor, remove it from the retainers and let it roll up slowly.

Fig. 3-21 By pulling the bracket 1 on the inside of the rear window, the rubber weather strip 2 can be released and removed.

In case of an emergency, pull off the rubber weather strip 2 from the circumference of the window and push the window out.

A 309 Litronic / 8720354

MJFCIFSS

3 - 21

Control, operation

Operating instructions

Operation

3.2.8

Interior illumination

Fig. 3-22

Interior illumination

The interior lighting is turned on with the slide regulator 1.

Push the slide regulator to the right.

Light 2 is turned on.

Push the slide regulator to the left.

The spot light 3 is turned on.

Push the sliding regulator to the center position.

The interior illumination is turned off.

3.2.9

Fire extinguisher (option)*

Fig. 3-23

Fire extinguisher / First-aid kit

The storage compartment for the fire extinguisher is located on the lower right in the operator's cab. *Operator regulations

3.2.10

Windshield wiper

3.2.10.1

Windshield wiper With the ignition turned on, press switch S14 on control panel C to activate the windshield wiper operation.

This switch has two settings:

3 - 22

MJFCIFSS

A 309 Litronic / 8720354

Operating instructions

Control, operation Operation

Push the switch in position 1 down (center position).

Continuous operation is activated.

Push the switch in position 2 down (final position).

Intermittent control is activated.

3.2.10.2

Window washer system With the ignition turned on, press switch S11 on control panel C fo activate the windshield washer system.

Press the button down and hold.

Water will be sprayed onto the front windshield through nozzles.

The windshield wiper runs continuously.

Release the button.

The water flow stops.

The windshield wiper continues to run continuously for approx. 3 seconds.

3.2.10.3

Windshield washing fluid container

Fig. 3-24

Windshield washing fluid container

The container for the windshield washing fluid is located on the left side of the cab.

Open the cover (see arrow) to refill the container with commercially available windshield washing fluid.

Quantity: see Lubrication Chart

3.2.10.4

Window wiper on cab roof

Fig. 3-25

A 309 Litronic / 8720354

Window wiper on cab roof

MJFCIFSS

3 - 23

Control, operation

Operating instructions

Operation

With the ignition turned on, press switch S14 on control panel C to activate the windshield wiper operation.

This switch has two settings: Push the switch in position 1 down (center position).

Continuous operation is activated.

Push the switch down to position 2 and hold (final position).

Water will be sprayed on the windshield.

The windshield wiper runs continuously.

3.2.11

Lighting

Fig. 3-26

Arrangement of lights

1

Parking and head light

3

Roof headlights (option)

2

Attachment headlights

4

Rotating beacon (option)

The switches for the lights are located on control panel C.

3.2.11.1

Parking light and low beam light With the ignition turned on and off, the parking light or low beam light is turned on by pressing switch S22.

This switch has two settings: Push the switch in position 1 down (center position).

The parking light is activated.

Push the switch in position 2 down (final position).

The headlight is activated.

3 - 24

MJFCIFSS

A 309 Litronic / 8720354

Operating instructions

Control, operation Operation

3.2.11.2

Attachment headlight, front Front roof headlight (option) With the ignition turned on, the roof and attachment headlights are turned on by pressing switch S22.

This switch has two settings: Push the switch in position 1 down (center position).

The front work headlight is turned on.

Push the switch in position 2 down (final position).

The front work headlight is turned on.

The front roof headlight is turned on.

3.2.11.3

Rear roof headlight (option) With the ignition turned on, the rear roof headlight is turned on by pressing switch S22-1.

This switch has two settings: Push the switch in position 1 down (center position).

No function.

Push the switch in position 2 down (final position).

The rear work headlight is switched on.

The rear roof headlight is turned on.

3.2.11.4

Rotating beacon (option) With the ignition turned on, press switch S8 to turn the rotating beacon on.

Press switch down.

The rotating beacon blinks.

The indicator light in the switch lights up.

Press switch up.

The rotating beacon is turned off.

The indicator light in the switch turns off.

3.2.12

3.2.12.1

Heating system / heating and air conditioning system (option) Overview The cab is equipped with a heating system as standard. The heating system can be used to heat and ventilate the cab. The switches for heater operation are located on control panel B. On request, the machine can be equipped with an air conditioning system.

A 309 Litronic / 8720354

MJFCIFSS

3 - 25

Control, operation

Operating instructions

Operation

Fig. 3-27 S92 S93

Overview of heating / air conditioning system

Control - Air vent Heat output control

S318 Air conditioning system (option) S398 Reversing switch

S284 Blower control

3.2.12.2

Blower control The blower output is regulated via rotary switch S284.

Position 0: The blower is turned off.

Positions 1 to 4: The fan motor runs in four different output stages.

3.2.12.3

Air duct The air flow is regulated via rotary switch S92 and via turnable and closeable air vents.

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MJFCIFSS

A 309 Litronic / 8720354

Operating instructions

Control, operation Operation

Fig. 3-28

Position of front air vents (left view) and vents on the rear cab wall (right view)

The air flow is either directed via nozzles 8a (foot area) and 8c (front windshield) or via air vents 8d (overhead area).

By pressing the reversing switch S398, the air flow will be reversed.

Press switch S398 down.

The air flow will be changed from nozzles 8d to nozzles 8a and 8c.

The indicator light in the switch lights up.

Push switch S398 upward.

The air flow will be changed from nozzles 8a and 8c to nozzles 8d.

The indicator light in the switch turns off.

When the reversing switch S398 is turned off, the air flow between nozzles 8a (foot area) and 8c (front windshield) is regulated via the knob S92.

Turn the knob S92 to the left.

The air flow will be changed from nozzles 8a to nozzles 8c.

Turn the knob S92 to the right.

The air flow will be changed from nozzles 8c to nozzles 8a.

3.2.12.4

Heater operation The desired heat output can be set via knob S93.

The Diesel engine must be running.

Turn the knob S93 to the left.

The heat output is decreased.

The heater is turned off when position "0" (left stop) is reached.

Turn the knob S93 to the right.

The heat output will be increased.

Note!

To attain optimum comfort when heating, it is recommended to use nozzles 8a (foot area) and 8c (front windshield).

A 309 Litronic / 8720354

MJFCIFSS

3 - 27

Control, operation

Operating instructions

Operation

3.2.12.5

Air conditioning operation (option) On request, the machine can be equipped with an air conditioning system. The air conditioning system is activated via switch S318.

The Diesel engine must be running.

Press switch S318 down.

The air conditioning system is turned on.

The indicator light in the switch lights up.

Push switch S318 upward.

The air conditioning system is turned off.

The indicator light in the switch turns off.

When turning on the air conditioning system and the knob S284 (blower control) is in position 0, the blower speed will automatically jump to position 1.

In air conditioning mode, the forced air will be cooled. The desired room temperature can be set with knob S93 (heater operation). The forced air is coldest when the knob S93 is in position 0 (left stop).

To dehumidify the cab, the air conditioning system can also be activated when the heater is on. In this case, turn on the air conditioning system only until the windows are no longer fogged.

Note!

For optimum comfort when operating the air conditioning system, it is recommended to use the nozzles on the rear cab wall 8d.

3.2.12.6

Notes for down time

Fig. 3-29

Water taps on the Diesel engine

using the air conditioning system, it is recommended to operate the air conditiony two weeks by pressing switch S318. If the compressor is out of service for a longer period of time, its shaft seal could be damaged due to vibration. taps (see arrows) on the Diesel engine should be closed.

3 - 28

MJFCIFSS

A 309 Litronic / 8720354

Operating instructions

Control, operation Operation

3.3 Operation 3.3.1 3.3.1.1

Safety instructions Bringing the machine safely into service

locked. he inside and outside mirrors are clean.

Secure all doors and windows to prevent unintentional movement. the surrounding area with the horn before starting the machine. and the other items to ensure comfortable and safe working conditions. e must be in functional protective position during operation. ated heaters only in sufficiently ventilated areas. Before starting the machine in a closed area, make sure the ventilation is sufficient.

Always follow all regulations valid for the current job site.

3.3.1.2

Starting the machine safely and instruments for proper function, bring all controls into neutral position and raise the safety lever. y personnel that the machine is being started by sounding the horn. the engine as outlined in the Operating manual. trols for their proper indication. engine only if there is sufficient ventilation. If necessary, open doors and windows to ensure sufficient fresh air supply. can cause the controls to be unresponsive.

check travel and swing brake, the steering function as well as the turn signals and lights.

3.3.1.3

A 309 Litronic / 8720354

Shutting down the machine safely

MJFCIFSS

3 - 29

Control, operation

Operating instructions

Operation

chine and secure it with wedges to prevent it from rolling off.

ized use.

3.3.1.4

Towing the machine safely operating manual. move the machine away from a dangerous place. towing the machine, check all cables, hooks and couplers for safety and stability. have a sufficient tensile strength and must be attached on the designated towing hooks on the undercarriage.

Be aware that any damage or accidents caused by towing the machine are never covered by the manufacturer's warranty. the required transport position, the permissible speed and distance.

service.

3.3.2 3.3.2.1

Starting / shutting down the machine Activities before starting Caution!

It is only possible to extinguish the source of fire if it is accessible.

Before starting, unlock all locks on the covers of the hydraulic excavator.

In the event of a fire, the doors can be opened immediately and the fire can be extinguished.

Location of locks: see Maintenance chapter Caution!

With the activities referred to below and a machine that is already at operating temperature, there is a risk of scalding or burning from hot coolant or hot oil.

Make sure to first read the information provided in the Maintenance chapter before carrying out these activities.

Before starting the machine, the following tasks should be carried out on a daily basis:

3 - 30

MJFCIFSS

A 309 Litronic / 8720354

Operating instructions

Control, operation Operation

the hydraulic tank*.

ing and combustion air intake. * To complete these tasks, refer to the Maintenance chapter.

3.3.2.2

Starting the Diesel engine Switch positions of ignition key

Fig. 3-30

Ignition switch

0

Neutral position

2

Preheating

1

Contact position

3

Starting position

P

Parking position

Turning the electrical system on

Fig. 3-31

Battery master switch

The battery master switch must be in position 1 (ON).

Turn the ignition key to contact position 1.

As soon as the ignition is turned on, the keypads and the display instruments runs through a self check.

Note!

If the keypad and display instruments do not run through a self check when the ignition key is in contact position, check if the battery master switch is positioned on

A 309 Litronic / 8720354

MJFCIFSS

3 - 31

Control, operation

Operating instructions

Operation

Make sure that the display instruments are functioning perfectly when they are turned on.

All indicator lights must turn on briefly.

Electronic immobilizer (option) On request, the machine can be equipped with an electronic immobilizer.

Fig. 3-32

Electronic immobilizer

Insert the coding key 1 in the coding lock S74 and then remove it again.

The LED turns off.

A signal tone sounds.

Turn the electrical system on.

Use the ignition key to start the electrical system within 9 seconds.

If the ignition is not turned on within 9 seconds, the coding key must be reinserted in the coding lock.

When the ignition is switched on, the immobilizer activates independently after approx. 30 seconds.

To reorder the coding key, state the code number noted on the accompanying code card (cheque card format).

3.3.2.3

Starting the engine Note!

Only actuate the starter when the Diesel engine is shut down.

Do not actuate the starter continuously for longer than 10 seconds.

If the engine does not start, turn the ignition key back to contact position 1.

Wait at least 1 minute before repeating the starting procedure.

Turn the ignition key back to position 0 before restarting the engine.

Starting procedure at ambient temperatures above 0 °C If the engine and batteries are in good condition, the engine can be started without preheating.

Sensor controlled low idle automatic S20 must be turned off.

The indicator light may not light up.

Turn the throttle control R75 from the zero point a ¼ turn to the right.

Turn the ignition key to starting position 3.

3 - 32

MJFCIFSS

A 309 Litronic / 8720354

Operating instructions

Control, operation Operation

Release the ignition key as soon as the engine is running.

All indicator lights must turn off.

The buzzer will sound briefly when the engine starts until the engine oil pressure builds up.

Starting procedure at ambient temperatures below 0 °C Preheating improves the starting behavior of the Diesel engine at low temperatures.

Sensor controlled low idle automatic S20 must be turned off.

The indicator light may not light up.

Turn the throttle control R75 from the zero point a ¼ turn to the right.

Turn the ignition key to position 1.

The indicator light H11 lights up.

Wait until the indicator light H11 turns off.

Preheating is completed.

Turn the ignition key to starting position 3.

Release the ignition key as soon as the engine is running.

All indicator lights must turn off.

The buzzer will sound briefly when the engine starts until the engine oil pressure builds up.

3.3.2.4

Throttle control

Fig. 3-33

Throttle control

The throttle control R75 permits continuous adjustment of the engine RPM over the full RPM range.

3.3.2.5

Engine overheating If the engine overheats, the indicator light H175 lights up and a warning signal (buzzer) sounds simultaneously.

Bring the Diesel engine to low idle immediately.

Shut down the Diesel engine as quickly as possible.

Remedy the error. (see also the Operating and maintenance manual for the Deutz engine).

A 309 Litronic / 8720354

MJFCIFSS

3 - 33

Control, operation

Operating instructions

Operation

Fig. 3-34

Diesel engine air intake

Note!

To ensure optimum conditions for the engine, remove any ice and snow from the engine hood in the area of the cooling and combustion air intake before starting the Diesel engine.

3.3.2.6

Notes after starting the engine Danger!

Danger of suffocation.

When operating in closed spaces, run the engine only with sufficient ventilation.

Open doors and windows to ensure sufficient supply of fresh air.

Caution!

At low oil temperatures, increased wear occurs in the Diesel engine and the hydraulic system and the controls will react sluggishly.

Bring the engine and hydraulic oil to operating temperature. The control operates sluggishly at low oil temperatures.

Carefully move the machine to an open area to check the function of the travel and swing gear brake.

Check that all attachment functions are operating properly.

3.3.2.7

Shutting the Diesel engine down Caution!

The engine could be damaged.

Do not shut down the engine suddenly from full throttle.

Reduce the engine RPM via the throttle control R75 to low idle.

Allow the Diesel engine to run in low idle for another 2-3 minutes to even out the temperature.

Now turn the ignition key to position 0 to shut down the engine.

Remove the ignition key.

3 - 34

MJFCIFSS

A 309 Litronic / 8720354

Operating instructions

Control, operation Operation

3.3.3

Jump start procedure Danger!

When connecting to jump start batteries, old batteries can be subject to increased gas formation.

Wear safety glasses and protective gloves during the jump start procedure and avoid open flames and creating any sparks in the vicinity of the discharged vehicle battery. DANGER OF EXPLOSION! Only use jump start cables with a sufficient cross section. Always follow the established jump starting procedure.

3.3.3.1

Connecting the batteries First connect the cable to the positive terminal (+) of the discharged battery and then to the positive terminal (+) of the jump start battery.

Connect the second cable to the negative terminal (-) of the discharged battery and then to the negative terminal (-) of the jump start battery.

Start the engine as described above.

Caution!

Before removing the jump start cable, be sure to bring the Diesel engine of the jump started machine into low idle.

For safety reasons, turn on a large user, such as work headlights, uppercarriage lighting etc. to avoid overvoltage. The electronics could otherwise be damaged.

3.3.3.2

Disconnecting the batteries First remove the cable from the negative terminal (-) of the jump start battery and then from the negative terminal (-) of the discharged battery.

Remove the second cable from the positive terminal (+) of the jump start battery and then from the positive terminal (+) of the discharged battery.

Check the electrical functions of the machine.

For battery care and maintenance, see the chapter "Battery care".

A 309 Litronic / 8720354

MJFCIFSS

3 - 35

Control, operation

Operating instructions

Operation

3.3.4

Travel operation The safety belt must always be worn before travel operation.

For travel, the uppercarriage must be positioned to the undercarriage in travel position, i.e. the steering axle (oscillating axle) on the front, the rigid axle to rear.

For travel on public roads, the uppercarriage and the undercarriage must be interlocked.

Fig. 3-35

Controls for travel

1

Retainer

H167 Indicator light, travel direction forward

3

Joystick, right

6

Brake pedal

H168 Indicator light, travel direction reverse S263 Rocker switch travel direction

7

Traveling pedal Before starting to travel, use your foot to release the retainer 1 on the brake pedal 6.

Release parking brake S16.

3.3.4.1

Gear selection The machine is equipped with a power shift 2-speed transmission with downshift lock.

When the machine is started up, the second gear is automatically engaged.

Note Maximum travel performance is only obtained when the servo control S35 is turned off.

3.3.4.2

Changing gear when stationary Press switch S42 down.

The 1st gear is engaged.

Press switch S42 again.

The 2nd gear is engaged.

3 - 36

MJFCIFSS

A 309 Litronic / 8720354

Operating instructions

Control, operation Operation

3.3.4.3

Changing gear during travel Since the transmission can be shifted under load, the gears can also be changed during travel.

During travel in 2nd gear: Press switch S42 down.

The 1st gear is preselected.

The shifting procedure is carried out automatically when the corresponding low travel speed has been reached.

During travel in 1st gear: Press switch S42 again.

The shifting procedure is carried out immediately. The 2nd gear is engaged.

3.3.4.4

Creeper gear Note!

The creeper gear should be selected when stationary or for slow driving to prevent a jerky braking action of the machine.

To obtain better traction on inclines and difficult terrain, the creeper gear can be shifted with switch S21.

Press switch S21 before or during travel to turn on the creeper gear.

To turn the creeper gear off, press switch S21 again.

3.3.4.5

Travel movement The selection of the travel direction is made via the rocker switch S263 on the left joystick. An infinitely variable regulation of the travel speed is possible with the accelerator pedal 7.

Danger!

Before driving in reverse, make sure that the area behind you can be entered safely.

After completing the travel movements, bring the travel selector switch to the 0 position.

If the uppercarriage is rotated by 180° to the undercarriage, the travel and steering directions are reversed.

Travelling forward Press rocker switch S263 down a.

The indicator light H167 lights up.

Slowly press travel pedal 7 down.

Travelling reverse Press rocker switch S263 up b.

The indicator light H168 lights up.

Slowly press travel pedal 7 down.

3.3.4.6

Travelling downhill The machine is equipped with an automatic brake valve, which prevents the hydraulic drive train from overspeeding.

A 309 Litronic / 8720354

MJFCIFSS

3 - 37

Control, operation

Operating instructions

Operation

Danger!

Before travelling downhill, turn the sensor controlled low idle automatic S20 off.

Travel downhill with maximum Diesel engine RPM. Regulate the speed using the travelling pedal.

3.3.4.7

Travelling on downhill grades of more than 10% Caution!

Applying the operating brake does not ensure safe parking on a downhill slope (loss of pressure due to leakage is possible).

Before leaving the cab and / or shutting down the machine, apply the parking brake S16.

Raise the safety lever.

Always use the 1st gear to travel downhill slopes of more than 10%.

Before travelling downhill, stop and engage the 1st gear.

3.3.5

All wheel steering, crab steering (option) In addition to the standard two wheel steering via the front axle, two additional steering modes are available.

Steering mode

Features

Two wheel steering

Front axle steering. The rear axle steering is locked.

All wheel steering

When the steering wheel is turned, the steering deflection of the front and rear axle is carried out in opposite directions. The turning radius is smaller.

Crab steering

When the steering wheel is turned, the steering deflection of the front and rear axles is identical. The machine can be driven sideways.

Tab. 3-1

Features of the steering modes

To change over the steering modes: Danger! may not be used when travelling on public roads.

On public roads, use only two wheel steering.

To switch the steering mode, the following initial conditions must be met: 0 S35 is turned on.

3 - 38

MJFCIFSS

A 309 Litronic / 8720354

Operating instructions

Control, operation Operation

Fig. 3-36 0

Front axle steering.

1

All-wheel steering

2

Crab steering

The desired steering mode is selected via the rotary switch selector S309 on the lefthand control panel.

Meet the initial conditions for the switchover.

Note!

If the wheels are not exactly aligned, the steering mode switchover is delayed.

If necessary, the machine corrects the positions of the wheels and automatically aligns these straight ahead. The condition of the ground can however delay or prevent this procedure.

Align the wheels as straight ahead as possible before switching the steering mode.

If necessary: Relieve the load on the axles by using the supports or attachments to facilitate the alignment of the wheels.

Turn switch S309 to position 1.

Travel movement is blocked (travel lock).

A warning buzzer sounds, the indicator light H191 flashes while the wheels align and then lights up continuously.

All-wheel steering is activated, travel movement is again released.

Turn switch S309 to position 2.

Travel movement is blocked (travel lock).

A warning buzzer sounds, the indicator light H192 flashes while the wheels align and then lights up continuously.

Crab steering is activated, travel movement is again released.

Turn switch S309 to position 0.

Travel movement is blocked (travel lock).

A warning buzzer sounds, the indicator lights H191 and H192flash while the wheels align, and then the lights turn off again.

Two-wheel steering is activated, travel movement is again released.

The control system interrupts the switchover of the steering mode if in the meantime any of the initial conditions is changed.

This is a malfunction and will be indicated by the alternate flashing of the indicator lights H191 and H192. In this situation, the travel stop will be deactivated and the rear axle will be uncoupled from the steering movement, i.e. two wheel steering is active.

The steering mode can be changed again once the initial conditions have been met again.

A 309 Litronic / 8720354

MJFCIFSS

3 - 39

Control, operation

Operating instructions

Operation

Caution!

If a malfunction is indicated, the steering deflection of the rear axle may not correspond to the selected steering mode. Unexpected travel movements of the machine can occur.

Turn switch S309 to position 0 and try the switchover again.

3.3.6

Travelling on public roads Note!

Travelling on public roads is subject to national regulations.

Before starting to travel, inform yourself about local requirements.

Observe all regulations and conditions.

Fig. 3-37

Required additional equipment, Germany

In Germany, for example, the following safety devices must be carried in accordance with the motor vehicle C.U.R. and the conditions in the exception authorization:

Before travelling on a public road, carry out the following tasks and checks: Clean the machine of all coarse dirt.

Clean the tire treads.

Empty the digging equipment.

Close all doors and the covers.

Turn the uppercarriage in the direction of travel (attachment over steering or oscillating axle) and lock to the undercarriage with the locking pin (see chapter Uppercarriage lock).

3 - 40

MJFCIFSS

A 309 Litronic / 8720354

Operating instructions

Control, operation Operation

To bring the attachment into a road travel position:

Fig. 3-38

Attachment for travel on public roads

When driving on a public road, the maximum overall height is 4000 mm.

This dimension is obtained if the attachment is positioned as follows: Tilt in the bucket and pull the stick as close as possible to the uppercarriage.

Extend hydraulic cylinder 1 until the outer edge of the red mark A is parallel with the rear edge of the basic boom (see arrow).

Fully retract the adjustable boom cylinder 2.

In Germany, the distance from the center of the steering wheel to the foremost point of the attachment may be a maximum of 3500 mm (according to StVZO). This dimension is obtained if the equipment is tilted to the left:

Fig. 3-39

On road travel in Germany

Move the attachment to the left until the outer edge of the red mark B is parallel to the front edge of the swing platform (see arrow).

Fig. 3-40

Securing the grapple for on road travel

For undercarriage with blade on the rear: Attach the grapple to the grapple bar.

A 309 Litronic / 8720354

MJFCIFSS

3 - 41

Control, operation

Operating instructions

Operation

Tilt the connecting link 3 up.

Secure the connecting clip 3 with two screws.

To bring the outrigger support / blade support into the road travelling position:

Fig. 3-41

Outrigger support and blade support when travelling on a public road

Move the support up to the stop (blade or outtriger).

Attach additional rear reflectors 1 to the left and right on the blade and secure with cotter pin 2 .

Securing the outrigger support additionally on the right and left hand side: Bring the outrigger in a vertical position, attach the bearing block 3with pins 4 and secure with cotter pin 5.

Before starting to drive: Switch automatic full floating axle locking S75 to position 0 .

Switch off the servo control: Push switch S35 upwards.

Indicator light in the switch goes out.

The joysticks do not function.

Automatic idling will be deactivated.

The maximum RPM of the diesel engine is higher.

Fig. 3-42

Engine speed adjustment, maximum RPM

If the servo control is switched off, the maximum RPM that can be reached is somewhat higher. If R75 is already set to the maximum RPM, it will be increased somewhat if the servo control S35 is switched off.

This provides greater performance for driving.

3.3.7

Towing the machine Towing the machine is problematic and is always carried out at the operator's risk.

3 - 42

MJFCIFSS

A 309 Litronic / 8720354

Operating instructions

Control, operation Operation

The machine may only be towed in exceptional circumstances, e.g. in order to move the machine away from a dangerous place for repair.

Damage or accidents, which occur while towing the machine, are never covered by the manufacturer's warranty.

Towing rods must have sufficient tensile strength and must be secured on the undercarriage using the towing hook provided for this purpose.

The following values may not be exceeded when towing:

Danger!

Danger of injury due to a torn rope.

To tow the machine, only use a sufficiently sized rod.

Preparation for towing depends on the function of the Diesel engine (hydraulic system).

3.3.7.1

Towing with the Diesel engine running The parking brake must be released when towing.

Press switch S16 down.

The indicator light in the switch turns off.

The parking brake is released.

If it is not possible to release the parking brake even though the Diesel engine is running (problem in the electrical system), then the solenoid valve of the parking brake must be released mechanically.

Fig. 3-43

Solenoid valve - Parking brake

On solenoid valve Y6, turn in the tommy screw.

Release operating brake 6 and tow the machine.

The machine can be towed and slowed down with the operating brake 6.

A 309 Litronic / 8720354

MJFCIFSS

3 - 43

Control, operation

Operating instructions

Operation

3.3.7.2

Towing with the Diesel engine not running Danger!

When the Diesel engine is not running and the transmission is disengaged, none of the brakes on the machine are functioning.

When the Diesel engine is not running, the steering is only operational with increased effort!

The machine may only be towed out of the danger area!

The transmission must be mechanically disengaged in the event of insufficient battery voltage and / or insufficient opening pressure (see Fig. 3-44).

Danger!

The machine can roll away.

Before disengaging the transmission, secure the machine properly to ensure that it does not roll away.

Fig. 3-44

Disengage the transmission mechanically

Use an Allan wrench to screw in the piston fully.

The parking brake is released.

The machine can be towed.

3.3.8

Oscillating axle lock

Fig. 3-45

3 - 44

Oscillating axle lock

MJFCIFSS

A 309 Litronic / 8720354

Operating instructions

Control, operation Operation

Locking the oscillating axle Turn switch S75 to position 1.

The indicator light H311 lights up.

The oscillating axle is permanently locked.

The stability of the machine is increased.

Turn on the oscillating axle automatic Danger!

When the automatic oscillating axle lock automatic is turned on (switch S75 in position A), releasing the operating brake will release the oscillating axle lock.

This results in a reduction of the stability of the machine and can cause the machine to tip over when a load is lifted and the uppercarriage is turned.

For safety reasons, the oscillating axle cannot be unlocked when the system is overloaded.

If the machine has to be moved with a raised load (e.g. filled bucket, load suspended on safety hook), you must turn off the automatic oscillating axle lock and permanently lock the oscillating axle (switch S75 in position 1) before taking on the load.

Turn switch S75 to position A. The indicator light H176 lights up.

When the operating brake is applied, the oscillating axle is automatically locked in the current position and is automatically unlocked again when the operating brake is released.

Note!

When working with the excavator, we recommend to lock the oscillating axle.

If possible, unlock the oscillating axle before travelling (without a load): Turn switch S75 to position 0.

3.3.9

Support

Fig. 3-46

A 309 Litronic / 8720354

Support variants

MJFCIFSS

3 - 45

Control, operation

Operating instructions

Operation

The machine can be equipped with different types of support: 1 Dozer blade 2 Split shield 3 Outrigger support It is possible to combine the support variants on the front and / or at the rear, depending on kit.

3.3.9.1

Switch supports Switch S335 determines which support can be activated.

Press switch S335.

Indicator light in the switch illuminates.

Shield support 1 is activated.

Press switch S355 again.

Indicator light in the switch goes out.

The split shield 2 or the claw support 3 is activated.

3.3.9.2

Operating the shield support

Fig. 3-47

Operating the shield support

The support is operated using control lever 5.

To extend the support, push control lever 5 forwards a.

To retract the support, pull control lever 5 backwards b.

3.3.9.3

Operating the split shield / claw support The claw support and the split shield consist of two elements which are independent of each other and which can be individually moved. By varying the position of the elements, uneven ground can be evened out.

Fig. 3-48

Individual control

The support is operated using control lever 5.

3 - 46

MJFCIFSS

A 309 Litronic / 8720354

Operating instructions

Control, operation Working with the machine

Press and hold down pushbutton L. The left-hand element* can be moved individually.

Press and hold down pushbutton R. The right-hand element* can be moved individually.

To extend the element, move the control lever 5 forward a.

To retract the element, pull control lever 5 backwards b. * out of sight of the operator when working over the rigid axle (superstructure rotated 180°)

3.4 Working with the machine 3.4.1

Working with the machine safely lf with the peculiarities of the job site, the special regulations and warning signals. Part of the surrounding area includes, for example, the obstacles in the working or movement area, the load carrying capacity of the ground and required safeguards for the job site to shield it from public highway traffic. ground. reduced visibility and changing ground conditions. location of power lines on the job site and work particularly careful in their vicinity. If necessary, inform the responsible authorities. ment to come near cables when working near electrical overhead lines. Danger of fatal injury! Inform yourself about required safety distances.

cured. ads, paths or squares, observe the valid traffic regulations and, if necessary, first bring the machine into proper condition to meet federal and local highway standards. ions of poor visibility or darkness. machine (except on two way excavators).

are carried out immediately. brake system as outlined in the operating manual. ed while the engine is running.

A 309 Litronic / 8720354

MJFCIFSS

3 - 47

Control, operation

Operating instructions

Working with the machine

d operated in such way that the stability is ensured and that there is no danger of tipping over. Only known loads may be moved with the attachments, especially in grapple operation. close as possible to the ground.

EXCEPTION: see WHEN LOADING AND UNLOADING

uphill, never sideways on a slope. e permitted speed or you could loose control over the machine. to a lower gear. When doing this, the Diesel engine must run at maximum RPM and the speed may only be reduced using the accelerator pedals. rock protection is present. e operation, etc. always use protective devices specifically designed for this purpose. overview of and whenever necessary, ask for assistance of a guide. Have only one person signal you. ator. The guide must position himself within view of the operator or be in voice contact with him. nt combination, there can be a danger of collision becab, the cab protection or the boom cylinders. To avoid damage, utmost attention is required when the bucket teeth enter this range.

3.4.1.1

Safe application in material handling operation (especially when handling timber) with a raised attachment and picked up load, for example when handling wood or timber. machine upward in vertical direction. The travel behaviour of the machine will be strongly influenced, for example reduction of dynamic stability.

For that reason, the following rules must be strictly observed: changed machine characteristics and surrounding conditions. aking, acceleration, changes in travel direction.

uppercarriage in travel position. , there is a danger due to possible oscillating movements and falling of the picked up load. front on the cab. is a danger of falling objects from overhead. y be picked up with the grapple.

3 - 48

MJFCIFSS

A 309 Litronic / 8720354

Operating instructions

Control, operation Working with the machine

length, the diameter and the specific weight. The existing influencing factors for a natural product, such as moisture, must be considered. en working with machines with grapples require special instruction and training of the machine operator. sufficient training and practical experience.

3.4.1.2

Safe application of machines with tower elevation the center of gravity of the machine will shift upward in vertical direction. The travel and work behaviour of the machine will thereby be strongly influenced, for example reduction of dynamic stability. direction before starting to work. In horizontal direction, the center of gravity of the uppercarriage is above the center of the undercarriage, which reduces the danger of tipping over.

For that reason, the following rules must be strictly observed: When driving the machine:

ven road surfaces endanger the stability of the machine. center of gravity) and surrounding conditions. aking, acceleration, changes in travel direction. lengthwise direction, to avoid impermissible transverse slopes of the machine. ly!

In material handling operation: must be supported and horizontally aligned. pacity of ground). Sinking of an outrigger below ground level would result in devastating consequences!

(Caution! Oscillating grapple), while holding the load as close as possible to the undercarriage and above the ground. stated in the load chart.

3.4.1.3

Additional notes for machines with fixed oper vation lengthwise and horizontal direction. Position the uppercarriage to the undercarriage in such a way that the steps and ladders are aligned. ly sure that they are free of dirt, oil, ice and snow.

A 309 Litronic / 8720354

MJFCIFSS

3 - 49

Control, operation

Operating instructions

Working with the machine

NOTE: To ensure that the doors open in all weather conditions, lubricate the weather strips at least every two month, or more often, if necessary, with talcum powder or silicon. Lubricate the door hinges and locks regularly. three point support, i.e. always have two hands and one foot or two feet and one hand in contact with the entry system. climbing higher. External influences, such as wind, can make it more difficult to open the door. For that reason, always guide the door by hand when opening the door. Make sure that the door is engaged when it is open, to prevent it from banging open or closed. close the door and fasten the safety belt. and climbing up the machine. undercarriage in such a way that the steps and ladders are aligned. support. Climb down until you can close the door safely. Always guide the door by hand when closing the door.

3.4.1.4

Protection from vibrations manner of utilization. Especially the following parameters have a significant influence: braking, control of operating elements of the machine during travel as well as working. ation impact to a great part, since he himself selects the speed, the gear ratio, the working manner and the travel route.

This results in a wide range of various vibration impacts for the same machine type.

The full body vibration impact for the machine operator can be reduced if the following recommendations are observed: ent parts and auxiliary devices for the corresponding tasks. chines, for example hydraulic excavators, a seat which meets EN ISO 7096).

weight and the size of the operator. that the characteristics of the seat remain as specified by the seat manufacturer. sure, brakes, steering, mechanical connections, etc. machine in a jerky manner. el route to avoid vibration impacts.

3 - 50

MJFCIFSS

A 309 Litronic / 8720354

Operating instructions

Control, operation Working with the machine

n where the machine is working and travelling in good order:

able terrain conditions, keep machines available and allow for sufficient time. equently used for travel, utilize special auxiliary systems for travel (if installed), which reduce the vibration for this application.

If such auxiliary systems are not available, regulate the speed to keep the machine from "rocking".

3.4.2

Sensor controlled low idle automatic This device automatically reduces the engine RPM to low idle after 6 seconds, if no hydraulic functions are activated by the joystick or the pedals. This saves fuel and reduces noise. Touching the joystick or operating the pedals resets the engine RPM to its original setting.

Actuate the sensor controlled low idle automatic by pressing switch S20.

Press switch down.

The sensor controlled low idle automatic is activated.

The indicator light in the switch lights up.

Press switch up.

The sensor controlled low idle automatic is deactivated.

The indicator light in the switch turns off.

Caution!

The sensor controlled low idle automatic must be turned off when starting up the Diesel engine. The indicator light in the switch may not light up.

3.4.3

Operating the swing gear Caution!

The machine is delivered in series with PCSA controls.

On request, the machine can be equipped with a control system that deviates from the PCSA controls (e.g. LIEBHERR control). In this case, observe the additional operating instructions for this control.

The joystick functions described here refer exclusively to PCSA controls.

3.4.3.1

Turning the uppercarriage The uppercarriage is turned with the left joystick.

A 309 Litronic / 8720354

MJFCIFSS

3 - 51

Control, operation

Operating instructions

Working with the machine

Fig. 3-49

Turning the uppercarriage

Deflect the joystick to the left c.

The uppercarriage turns to the left.

Deflect the joystick to the right d.

The uppercarriage turns to the right.

3.4.3.2

Slowing the uppercarriage down The machine is equipped with a hydraulic and a mechanical swing gear brake.

Hydraulic swing gear brake Move the left joystick 4 to neutral.

The uppercarriage will be adequately slowed down hydraulically.

Move the left joystick 4 in the opposite direction.

The uppercarriage will be hydraulically slowed down to the maximum degree.

Positioning swing brake (option) The positioning swing brake is used for progressive and sensitive braking action of the uppercarriage.

Fig. 3-50

3 - 52

Positioning swing brake

MJFCIFSS

A 309 Litronic / 8720354

Operating instructions

Control, operation Working with the machine

Note!

Increased wear.

Do not use the positioning swing brake purely as an operating brake, only as a retaining and parking brake for the swing gear.

We recommend to slow down the uppercarriage hydraulically (by counter rotating).

Actuate the pedal 10.

The uppercarriage is located in the desired position after sensitive braking action.

3.4.4

Locking the superstructure

Fig. 3-51

Superstructure locking

When driving on public roads, transporting, taking out of service or carrying out maintenance and repair work, the superstructure must be locked to the chassis.

Locking of the superstructure happens automatically with the help of a hydraulic locking pin.

Locking: Rotate the superstructure in the direction of travel parallel to the chassis.

If necessary, correct the position of the superstructure until the locking pin 1 is located centrally to the pillow block 2.

Switch off servo control S35 or push the safety lever up.

The locking pin 1 extends, the superstructure is locked (B).

When the diesel engine is shut down, locking pin 1 also extends.

Unlocking: Switch on servo control S35 and push the safety lever down.

Locking pin 1 retracts, the superstructure is released (A).

A 309 Litronic / 8720354

MJFCIFSS

3 - 53

Control, operation

Operating instructions

Working with the machine

3.4.5

Working position

Fig. 3-52 Work with the machine is generally to be carried out over the rigid axle.

Fig. 3-53 1

Locking the oscillating axle

Retainer

6

Brake pedal

Caution!

Parking brake S16 may not be applied.

A buzzer sounds as a warning signal when the parking brake is applied.

Preselector switch S263 for travelling forward and reverse must be in position 0.

Press down fully on brake pedal 6 until the retainer 1 engages.

To lock the oscillating axle: Turn switch S75 to position I. The oscillating axle is completely locked.

- or Turn switch S75 to position A. Lock the oscillating axle via the brake pedal.

3 - 54

MJFCIFSS

A 309 Litronic / 8720354

Operating instructions

Control, operation Working with the machine

3.4.6

Joystick functions Caution!

The machine is delivered in series with PCSA controls.

On request, the machine can be equipped with a control system that deviates from the PCSA controls (e.g. LIEBHERR control). In this case, the additional operating instructions for this control system must be observed.

The joystick functions described here refer exclusively to PCSA controls.

3.4.6.1

Operating the stick cylinder The stick cylinder is operated using the left joystick 4.

Fig. 3-54

Operating the stick cylinder

Pull the joystick back a.

The stick will be retracted.

Push the joystick forwards b.

The stick will be extended.

3.4.6.2

Operating the boom cylinder The boom cylinder is operated using the right joystick 3.

Fig. 3-55

Operating the boom cylinder

Pull the joystick back g.

The attachment will be raised.

Push the joystick forward h.

The attachment will be lowered.

A 309 Litronic / 8720354

MJFCIFSS

3 - 55

Control, operation

Operating instructions

Working with the machine

3.4.6.3

Operating the bucket cylinder The bucket cylinder is operated using the right joystick 3.

Fig. 3-56

Operating the bucket cylinder

Push the joystick to the left e.

The bucket will be curled in.

Push the joystick to the right f.

The bucket will be curled out.

3.4.6.4

Operating the swing cylinder The swing cylinder is operated using the right joystick 3.

Fig. 3-57

Operating the swing cylinder

Press switch S63 on the right joystick down The control of the swing cylinder is activated.

The indicator light H186lights up.

Move the joystick to the left e.

The attachment swings to the the left.

Push the joystick to the right f.

The attachment swings to the right.

3.4.6.5

Operating the grapple cylinder The grapple cylinder is operated using the right joystick 3.

3 - 56

MJFCIFSS

A 309 Litronic / 8720354

Operating instructions

Control, operation Working with the machine

Fig. 3-58

Operating the grapple cylinder

Danger!

Never allow anyone to guide the grapple by hand!

Move the joystick to the left e.

The grapple will close.

Push the joystick to the right f.

The grapple will open.

3.4.6.6

Combined movements Moving a joystick diagonally allows a combination of the corresponding work functions. Thus different attachment movements can be actuated at the same time.

3.4.7

Lowering the attachment when the engine is not running In an emergency, the attachment can be lowered, even if the engine is not running.

Fig. 3-59

Lowering the attachment when engine is not running

Turn the ignition key to contact position 1.

Operate the joystick or the foot pedals until the attachment is lowered.

Note This reserve is limited and is only sufficient for small movements of the pilot control devices.

Move the joystick only in the direction for lowering the attachment.

A 309 Litronic / 8720354

MJFCIFSS

3 - 57

Control, operation

Operating instructions

Working with the machine

3.4.8

Turning, rotating, locking and unlocking the attachments Switch S19 is used to activate an additional function:

Fig. 3-60

Attachment examples

To operate, press the push button. The push buttons are located on the left and /or right joystick (depending on the machine configuration):

Fig. 3-61 E

Push button on the joystick

Operation with left joystick (standard)

F

Operation with left and right joystick (option)

Danger!

Never allow anyone to guide the grapple by hand!

Press switch S19 down.

Additional function (e.g. rotating grapple) is activated.

The indicator light in the switch lights up.

Press and hold left push button L. Grapple will rotate to the left (counterclockwise).

- or The rotating bucket is turned to the left (counterclockwise), i. e. it moves down to the left.

- or Locking pins will be extended.

3 - 58

MJFCIFSS

A 309 Litronic / 8720354

Operating instructions

Control, operation Working with the machine

Press and hold right push button R. Grapple will rotate to the right (clockwise).

- or The rotating bucket is turned to the right (clockwise), i. e. it moves down to the right.

- or Locking pins will be retracted.

3.4.9

Accessory kit AHS 12 (option) With accessory kit AHS 12, two additional users can be operated, i. e. the adjustable boom cylinder and one working tool (such as the hydraulic hammer) can be operated.

A

Caution!

Incorrect preselection of the pressure and flow setting can result in damage to the working tool (e.g. hydraulic hammer) or in limited function (e.g. adjustable boom cylinder).

Danger!

If a large or wide working tool (such as the grapple) is fluctuating in the vicinity of the cab, the cab could be touched or penetrated, which would endanger the operator.

Note!

If the machine is generally being used for hammer operation, there is a risk that the hydraulic oil becomes contaminated quicker than usual.

Adjust the maintenance intervals for hydraulic oil and filter cartridge changes for heavy dust application.

Fig. 3-62

Multi-function kit AHS 12

A suitable operating mode can be selected using switch S241. The switch has three positions: Press switch to position 0.

The adjustable boom cylinder is activated.

The attachment can be lowered or raised via the foot pedals m and k.

A 309 Litronic / 8720354

MJFCIFSS

3 - 59

Control, operation

Operating instructions

Working with the machine

Move switch to position 1 (center position).

The auxiliary user with high pressure is activated (e.g. sorting grapple, scrap cutter).

The indicator light H196 lights up.

Both foot pedals m and k full oil flow and full pressure.

Move switch to position 2 (final position).

The auxiliary user with reduced pressure (e.g. hydraulic hammer, ram) is activated.

The indicator light H196 turns off.

The indicator light in the switch lights up.

The right foot pedal k is pressure and flow reduced, the left foot pedal m full oil flow and pressure.

Operate the attachment using pedals m and k.

Push foot pedal k down: The adjustable boom cylinder will be extended, i.e. the attachment moves up.

- or Scrap cutter or sorting grapple will be closed.

- or The hydraulic hammer is activated.

Push foot pedal m down: The adjustable boom cylinder will be extended, i.e. the attachment moves up.

- or Scrap cutter or sorting grapple will be opened.

3.4.10 3.4.10.1

Overload warning device General The overload warning device shows the machine operator when the permissible load carrying capacity has been reached, both optically via the indicator light H16 and acoustically, via a buzzer.

The overload warning device is designed to prevent the permissible load level from being exceeded unintentionally. In this event, the working range must be reduced or the load must be set down without increasing the working range.

The overload warning device does not relieve the operator of the responsibility of lifting only known loads or permissible loads, based on the load carrying capacity of the machine.

The permissible load carrying capacity depends on the condition of the machine (undercarriage, attachment) and must be taken from the load chart in the cab.

The load carrying capacity values attain a maximum of 75% of the tipping capacity or 87 % of the hydraulic lifting power in accordance with ISO 10567.

Note!

The load values change due to the installation or removal of attachment parts and working tools.

For backhoe attachment (without the backhoe, incl. bucket cylinder, change over lever and connecting link) the values on the top of the stick apply. The machine can be turned by 360° on solid, level ground. If the bucket cylinder, change over lever and connecting link are removed, the values increase by an additional 240 kg. If a quick change adapter is used, the values are reduced by 116 kg (QCA 33) or 225 kg

3 - 60

MJFCIFSS

A 309 Litronic / 8720354

Operating instructions

Control, operation Working with the machine

(QCA 48).

3.4.10.2

Operating principle Danger!

When carrying out load lifting work with the machine, the applicable accident prevention regulations must be observed.

The overload warning device does not shut down the machine if the permissible load level is exceeded. The machine operator is only informed of the situation.

The overload warning device consists of a simple pressure switch, which is connected to the piston side of the hoist cylinder.

If the load pressure in the hoist cylinder reaches the level of the shift pressure, the pressure switch emits a signal, the indicator light H16 lights up and the buzzer sounds.

The shift pressure in the pressure switch is selected in such a way that the stability factors can be maintained, even in unsupported condition (small stability momentum).

3.4.10.3

Operation Danger!

No load lifting work may be carried out if the overload warning device is defective.

The overload warning device must be repaired by an expert technician.

The overload warning device is activated via switch S18 in the control panel A in the right control console.

Press switch S18 down.

The overload warning device is activated.

The indicator light in the switch lights up.

Note!

The overload warning device must be checked before the first use and annually by an expert technician in accordance with the inspection and adjustment guidelines provided in the service manual.

The operator must check the function of the overload warning device before each work shift.

To check the overload warning device, extend the hoist cylinder to the stop.

Continue to move the joystick in the direction Raise boom.

The warning symbol must light up.

The buzzer must sound.

Note!

Deactivate the overload warning device when working with a digging tool, since the increased effort of the machine will cause the overload warning device to be constantly active.

Press switch S18 up.

The overload warning device is deactivated.

The indicator light in the switch turns off.

A 309 Litronic / 8720354

MJFCIFSS

3 - 61

Control, operation

Operating instructions

Installation and removal of attachment parts

3.5 Installation and removal of attachment parts 3.5.1

Safe installation and removal of attachment parts

machine without prior written approval by LIEBHERR. LIEBHERR must be provided with the required technical documentation necessary for this purpose. parts, which are supplied via the machine's hydraulics system, such as an attachment with cylinder movement, it must be ensured that different types of oil are not mixed together.

Mixing environmentally friendly hydraulic oils made by different manufacturers as well as mixing them with mineral oils must be avoided.

long as it is not safely resting on the ground or is not properly supported with wooden beams. and with the starter key in contact position actuate both joysticks as well as the itable lifting devices with sufficient load carrying capacity. gloves when handling wire cables. engine off and raise the safety lever.

When working on the attachment, never align bores with your fingers, always use a suitable alignment tool. lic lines are properly attached and that all fittings and connections are properly tightened. in the hydraulic circuit to prevent dirt infiltration. Permit only authorized persons near the machine or the lifting device.

3.5.2

Safe removal and installation of attachment pins lling device to push out the pins on the attachment. held by another person. of the pin and hit the screw only. first to the stop, then install the castle nut by hand until contact and tighten it only to the point where the cotter pin can be installed.

3 - 62

MJFCIFSS

A 309 Litronic / 8720354

Operating instructions

Control, operation Installation and removal of attachment parts

3.5.3

Installation and removal of digging tool

Fig. 3-63

Installation and removal of digging tools

The following is a description of the installation and removal of digging tools. Digging tools include backhoe bucket, ditch cleaning buckets or ripper.

3.5.3.1

Removing the digging tool Position the attachment in such a way that the entire bottom part of the digging tool is laying on the ground.

Unscrew the locking plate 5 and remove the locking plate 6 and knock out pin 3 and pin 4.

If necessary, raise the attachment slightly when knocking out pin 4 to relieve it.

3.5.3.2

Installing a new digging tool Position the digging tool to be installed in such a way that its entire flat bottom is laying on the ground.

Start the engine and move the attachment until the bucket stick bearing and the bearing points 1 of the digging tool are aligned.

Guide in pin 4 and secure it with plate 6.

Extend the bucket cylinder slowly until the bore hole in the connecting link 7 is located precisely between the bearing points 2.

Guide in pin 3 and secure it with plate 5.

A 309 Litronic / 8720354

MJFCIFSS

3 - 63

Control, operation

Operating instructions

Installation and removal of attachment parts

Grease all lube points on pins 3 and 4 until clean grease emerges on the corresponding bearing points.

3.5.3.3

Bucket cylinder operation Two hydraulic lines on the stick are used either for bucket cylinder operation or grapple operation.

The lines are switchable via a valve block 15: a - Bucket cylinder operation (for digging tools) b - Grapple operation (for grapple, scrap cutter etc.)

Turn the both square head bolts on valve block 15 in such a way that the markings are positioned transverse to the travel direction (position a, bucket cylinder operation).

Note!

If the machine is equipped with a hydraulic quick change adapter and LIKUFIX, it is not necessary to switch between bucket cylinder operation and grapple operation. There is no valve block 15.

3 - 64

MJFCIFSS

A 309 Litronic / 8720354

Operating instructions

Control, operation Installation and removal of attachment parts

3.5.4

Installation and removal of grapple on stick

Fig. 3-64

A 309 Litronic / 8720354

Installation and removal of grapple on stick

MJFCIFSS

3 - 65

Control, operation

Operating instructions

Installation and removal of attachment parts

Before installing a clamshell bucket or multiple tine grab, make sure that the required hydraulic lines for grapple operation are installed on the stick.

The installation and removal of the grapple must be carried out by two people.

Danger!

Danger of injury.

Ensure that the machine operator follows the hand signal given by the guide when moving the attachment.

3.5.4.1

Installing the grapple If necessary, remove the digging tool.

Retract the bucket cylinder to the stop.

Install screws 8 between connecting link 7 and the change over lever 9.

Position the grapple with fully opened shells.

Move the attachment to bring the lower mount of the stick between the bearing points of the grapple suspension 1.

Guide in pin 4 and secure it with plate 6.

Connect hydraulic hose 11 and hydraulic hose 12 for the shell cylinder supply to the pipes for the bucket cylinder.

For a grapple with a hydraulic rotating grapple drive, also connect hoses 13 and 14 to the pipes for this auxiliary device.

3.5.4.2

Grapple operation Two hydraulic lines on the stick are used either for bucket cylinder operation or grapple operation.

The lines are switchable via a valve block 15: a - Bucket cylinder operation (for digging tools) b - Grapple operation (for grapple, scrap cutter etc.)

Turn the both square head bolts on valve block 15 in such a way that the markings are positioned in travel direction (position b, grapple operation).

Note If the machine is equipped with a hydraulic quick change adapter and LIKUFIX, it is not necessary to switch between bucket cylinder operation and grapple operation. There is no valve block 15.

Carry out all work movements several times without a load (open and close the shells or turn the grapple to the left and to the right) to remove any air in the hydraulic circuits.

3.5.4.3

Removing the grapple Set down the grapple on level ground with fully opened shells.

Shut down the engine and, with the ignition key in the contact position, move the right joystick briefly to the left and then to the right to relieve the pressure in the hydraulic circuits.

To relieve the grapple rotator press the two push buttons in the left (or left and

3 - 66

MJFCIFSS

A 309 Litronic / 8720354

Operating instructions

Control, operation Installation and removal of attachment parts

Raise the safety lever.

Disconnect hydraulic hose 11, hydraulic hose 12 and, if present, hydraulic hoses 13 and 14 from the pipes on the stick.

Close off open lines immediately to prevent dirt infiltration.

Support the grapple so that it is stable.

Remove the plate 6 and carefully knock out pin 4. If necessary, start the engine and raise the attachment slightly.

3.5.5

Fitting/removing the Passfix bolts Some equipment parts have bearing points fitted with so-called Passfix bolts. These bolts should be fitted and removed as described below.

Fig. 3-65

Overview Passfix bolts

1 2

Bolts Clamping bushing

3

Conical spring washer

4 5

Lock washer Clamping screw

Removing the Passfix bolts:

Fig. 3-66

A 309 Litronic / 8720354

Pull-off tool and removal procedure

MJFCIFSS

3 - 67

Control, operation

Operating instructions

Installation and removal of attachment parts

6

Adapter

7

Puller

8

Pulling screw

Remove clamping screw 5, lock washer 4 and conical spring washer 3 on both sides.

Depending on the size of clamping bushing 2 turn the supplied puller 7 with or without using adapter 6 into clamping bushing 2.

Screw in pulling screw 8 as far as possible.

Tighten pulling screw 8 whilst holding puller 7 using a suitable spanner to ensure that bolt 1 and clamping bushing 2 are fully tensioned (A).

Forcefully hit the the head of the pulling screw 8 with a hammer (B).

The clamping bushing should come off.

If this is not the case, further tighten pulling screw 8 and try using the hammer again to loosen the bushing.

Repeat this procedure on the other side.

Fitting the Passfix bolts: Note!

The hole near clamping bushing 2, the clamping bushing and the conical surface of bolt 1 must be free of grease.

Insert bolts 1 into the equipment and ensure it is centred.

Fit the clamping bushings on both sides 2.

Note!

The clamping bushing 2 must be fitted with the slit showing at the bottom (improved corrosion protection).

Fit clamping screw 5, lock washer 4 and conical spring washer 3 on both sides.

Hand-tighten clamping screws 5 on both sides. Ensure that bolt 1 remains centred.

The bushings must be under tension.

Tighten clamping screws 5 on both sides (400 Nm) using a torque wrench.

3.5.6 3.5.6.1

Mechanical quick change adapter (option) Safety instructions and removal of working tools. Move the attachment as slowly as possible when installing or removing a working tool.

Familiarize yourself with the operating principle of the quick change adapter before installing or removing any working tools. the ground as possible when locking and unlocking to avoid dangerous movements. stand on the working tool or attachment.

3 - 68

MJFCIFSS

A 309 Litronic / 8720354

Operating instructions

Control, operation Installation and removal of attachment parts

machine operator must ensure that the locking pins for the quick change adapter are inserted in the proper bore holes on the working tool and that the working tool is attached properly. Check visually to ensure that the working tool is tightly seated. e tool, but only lift the tool to the point where the seating can be checked, for example the pin in the pin eye, by curling the bucket in and out. to ensure it is still seated tightly. hook can exceed or fall below the load carrying capacity of the carrier machine.

During operation, make sure that the values given in the load chart and the technical data of the carrier machine are adhered to.

3.5.6.2

Overview

Fig. 3-67

3.5.6.3

Mechanical quick change adapter

1

Locking pin (extended)

3

Crank

5

Load hook

2

Locking screw

4

Plug

6

Pick-up hook for working tool

Attaching the working tool Bring the equipment into position:

Fig. 3-68

Positioning the attachment

The working tool must be in stable position or lying loosely on the ground.

Move the stick and working tool into position.

Retract the bucket cylinder fully.

A 309 Litronic / 8720354

MJFCIFSS

3 - 69

Control, operation

Operating instructions

Installation and removal of attachment parts

To unlock the quick change adapter: Danger!

Danger of injury!

Ensure that the attachment or tool cannot be moved by others when this action is being carried out.

Approach the quick change adapter from the side and unscrew the locking screw 2 from the locking pin 1 using the crank 3 (see Fig. 3-67).

Insert the crank 3 in the locking pin 1 and turn to the left (counterclockwise) until both locking pins 1 are retracted completely.

Picking up the working tool:

Fig. 3-69

Picking up the working tool

Move the quick change adapter into a position that allows the working tool to be picked up with the pick-up hook.

Lift the working tool off the ground and fully extend the bucket cylinder until the bearing plate for the working tool is resting on the quick change adapter stop.

The bore holes of the working tool and the locking pins of the quick change adapter must be aligned.

To lock the quick change adapter:

Fig. 3-70

3 - 70

Locking the quick change adapter

MJFCIFSS

A 309 Litronic / 8720354

Operating instructions

Control, operation Installation and removal of attachment parts

Danger!

Prior to locking, there is no fixed connection between the working tool and the quick change adapter. The working tool could under certain circumstances fall out and injure people.

Approach the quick change adapter with the utmost caution.

Raise the safety lever to secure the attachment against unintentional movement.

No work movements can be carried out when pilot control devices, e.g. the joystick or foot pedals, are operated.

Insert the crank 3 in the locking pin 1 and turn to the right (clockwise), until both locking pins 1 are fully extended.

If properly picked up, the working tool is now connected.

Screw the locking screw 2 into the locking pin.

Danger!

An incorrectly locked quick change adapter could open during operation!

Ensure that the locking pins are always closed off by the plug 4 on the one side and by the locking screw 2 on the other side.

Check daily to ensure that the locking screw 2 is seated tightly.

Caution!

Hydraulic lines are pressurized!

Before connecting the hydraulic lines, release the pressure using the joystick (shut down the Diesel engine, turn the ignition key to the contact position, operate the joystick).

Connect the hydraulic lines or electrical lines, if necessary (e.g. for grapple installation).

3.5.6.4

Removing a working tool Bring the equipment into position: Caution!

Hydraulic lines are pressurized!

Before disconnecting the hydraulic lines, release the pressure using the joystick (shut down the Diesel engine, turn the ignition key to the contact position, operate the joystick).

Disconnect hydraulic lines or electrical lines, if necessary (e.g. for removal of grapple).

Extend the bucket cylinder fully.

A 309 Litronic / 8720354

MJFCIFSS

3 - 71

Control, operation

Operating instructions

Installation and removal of attachment parts

To unlock the quick change adapter:

Fig. 3-71

Unlocking the quick change adapter

Danger!

Danger of injury!

Once unlocked, there is no fixed connection between the adapter and the working tool. The working tool could work itself out independently.

Ensure that the attachment or tool cannot be moved by others when this action is being carried out.

During the unlocking procedure, always keep the working tool as close to the ground as possible to avoid dangerous movements.

Approach the quick change adapter from the side and unscrew the locking screw 2 from the locking pin 1 using the crank 3.

Insert the crank 3 in the locking pin 1 and turn to the left (counterclockwise) until both locking pins 1 are retracted completely.

To place down the working tool:

Fig. 3-72

Placing the work tool down

Slowly retract the bucket cylinder and place the working tool down on the ground.

The new working tool can be picked up.

3 - 72

MJFCIFSS

A 309 Litronic / 8720354

Operating instructions

Control, operation Installation and removal of attachment parts

3.5.6.5

Using the quick change adapter for load lifting work

Fig. 3-73

Mechanical quick change adapter

The quick change adapter is equipped with two integrated load hooks. The machine may only be used for load lifting work if the safety devices required for this purpose are present and functioning correctly (see The maximum load carrying capacity of each individual load hook is stated on the quick change adapter. The load carrying capacity of the quick change adapter or the integrated load hook can exceed or fall below the load carrying capacity of the carrier machine.

During operation, make sure that the values given in the load chart and the technical data of the carrier machine are adhered to.

Load lifting work can be carried out with attached or removed working tools. With removed working tools, it is appropriate to fully retract the locking pins when carrying out lifting work. This prevents the load lift device from being deflected too strongly and damaged by the locking pins.

Danger!

Never use the pick-up hook 6 to fasten a load, because there is no secure hold for the load pick-up device, e.g. ropes or chains, in the pick-up hook.

3.5.7 3.5.7.1

Hydraulic quick change adapter (option) Safety instructions and removal of the working tools. Move the work equipment as slowly as possible when attaching and dismounting a working tool.

Familiarize yourself with the control and operating principle of the quick change adapter before installing or removing any working tools. adapter is monitored by a visual and acoustic warning device (buzzer and indicator light). The function of the warning device should be checked daily by operating the quick change adapter. ing or unlocking procedure, stop all work at once. If the buzzer and indicator light are not activated while a deliberate locking or unlocking procedure is being carried out, stop all work at once.

A 309 Litronic / 8720354

MJFCIFSS

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Control, operation

Operating instructions

Installation and removal of attachment parts

This could be caused by an uncontrolled position change of the locking pins, due to mechanical or hydraulic damage. A defect may also be present in the electrical system (e.g. proximity switch or buzzer).

Resume operation only after any defective parts have been repaired or replaced. purpose is pressed.

Always keep the working tool as close to the ground as possible during the unlocking procedure to avoid dangerous movements. Activate the quick change adapter only to carry out a deliberate locking or unlocking procedure. e machine operator must ensure that the locking pins for the quick change adapter are inserted in the proper bore holes on the working tool and that the working tool is attached properly. Check visually to ensure that the working tool is tightly seated. e tool, but only lift the tool to the point where the seating can be checked, for example the pin in the pin eye, by curling the bucket in and out. ck change adapter or the integrated load hook can exceed or fall below the load carrying capacity of the carrier machine.

During operation, make sure that the values given in the load chart and the technical data of the carrier machine are adhered to.

3.5.7.2

Overview

Fig. 3-74 1

3 - 74

Hydraulic quick change adapter

Locking pin (extended)

5

Load hook

MJFCIFSS

6

Pick-up hook for working tool

A 309 Litronic / 8720354

Operating instructions

Control, operation Installation and removal of attachment parts

3.5.7.3

Operating elements

Fig. 3-75

Operating elements for the hydraulic quick change adapter

Use switch S19 to activate the auxiliary hydraulic device for the grapple rotator and quick change adapter.

Press switch down.

The auxiliary hydraulic device is activated.

The indicator light in the switch lights up.

Press switch up The auxiliary hydraulic device is deactivated.

The indicator light in the switch turns off.

Press button S47 to activate the quick change adapter function.

Press the button down and hold.

The quick change adapter is activated.

The indicator light in the button lights up.

Press push buttons L and R to lock and unlock the work tool.

The indicator light H26 lights up during the unlocking procedure or when the locking pins are retracted. The buzzer in the cab sounds simultaneously.

3.5.7.4

Two-hand operation The quick change adapter is activated via a two-hand control. The locking pins can only be moved at first if button S47 is pressed and held down and one of the push buttons L or R are pressed simultaneously.

The control is equipped with a retaining function, allows both joysticks to be operated simultaneously for the installation or removal of working tools. If one of the push buttons, L or R is continually pressed, then button S47 can be released and the direction of movement of the locking pins is retained.

If the direction of movement is to be changed, the key switch S47 must be pressed down again and the corresponding push button L or R must be pressed.

A 309 Litronic / 8720354

MJFCIFSS

3 - 75

Control, operation

Operating instructions

Installation and removal of attachment parts

3.5.7.5

Attaching the working tool Bring the equipment into position:

Fig. 3-76

Bringing the equipment into position

The working tool must be in stable position or lying loosely on the ground.

Bring the stick and working tool into position.

Retract the bucket cylinder fully.

To unlock the quick change adapter: Press switch S19 down.

The auxiliary hydraulic device is activated.

The indicator light in the switch lights up.

Press and hold button S47 down.

The hydraulic quick change adapter is activated.

The indicator light in the switch lights up.

On the left joystick 4, press and hold the right push button R down until the locking pins are fully retracted.

The buzzer sounds.

The indicator light H26 lights up.

The quick change adapter is unlocked.

To pick up the working tool:

Fig. 3-77

Picking up the working tool

Move the quick change adapter into a position that allows the working tool to be picked up with the pick-up hook.

Lift the working tool off the ground and fully extend the bucket cylinder until the bearing plate for the working tool is resting on the quick change adapter stop.

The bore holes of the working tool and the locking pins of the quick change adapter must align.

3 - 76

MJFCIFSS

A 309 Litronic / 8720354

Operating instructions

Control, operation Installation and removal of attachment parts

To lock the quick change adapter: Press switch S19 down.

The auxiliary hydraulic device is activated.

The indicator light in the switch lights up.

Press and hold button S47 down.

The quick change adapter is activated.

The indicator light in the switch lights up.

On the left joystick 4, press and hold the left push button L down until the locking pins are fully extended.

The buzzer turns off.

The indicator light H26 turns off.

The quick change adapter is locked.

If properly picked up, the working tool is now connected.

Release button S47.

The hydraulic quick change adapter is deactivated.

The indicator light in the switch turns off.

Press switch S19 up.

The auxiliary hydraulic device is deactivated.

The indicator light in the switch turns off.

Caution Hydraulic lines are pressurized!

Before connecting the hydraulic lines, release the pressure using the joystick (shut down the Diesel engine, turn the ignition key to the contact position, operate the joystick).

Connect hydraulic lines or electrical lines, if necessary. (e.g. for grapple installation).

A direct visual check must be made to ensure that the working tool is seated tightly. also be performed with the working tool.

This means that the working tool should be raised before use to the point where tight seating of, for . example, the pin in the pin eye, can be checked by curling in and out.

Danger!

The electronic monitoring system for the quick change adapter displays defective functions. This could be caused by an uncontrolled position change of the locking pins, due to mechanical or hydraulic damage. A defect may also be present in the electrical system (e.g. proximity switch or buzzer).

If the buzzer and indicator light are activated without initiation of a deliberate locking or unlocking procedure, stop all work at once.

If the buzzer and indicator light are not activated while a deliberate locking or unlocking procedure is being carried out, stop all work at once.

Only resume working only after any defective parts have been repaired or replaced.

Perform the working cycle.

Before starting to use the working tool (e.g. grapple, ditch cleaning bucket), the special installation guidelin

A 309 Litronic / 8720354

MJFCIFSS

3 - 77

Control, operation

Operating instructions

Installation and removal of attachment parts

3.5.7.6

Removing a working tool Bring the equipment into position: Caution Hydraulic lines are pressurized!

Before disconnecting the hydraulic lines, release the pressure using the joystick (shut down the Diesel engine, turn the ignition key to the contact position, operate the joystick).

Disconnect hydraulic lines or electrical lines, if necessary (e.g. for removal of grapple).

Extend the bucket cylinder fully.

To unlock the quick change adapter: Danger!

Danger of injury!

Once unlocked, there is no fixed connection between the adapter and the working tool. The working tool could work itself out independently.

During the unlocking procedure, always keep the working tool as close to the ground as possible to avoid dangerous movements.

Press switch S19 down.

The auxiliary hydraulic device is activated.

The indicator light in the switch lights up.

Press and hold button S47 down.

The quick change adapter is activated.

The indicator light in the switch lights up.

On the left joystick 4, press and hold the right push button R down until the locking pins are fully retracted.

The buzzer sounds.

The indicator light H26 lights up.

The quick change adapter is unlocked.

To place down the working tool:

Fig. 3-78

Placing the work tool down

Slowly retract the bucket cylinder and place the working tool down on the ground.

The new working tool can be picked up.

3 - 78

MJFCIFSS

A 309 Litronic / 8720354

Operating instructions

Control, operation Installation and removal of attachment parts

3.5.7.7

Using the quick change adapter for load lifting work

Fig. 3-79

Hydraulic quick change adapter

The quick change adapter is equipped with two integrated load hooks. The machine may only be used for load lifting work if the safety devices required for this purpose are present and functioning correctly (see The maximum load carrying capacity of each individual load hook is stated on the quick change adapter. The load carrying capacity of the quick change adapter or the integrated load hook can exceed or fall below the load carrying capacity of the carrier machine.

During operation, make sure that the values given in the load chart and the technical data of the carrier machine are adhered to.

Load lifting work can be carried out with attached or removed working tools. With removed working tools, it is appropriate to fully retract the locking pins when carrying out lifting work. This prevents the load lift device from being deflected too strongly and damaged by the locking pins.

Danger!

Never use the pick-up hook 6 to fasten a load, because there is no secure hold for the load pick-up device, e.g. ropes or chains, in the pick-up hook.

Before load-lifting work, deactivate the quick change adapter.

Switches S19 and S47 are pushed up.

The indicator lights in the switches are turned off.

3.5.7.8

Quitting the buzzer (warning tone) The indicator light H26 and the buzzer (warning tone) indicate that the quick change adapter is not locked or is incorrectly locked.

After placing down the work tool, the buzzer (warning tone) continues to sound as long as the locking pins remain retracted.

When the overload warning device is switched on, the warning tone for the quick change adapter can be quitted.

If no new working tool is to be taken up, it is sensible to switch off the warning tone so avoid constant noise disturbance. Also, another buzzer (overload warning device) can be heard more easily.

A 309 Litronic / 8720354

MJFCIFSS

3 - 79

Control, operation

Operating instructions

Installation and removal of attachment parts

Press switch S360.

The buzzer is turned off.

The indicator light H26 lights up.

The acoustic warning device will only activate automatically if the locking pins have been extended again.

To reactivate the warning tone for the quick change adapter, fully extend the locking pins until the indicator light H26 turns off.

The buzzer (warning tone) for monitoring the quick change adapter is reactivated.

3.5.8

LIKUFIX Hydraulic coupling system (option) LIKUFIX enables automatic coupling of hydraulic lines in connection with the hydraulic quick change adapter. The machine operator does not need to connect or disconnect hydraulic lines for working tools himself.

3.5.8.1

Overview

Fig. 3-80

3.5.8.2

LIKUFIX

1

Protective cover on quick change adapter

4

LIKUFIX hydraulic coupling on working tool

2

Protective cover on working tool

5

Alternative hydraulic connection on working tool

3

LIKUFIX hydraulic coupling on quick change adapter

Installation and removal of working tools Installation and removal is carried out as described in the chapter "Hydraulic quick change adapter".

3 - 80

MJFCIFSS

A 309 Litronic / 8720354

Operating instructions

Control, operation Installation and removal of attachment parts

Fig. 3-81

Connecting LIKUFIX

In addition, note the following: Before installation, remove the protective covers on the quick change adapter 1 and the working tool 2.

Always keep hydraulic couplings 3 and 4 clean.

Perform a visual check for cleanliness before installation. If necessary, clean all coupling parts and the sealing surfaces with a clean, oil-soaked cloth.

When changing a work tool, connect or disconnect the hydraulic coupling slowly.

When attaching the quick change adapter, tilt it until the coupling plates are connected due to the curb weight of the working tool.

Extend the locking pins.

If the plates do not connect as a result of curb weight, foreign objects (such as stones) may be the cause. In this case, clean all coupling parts to prevent damage when connecting.

The oil flow and pressure must be matched to the corresponding work tool.

When the work is completed, and particularly before transport, reattach the protective covers 1 and 2.

3.5.8.3

Installing LIKUFIX work tools to a quick change adapter without LIKUFIX It is possible at any time to attach a working tool with a LIKUFIX hydraulic coupling to a machine with a quick change adapter (mechanical or hydraulic).

Fig. 3-82

A 309 Litronic / 8720354

LIKUFIX work tool on quick change adapter without LIKUFIX

MJFCIFSS

3 - 81

Control, operation

Operating instructions

General working methods

Caution!

The LIKUFIX hydraulic coupling could be damaged.

Do not use a quick change adapter with a reinforcement kit, since the reinforced steel part 6 could damage the LIKUFIX hydraulic coupling on the work tool.

In this case, the quick-change adapter must be modified by LIEBHERR Service.

For installation without LIKUFIX hydraulic coupling, LIEBHERR work tools usually have an alternative connection option.

Example: On the ditch cleaning bucket, the hydraulic lines are either connected using LIKUFIX 4 or using an auxiliary hydraulic connection 5.

3.6 General working methods 3.6.1

Guidelines for minimum impact working methods To increase the service life of the machine and avoid unnecessary damage and resulting repairs, please observe the following points: by stopping the attachment against the walls of the ditch. against the material to be removed, even lengthwise. Repeatedly hitting the work equipment against rocks or other hard material will lead to damage to the steel parts and machine components. nd work tool, the work tool can hit or penetrate the cab. This could damage the cab and injure the machine operator. rocky material. This will extend the work cycles and could result in damage to the bucket as well as other machine components.

RR dealer if special teeth for heavy or special applications are required. ill into material is not permitted. this should occur, slowly lower the machine to the ground. Do not permit the machine to drop to the ground quickly and do not catch the downward movement with the hydraulics, since this could result in damage to the machine.

3.6.2

Preparatory activities Danger!

Risk of fatal injury and damage to the machine when working.

Observe the safety information "Notes for safe working" at the beginning of these operating instructions.

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MJFCIFSS

A 309 Litronic / 8720354

Operating instructions

Control, operation General working methods

Fig. 3-83 Position the machine so that the load or the digging material can be picked up over the rigid axle or the idler.

For mobile excavators, lower the support when possible and lock the oscillating axle.

Danger!

Insufficient support and machine damage.

Do not use a dozer blade to support the machine.

Fig. 3-84

Safe working

Danger!

Risk of fatal injury due to slewing of the machine.

Ensure that there is no-one within the danger zone r of the machine.

Caution!

Risk of injury when working.

Always wear safety boots and a safety helmet and safety glasses, particularly when leaving the cab during demolition work.

Always wear the seat belt.

Use the horn to give a short warning signal before starting work.

A 309 Litronic / 8720354

MJFCIFSS

3 - 83

Control, operation

Operating instructions

General working methods

3.6.3

Working with the backhoe bucket Danger!

Risk of fatal injury and damage to the machine when moving the backhoe bucket.

Make sure that the backhoe bucket is not moved too close to the cab.

The backhoe bucket can damage the cab and injure the machine operator.

Make sure that there is no-one in the danger zone of the backhoe bucket.

When working with the backhoe bucket, do not apply parking brake S16.

The travel gear could be damaged.

The machine must be in working position.

Fig. 3-85

Aligning, taking up the digging material, lifting

Aligning the stick and backhoe bucket (1) Align the stick in such a way that its underside is at an angle of approx. 45° to the ground.

Align the backhoe bucket in such a way that its bottom can penetrate the ground at an angle of approx. 90°.

Taking up digging material (2): To lift out the digging material, slowly and evenly pull the stick in and slowly and evenly rotate the backhoe bucket simultaneously.

As soon as the stick is perpendicular to the ground, raise the boom slowly and evenly, in addition to pulling in the stick and backhoe bucket. Stopping suddenly will result in impact loads and vibrations.

Lifting digging material (3): When the backhoe bucket is full or the stick can no longer be pulled in, raise the boom and backhoe bucket until the filling surface is parallel to the ground.

3 - 84

MJFCIFSS

A 309 Litronic / 8720354

Operating instructions

Control, operation General working methods

3.6.4

Loading the transport vehicle Danger!

Risk of fatal injury due to falling digging material.

Do not load the transport vehicle so high that the digging material falls over the walls of the vehicle.

Make sure that there is no-one within the danger zone or in the transport vehicle when loading.

Fig. 3-86

Emptying digging material

If possible, the machine should be positioned higher than the transport vehicle to avoid having to lift the digging material unnecessarily.

Position the transport vehicle in such a way that it can be loaded from the rear or from the side.

Move the attachment of the machine over the loading surface of the transport vehicle.

Distribute the digging material evenly over the loading area of the transport vehicle by moving the backhoe bucket and stick out, turning the superstructure and possibly also moving the boom.

If the backhoe bucket is not sufficiently emptied or there is still digging material in the backhoe bucket, curl the backhoe bucket in and out several times to loosen the digging material.

3.6.5

Working with the hydraulic hammer Please also refer to the operating instructions provided by the manufacturer of the hydraulic hammer.

A 309 Litronic / 8720354

MJFCIFSS

3 - 85

Control, operation

Operating instructions

General working methods

Danger!

Misuse of the hydraulic hammer can injure people or damage the machine.

The use of an unapproved hydraulic hammer could damage steel parts or other machine components.

Only use hydraulic hammers approved by LIEBHERR. Close all windows in the cab before working.

Use the hydraulic hammer only to break up rocks, concrete and other breakable materials.

Do not try to break up rocks or concrete by moving the lever on the work equipment or by the hydraulic hammer.

Do not use the drop power of the hydraulic hammer to break up rocks or other materials.

Do not move any objects with the hydraulic hammer, and do not lift to the machine with the hydraulic hammer.

Only use the hydraulic hammer in t Do not operate the hydraulic hammer pointing in the direction of the machine, since exploding rocks or concrete could damage the machine and / or injure the driver.

Fig. 3-87

Hydraulic hammer

The machine must be positioned in the working position on level, solid ground.

The stick may not be positioned vertically.

No cylinder may be fully retracted or extended.

Do not operate the hydraulic hammer on the same spot continually or for longer than 15 seconds.

Excessive continuous operation of the hydraulic hammer causes unnecessary overheating of the hydraulic oil.

Change the position of the machine and resume hammer operations.

3 - 86

MJFCIFSS

A 309 Litronic / 8720354

Operating instructions

Control, operation General working methods

Fig. 3-88

Permissible A and not permissible B work areas for machine with a hydraulic hammer

Danger!

The stability of the machine could be affected.

When using a hydraulic hammer, only work with the machine in area A.

3.6.6

Grading Grading work can either be carried out using the digging tool or with a dozer blade (option).

Fig. 3-89

Grading

The machine must be in working position.

The outriggers should be raised.

Danger!

Serious risk of injury when moving the machine.

Make sure that there is no-one within the working range of the machine.

Caution!

The machine could be damaged.

Never move the machine as long as the attachment is touching the ground.

A 309 Litronic / 8720354

MJFCIFSS

3 - 87

Control, operation

Operating instructions

General working methods

To grade with a backhoe bucket, place it flat on the ground (see Fig. 3-89) and move the stick slowly forward and backward. Move the boom evenly up and down while the stick is moving.

If a dozer blade is installed (option), lower the dozer blade to the ground and move slowly forward and backward with the machine.

3.6.7

Working with the grab Danger!

Risk of fatal injury and damage to the machine due to an oscillating grab.

ine could be affected.

Ensure that the grab does not swing too close to the cab.

Hold the stick in such a way that the grab cannot swing towards the machine when travelling or slowing the machine down.

Move the joystick slowly and evenly to prevent the grab from swinging.

Ensure that the grab does not swing toward any persons in the working area.

Do not lift a load if the boom and stick are extended too far and do not swing a heavy load too far to the left or right.

Observe the load chart: This shows the permissible load carrying capacities at the end of the stick, depending on working radius.

3.6.7.1

Clamshell grab (construction equipment) The machine must be in working position.

Fig. 3-90

Align the stick, close the clamshell grab, lift the digging material

Align the stick (1): Open the clamshells fully.

Lower the stick perpendicular to the excavation area.

3 - 88

MJFCIFSS

A 309 Litronic / 8720354

Operating instructions

Control, operation General working methods

Closing the clamshells (2): Danger!

When closing, the shell type bucket can lift the machine. The machine could roll away!

Avoid lifting the machine when closing the grab, by raising the stick sufficiently.

Close the clamshells.

Raise the stick slightly to reduce ground pressures.

Lifting digging material (3): Close the clamshells fully.

Raise the boom.

Move the machine to the unloading area (e.g. transport vehicle).

Fig. 3-91

Emptying digging material

Push the stick out as far as possible to avoid danger due to the oscillating grab.

Open the clamshells, dump the digging material.

3.6.7.2

Multiple tine grab (industrial equipment) The machine must be in working position.

Fig. 3-92

Taking up the load

The maximum lifting capacity is attained when the load is taken up as close to the chassis as possible.

A 309 Litronic / 8720354

MJFCIFSS

3 - 89

Control, operation

Operating instructions

General working methods

Fig. 3-93

Transporting a load

Transport the load close to the chassis, but with a sufficient safety distance to the cab (oscillating grab!) and as close to the ground as possible.

Caution!

Particularly when handling wood, it can be necessary, when working with a grab, to move the machine with raised attachment and suspended load. This will shift the center of gravity of the machine upward in vertical direction. The travel behaviour of the machine will be negatively affected.

Observe chapter 'Safe operation in material handling application'.

3.6.8

Load lifting work Load lifting work is understood to mean lifting, transporting and unloading loads using a lifting device (rope, chain etc.), where personnel are required to assist in securing and releasing the load. This includes, for example, the lifting and lowering of pipes, shaft rings or containers.

Danger!

The machine may only be operated for load lifting work if the specified safety devices are present and functioning correctly.

Machines used for load lifting work must be equipped with the following safety devices, in accordance with European standard EN 474-5: Load lifting devices to safely secure / lift a load (option) Safe lifting devices include, for example, load hooks which are mounted instead of the digging tool. Load hooks can also be replaced with safety hooks welded to the digging tool.

Overload warning device (option) The overload warning device must alert the machine operator visually or acoustically if the permitted load value according to the load chart has been reached or exceeded.

Pipe fracture safety valve on the hoist cylinders (option) The pipe fracture safety valve must meet with the requirements of ISO 8643.

Load chart inside the cab.

3 - 90

MJFCIFSS

A 309 Litronic / 8720354

Operating instructions

Control, operation Transport

If the points referred to above are not or are only partially fulfilled, then the machine must not be used for load lifting work.

3.7 Transport 3.7.1

Transporting the machine safely lifting devices with sufficient capacity nd and block the chains or wheels with wedges. be sure that the loading ramp incline is less than 30° and is covered with wooden planks to prevent skidding. wheels of the machine before moving up the ramp.

tor).

machine from rolling backward. as possible to the loading surface and always drive carefully up the ramp and onto the transport vehicle. limitations in transport, if the backhoe bucket attachment is installed, tilt the stick in and remove the bucket. undercarriage with the locking pin (only A-models). vent them from slipping. essure in all pressure lines, pull the ignition key and raise the safety lever. the transport route, especially the width, height and weight limits. enough clearance underneath all bridges, underpasses, utility lines and in tunnels. loading procedure. Remove all chains and wedges. Start the engine as outlined in the Operating manual. Carefully drive off the loading platform down the ramp.

Keep the attachment as close as possible to the ground level. Have another person guide and signal you.

A 309 Litronic / 8720354

MJFCIFSS

3 - 91

Control, operation

Operating instructions

Transport

3.7.2 3.7.2.1

Transporting the machine on a flatbed trailer Preparatory activities Before driving onto the flatbed trailer, proceed as follows:

Fig. 3-94

Loading ramp

The ramp incline must be fl incline angle W < = 30°.

ated climbing ability. Ramp

Have wedges ready.

Carefully place and secure wooden planks on metal ramp surfaces.

Before driving on the ramp, clean the tires to remove any ice, snow or mud.

3.7.2.2

Loading the machine onto the flatbed trailer To drive the machine onto the flatbed trailer:

Fig. 3-95 1

Driving up on the flatbed trailer

Rigid axle

2

Oscillating axle

The machine must be driven up on to the flatbed trailer with the rigid axle 1 in front. To do this, turn the uppercarriage by 180°.

Danger!

If the uppercarriage is rotated by 180° to the undercarriage, the travel and steering directions are reversed.

Drive and steer with increased caution.

Align the machine precisely to the loading ramp.

Drive the machine onto the flatbed trailer.

Note

Note Have another person guide and sign you.

Turn the uppercarriage carefully by 180º (travel direction over oscillating axle) and lower the attachment (see Fig. 3-96).

3 - 92

MJFCIFSS

A 309 Litronic / 8720354

Operating instructions

Control, operation Transport

Press switch S16 down.

The parking brake is applied.

The indicator light in the switch lights up.

Fig. 3-96

Transport position - machine

Shut down the engine, raise the safety lever.

Secure the uppercarriage to the undercarriage with the bearing block.

Lower the safety lever.

Turn the ignition key to the contact position and relieve pressure lines by moving the joystick carefully several times.

Remove the ignition key and raise the safety lever.

Close and lock all doors, covers and panels on the machine.

To secure the machine: The machine must be secured against slipping before starting to travel.

Fig. 3-97

Securing the machine

Danger!

Serious accidents can occur if the machine slips on the loading ramp.

Secure the machine against slipping.

To do this, use wedges and a tension cable or tension chains.

Secure the machine at the points provided for the purpose using tension cables or tension chains (see Fig. 3-97). The loading points are identified on sign 45 on the undercarriage.

Secure tension cables and chains on the flatbed trailer, depending on the type.

3.7.2.3 Danger

Transport route Danger!

Driving beneath obstacles which are too low can cause serious accidents.

Drive under obstacles, particularly electrical lines, with increased caution.

A 309 Litronic / 8720354

MJFCIFSS

3 - 93

Control, operation

Operating instructions

Transport

Check out the travel route before starting the trip.

3.7.3

Loading the machine with a crane Danger!

The load could slip or fall if incorrectly loaded.

Only permit experienced personnel to secure loads and signal the crane operator.

The guide must position himself within view of the operator or be in voice contact with him.

Ensure that the length of the suspension gear is sufficient.

Fig. 3-98

Suspending the machine

Only use cargo handling gear which is sufficiently dimensioned or which has been specially developed by LIEBHERR for this purpose.

Lower the equipment, retract the stick and curl the digging tool in completely.

Press switch S16 down.

The parking brake is applied.

The indicator light in the switch lights up.

Shut down the engine, raise the safety lever.

Secure the uppercarriage to the undercarriage with the bearing block.

Lower the safety lever.

Turn the ignition key to the contact position and relieve pressure lines by moving the joystick carefully several times.

Remove the ignition key and raise the safety lever.

Close and lock all doors, covers and panels on the machine.

Attach the cargo handling gear to the intended points on the support. If the machine does not have front support, then attach the cargo handling gear on the attachment.

3 - 94

MJFCIFSS

A 309 Litronic / 8720354

Operating instructions

Control, operation Transport

Danger!

Standing under the raised machine is not permitted!

Raise the machine carefully with the crane and load.

When putting the machine back into service, proceed as outlined in the operating and maintenance instructions.

A 309 Litronic / 8720354

MJFCIFSS

3 - 95

Control, operation

Operating instructions

Transport

3 - 96

MJFCIFSS

A 309 Litronic / 8720354

4 Malfunctions Warning and error messages: bols (see chapter "Control and operating elements").

Identification and remedy of problems and errors: tenance.

For that reason, in case of a problem, carefully read the corresponding chapter in the operating instructions again.

sible if you contact LIEBHERR Service.

Precise information makes it possible to find and remedy cause of the problem quickly. To do so, precise information about the type and serial number of the machine is required.

Fig. 4-1

LIEBHERR Service

If the cause of the problem cannot be determined or remedied by using the error codes and problem charts, please consult LIEBHERR Service.

Malfunctions

Operating instructions

Problems and remedies

4.1 Problems and remedies 4.1.1

Diesel engine and fuel system

Problem / error Diesel engine does not start

Cause

Remedy

Fuel tank almost or completely empty

Refuel and bleed fuel system

Under pressure in tank

Remove tank cap

Fuel filter dirty

Clean or change filter and bleed fuel system, drain fuel / clean tank

Ambient temperature below 0°C

For control and operation in specific climatic conditions, see operating instructions

Starter motor not pulling through

Check line connections, overhaul starter motor

Batteries have no power

Charge / replace

Fuel tank empty (under pressure in tank)

Refuel and bleed fuel system

Fuel filter dirty

Clean or change filter and bleed fuel system (tank)

Particularly in winter: high viscosity engine oil used

Use engine oil suitable for ambient temperature.

Dry air filter dirty

Clean or change main filter element

Air in fuel system

Bleeding the fuel system

Vent on fuel tank obstructed

Clean

Fuel line kinked

Check line and repair, if necessary

Diesel engine emitting grey or black smoke

Dry air filter dirty

Clean or change filter

Diesel engine continually emitting white smoke (steam)

Water in combustion chamber

Consult LIEBHERR Service

Diesel engine does not reach full RPM

Throttle control is not set to maximum value

Set throttle control to maximum value

Injection system is adjusted incorrectly

Consult LIEBHERR Service

Dry air filter dirty

Clean or replace filter

Insufficient fuel supply

Clean fuel filter, change fuel filter, check lines, drain water from tank

Insufficient coolant

Add coolant, check for leaks

Water pump defective

Repair

Thermostats do not work

Change thermostats

Radiator contaminated

Clean radiator

Oil level too low

Correct oil level

Oil pressure display faulty

Change oil pressure switch

Engine starts, but stops right away again or runs irregularly

Diesel engine gets too hot

Diesel engine has insufficient oil pressure Note Shut down Diesel engine immediately

4-2

MJFCIFSS

A 309 Litronic / 8720354

Operating instructions

Malfunctions Problems and remedies

Problem / error

Cause

Diesel engine uses too much oil

External leak on Diesel engine

Oil in coolant or coolant in oil

Retighten screws, replace seals, if necessary Consult LIEBHERR Service

Unusual noise / sound development on exhaust side

4.1.2

Remedy

Exhaust system leaking

Check exhaust system / repair

Hydraulic system

Problem / error

Cause

Remedy

Unusual noise / sounddevelopment on hydraulic pumps Note Shut down Diesel engine immediately

Shut off valve on hydraulic tank closed

Open shut off valve

Hydraulic pumps sucking air

Check oil level in hydraulic tank, check suction lines for leaks

Engine is stalling

No performance setting via proportional solenoid valve Y50

Unplug cable of Y50 connection, remove cotter pin, move lever to emergency setting

Hydraulic oil temperature too high

Radiator contaminated

Clean radiator

Fan or fan control defective

Remedy error / consult LIEBHERR Service

Hydraulic oil level too low

Oil loss

Repair leaks, replace hoses, add oil via return filter

No travel function

Raise safety lever

Lower safety lever

No travel direction preselected

Determine travel selection switch via travel selector switch in right joystick

Pressure switch - parking brake defective

Consult LIEBHERR Service

Parking brake not released

Release parking brake via switch

Parking brake will not release despite pressing the switch

Servo pressure available: Actuate emergency function Y6 Servo pressure not available: Consult LIEBHERR Service

Swing gear not functioning

Operating brake engaged

Release operating brake

No servo control

Lower safety lever

Swing brake activated

Lower safety lever

Turn on servo control Release swing brake No working movement

No servo control

Lower safety lever Turn on servo control

A 309 Litronic / 8720354

No servo pressure present

Consult LIEBHERR Service

No pump high pressure present

Consult LIEBHERR Service

MJFCIFSS

4-3

Malfunctions

Operating instructions

Problems and remedies

4.1.3

Travel gear

Problem / error

Cause

Remedy

Machine does not move, neither forward nor backward

Safety lever is raised Parking brake has been applied via switch S16 No travel direction preselected Apply operating brake, using brake pedal and retainer

Lower the safety lever. Release parking brake using switch S16.

Preselect direction of travel using switch S30.

Release operating brake by releasing the retainer. Consult LIEBHERR Service.

Machine moves too slowly

Incorrect gear reduction via switch S42.

Creeper gear activated via switch S21. Travel pedal cannot fully shift through.

Select a different reduction via switch S42.

Deactivate creeper gear via switch S21.

Clean cab floor.

Consult LIEBHERR Service.

4.1.4

Electrical system

Problem / error

Cause

Remedy

Battery charge indicator light does not turn off

V- belt for alternator loose or torn

Tension or replace V-belt

Alternator defective

Replace alternator

Batteries do not charge or charge insufficiently

Batteries defective

Replace batteries

Battery connections dirty / oxidized

Clean battery connections

Cable loose or damaged

Connect or replace cable

Indicator light or display instrument not functioning or functioning incorrectly

Bulb burnt out, display instrument defective

Replace defective part

Some or all functions on instrument panel malfunction

Plug connector separated or damaged, ground lead interrupted, short circuit - fuse defective

Install plug connector correctly or change, repair short circuit, replace fuse or activate circuit breakers

Engine throttle control via knob R75 not functioning

Excavator electronic for throttle control not functioning.

Consult LIEBHERR Service

Switch S20 Sensor controlled low idle automatic is activated.

Joystick or deactivate switch S20 for sensor controlled low idle automatic. Consult LIEBHERR Service

No signal coming from RPM sensor B12.

Consult LIEBHERR Service

Sensor controlled low idle automatic not functioning, RPM does not drop

Permanent sensor signal

Consult LIEBHERR Service

Switch S20 is deactivated

Activate switch S20

Servo control cannot be activated via switch

Switch defective Problem in excavator electrical system

Replace switch Consult LIEBHERR Service

Parking brake cannot be released with the switch Swing gear brake cannot be released with the switch

4-4

MJFCIFSS

A 309 Litronic / 8720354

Operating instructions

Malfunctions Fuses and relays

4.1.5

Heating and Air conditioning system

Problem / error

Cause

Heater does not supply warm air

Heater fan is not running Only low air flow in cab

4.1.6

Remedy

Shut off valves for coolant line on Diesel engine closed

Open shut off valve

Engine not at operating temperature

Bring engine to operating temperature

No power supply

Check fuse and wiring / repair

Fan motor defective

Change fan motor

Outside air filter / recirculated air filter dirty

Clean air intake opening, replace outside air filter

Air vent closed

Open air vent

Work attachment

Problem / error

Cause

Remedy

Cylinder gives way under load

Piston seal in cylinder defective

Overhaul cylinder

Bearing clearance too high on attachment

Bearing points worn out

Replace bearing parts

Grapple / bucket do not move

Valve block on bucket cylinder incorrectly switched

Change over valve block

Attachment unit cannot be turned, rotated or operated

Auxiliary function has not been released

Release auxiliary function using switch S19

Lines are not connected

Connect lines

4.2 Fuses and relays Danger!

Incorrect or bypassed fuses do not provide the required protection for machine operator or the electrical system.

Only use original fuses.

If required, order replacement fuses from LIEBHERR. Never bypass electrical fuses.

A 309 Litronic / 8720354

MJFCIFSS

4-5

Malfunctions

Operating instructions

Fuses and relays

4.2.1

Fuse box E50

Fig. 4-2

Fuse box E50

Fuse box E50 is located on the left hand side in the engine compartment, on the rear of the hydraulic tank.

4.2.2

F19

50 A

Preheating

F20

50 A

Main fuse

F22

7.5 A

Sensor, engine coolant level + hazard warning system

F303 F332

7.5 A 25 A

Engine stop Starter

K16-1 K288

Relay terminal 50 Relay terminal 15

K302

Preheating relay

Panel ignition switch

Fig. 4-3

4-6

Fuses panel ignition switch

MJFCIFSS

A 309 Litronic / 8720354

Operating instructions

Malfunctions Fuses and relays

F304 F305

15 A 15 A

Ignition switch back-up fuse Interior lighting / cigarette lighter / clock

F306 F312

15 A 7.5 A

Reserve Turn signal

F313

5A

Brake light

F314

3A

Safety lever

F315

15 A

Excavator control

F316

7.5 A

Sensoric sensor control / panel

F318

20 A

Heater / air conditioner* (terminal 30)

F319 F320

15 A 15 A

Heater / air conditioner* (terminal 15) Reserve

F321

15 A

Reserve

F322 F326

7.5 A 15 A

Voltage transformer Fast travel / quick change adapter

F325 F327

7.5 A 15 A

Parking brake / drive Reserve

F328 F329

15 A 5A

Reserve Servo control

F330

7.5 A

AHS / AS 1 / Mode

F331 F336

15 A 20 A

Reserve Back-up fuse for lighting

F337 F338

15 A 15 A

Support / magnet Horn

F339

20 A

Air conditioning condenser*

* Option

4.2.3

A 309 Litronic / 8720354

Panel, cab

Fig. 4-4

Fuses and relays panel cab

F307

7.5 A

Parking light, left / tail light

F308 F309

7.5 A 7.5 A

Parking light, right / tail light Headlight, left

F310

7.5 A

Headlight, right

MJFCIFSS

4-7

Malfunctions

Operating instructions

Fuses and relays

F311

15 A

Windshield wiper / washer system

F317

7.5 A

Rotating beacon*

F323 F324

15 A 15 A

Attachment work headlight* Work headlight / roof*

F343

7.5 A

Roof windshield wiper*

K414

Relay Intermittent control

* Option

4.2.4

Distributor plate All other relays are located in the distributor plate of the right control panel.

Fig. 4-5

4-8

Relay Distributor plate

K250 K251

Oscillating axle automatic Hand brake

K252 K315

Servo - hand brake Brake light

K370 K375

Grapple Installation kit - quantity

K386

Safety lever

K445

Turn off travel, all wheel steering

MJFCIFSS

A 309 Litronic / 8720354

5 Maintenance 5.1 Maintaining the machine safely 5.1.1

General Safety instructions ied out by trained expert technicians. ods for repeat checks / inspections as outlined in the Operating manual. Always use appropriate tools to carry out maintenance work. manual to see who is authorized or required to perform certain work.

The tasks listed under daily / weekly may be carried out by the machine operator or maintenance personnel after having received appropriate instructions.

The remaining tasks may only be carried out by expert technicians with appropriate training. rements set forth by the manufacturer.

This is always ensured with Original spare parts. intaining the machine. For certain work, safety glasses and protective gloves are required, in addition to a hard hat and safety boots. the machine during maintenance.

work. Make sure he knows the person who is in charge of the work. nance work on the machine on firm and level ground, with the attachment placed down and the engine shut off. re you always tighten any loosened screw connections. tenance and repairs, make sure that after completion of work, the safety devices are reinstalled and checked for proper function. hen working under the machine, make sible and attached to the starter switch.

Pull the ignition key and close the battery master switch.

5.1.2

Cleaning n the machine, especially connections and fittings to remove oil, fuel or cleaning substances.

Do not use harsh cleaning products and use only lint-free cleaning cloths. eaning products or steam within the first two months after delivery (or after repainting).

cleaning products,

Maintenance

Operating instructions

Maintaining the machine safely

ons and the swing ring to avoid infiltration of water and steam into the bearing points. exposed to water, steam or cleaning products.

This applies especially to electric motors, electric components, switch boxes, plug connections and air filters. the fire warning system and the fire extinguisher do not come in contact with hot cleaning fluids when cleaning the engine compartment.

The fire extinguishing system could be actuated.

lines for leaks, loose connections, chafing and damage.

infiltrated water or cleaning fluid.

5.1.3

Crack inspection depending on application, job site, duration of use and conditions of use. The different load conditions result in the different service life durations for various machines components. This could lead to cracks and loose connections, particularly on load bearing parts. This applies particularly in the case of machines used in material handling or industrial applications or for machines with special equipment, such as demolition excavators. To ensure that operating safety is maintained, the machine must be checked regularly for cracks, loose connections or other visible damage. ep the machine clean and to clean it regularly. schedule, e personnel of the machine operator. tions with the machine supported, on firm and level ground, at changing loads with the attachment in length and crosswise direction. The currently valid accident prevention regulations must be adhered to. ly: er swing ring seating with tower and ball swing ring. th bearing block for boom and boom cylinder, upper swing ring seating, cab bearing, mounting of swing gear and counterweight. nts, e. g. boom, stick, quick change adapter, digging tool and grapple. and pin connections, steps, ladders and mounting elements. sually. To increase the level of inspection, if a crack is suspected or is in areas which are not easily visible, such as the swing ring seating, then the dye penetration procedure should be used to check for cracks. ely. Welding on load bearing parts of earth moving machines, material handling and transport units may only be made by especially trained expert personnel and only in accordance to accepted regu-

5-2

MJFCIFSS

A 309 Litronic / 8720354

Operating instructions

Maintenance Maintaining the machine safely

lation of welding technology. In case of doubt, contact LIEBHERR Service to discuss suitable measures.

5.1.4

Welding rk on the machine only if this is explicitly permitted. Before any welding, torching and grinding tasks, clean the machine and the surrounding area to remove dust and flammable materials.

Ensure sufficient ventilation. There is a danger of fire and / or explosion. out any arc welding work on the machine.

Disconnect the negative pole first, then the positive pole. Proceed in reverse order when reconnecting. welding location.

5.1.5

Operating and service fluids applicable safety regulations for the corresponding product. disposal of operating and service fluids as well as exchange parts.

(Danger of burning and scalding).

5.1.6

Repair able lifting devices with sufficient load carrying capacity. When replacing individual parts and larger components, attach and secure them carefully to the lifting tackle, to avoid any danger. Use only suitable and technically sound lifting devices as well as load tackle with sufficient load carrying capacity.

Do not stand or work under suspended loads. ciently sized lifting devices.

Always wear work gloves when handling wire ropes.

The guide must position himself within view of the operator or be in voice contact with him. forms.

Do not use parts of the machine as climbing devices, if they are not designed for this purpose.

Wear a harness when working in great heights.

Keep handles, steps, railings, platforms, and ladders free of dirt, ice and snow. the machine is properly supported. Never use metal on metal support. is raised with the attachment, without being properly supported from below with hardwood beams. ys that any shifting weight will not endanger the stability of the machine and avoid metal to metal contact.

A 309 Litronic / 8720354

MJFCIFSS

5-3

Maintenance

Operating instructions

Maintaining the machine safely

pecially trained expert personnel. secure the uppercarriage to the undercarriage with the locking pin. onnel may work on the hydraulic system. can have enough pressure to penetrate the skin. before the attachment has been lowered, the engine has been shut down and the hydraulic system pressure has been relieved. Before working on the hydraulic circuit, with the ignition key in contact position, move all servo controls (joysticks and pedals) in all directions to relieve the servo pressure and the remaining pressures in the working circuits. Then relieve the pressure in the tank, as described in this operating manual.

5.1.7

Electrical system All defects, such as loose connections, burnt out fuses and bulbs, burnt or damaged wires or cables must be repaired immediately by an electrician or especially trained personnel.

gy supply, turn the machine off immediately. sion of an electrician may work on the electrical equipment of the machine, according to the electro-technical guidelines. emergency off or master switch with voltage release. Rope of the work area off with a red and white safety chain and a warning sign. Use only insulated tools. mponents, shut off the voltage and connect the supply cable to the ground and ground the components, such as the condenser, with a grounding rod. truly free of current, ground them and short circuit them. Insulate adjacent, current carrying parts. out any arc welding work on the machine.

Disconnect the negative pole first, then the positive pole. Proceed in reverse order when reconnecting.

5.1.8

Pressure accumulator

cidents.

system (hydraulic system including hydraulic tank, as described in this operating manual. chanical work on them.

5-4

MJFCIFSS

A 309 Litronic / 8720354

Operating instructions

Maintenance Maintaining the machine safely

The pressure accumulator can be damaged due to heat exposure and can rupture due to mechanical treatment. THERE IS A DANGER OF EXPLOSION! r only with nitrogen. When using oxygen or air, there is a DANGER OF EXPLOSION! ring operation, there is a danger of burning. plication before use. the pressure accumulators. Make sure that the marking remains visible.

5.1.9

Hydraulic hoses and lines d regularly, every 2 weeks, in case of suspected intentional damage immediately for leaks and external visible damage!

Any damaged parts must be replaced immediately! Escaping oil can cause injuries and fires. ess. For that reason, their service live is limited. quent causes of failure. standards, regulations and guidelines for hoses and lines at the job site must be observed. ranges of permitted use can shorten the service life ( for example in high temperatures, frequent work cycles, extremely high impulse frequencies, multi shift operation). e following conditions are found during inspection: cracks); shape of the hose or hose line, when under pressure or not under pressure, or in bends (e.g. separation of layers, blisters or bubbles); allation instructions; which reduce the strength of the fitting or the hose / fitting connection; h reduces function and strength;

pressure hoses, always attach the screws of half clamps or full flange on both ends of hose first and then tighten. with a bent fitting, always tighten the end with the bent fitting first when tightening the flanges, then the end with the straight fitting. and tightened thereafter. erly mounted. This prevents vibration and damage during operation.

A 309 Litronic / 8720354

MJFCIFSS

5-5

Maintenance

Operating instructions

Maintenance access doors

structures is prevented. her parts of approx. ½ of the outside diameter of the hose. The distance should not be less than 10 to 15 mm. check before initial use, that there is not chafed area over the entire area of movement.

5.2 Maintenance access doors 5.2.1

Overview of access doors

Fig. 5-1

Access doors on the machine

1

Engine hood

2

Side door, right

3

Cover battery box

4

Cover - swing platform

The machine has 4 access doors for maintenance. The locks integrated in the handles must be unlocked before starting to travel.

5-6

MJFCIFSS

A 309 Litronic / 8720354

Operating instructions

Maintenance Maintenance access doors

Access door

Lock

Engine hood

Gas pressure spring

Side door, right

Mechanical retainer

Cover battery box

Gas pressure spring

Tab. 5-1

5.2.2

Access to:

Access doors

Door lock

Fig. 5-2

Door lock

To stop the access doors from moving unintentionally (e.g. due to wind), open them fully and allow the door lock (see arrow) to engage.

A 309 Litronic / 8720354

MJFCIFSS

5-7

Maintenance

Operating instructions

Tires

5.2.3

Engine hood release

Fig. 5-3

Engine hood release

To unlock the engine hood, release the remote control 1 and fold up.

Before closing the engine hood, close the remote control again.

5.3 Tires

Fig. 5-4

5-8

Exploding tire

MJFCIFSS

A 309 Litronic / 8720354

Operating instructions

Maintenance Tires

Danger!

Repair work on the wheels, e.g. removing tires from the rim or installing tires on the rim may only be carried out by expert personnel using the appropriate assembly tool.

If the tire inflator is operated incorrectly or carelessly, the following dangers can arise, leading to severe injury or even death:

Tires which have become flat may not be inflated. They must be repaired at a professional shop.

An incorrectly seated lock ring could burst off. Danger of injury.

When inflating the tires, use a tire inflator hose of a sufficient length with a self retaining hose valve.

When inflating the tires, stand outside of the danger zone.

Do not use different tire sizes.

5.3.1

Checking the tire pressure The air pressure in the tires has a considerable influence on the overall operational behavior of the machine. For this reason, the tire pressure should be checked regularly and corrected if necessary.

When working on the tires, ensure that the machine is positioned safely and is secured with wedges to prevent it from rolling off.

Ensure that the correct nominal tire pressure values, corresponding to the mounted tire and the machine group, are available for the tires.

Take the nominal values from the chart below.

Attach measuring equipment and correct air pressure, if necessary.

5.3.1.1

Tire pressures Size

Manufacturer

PR

bar

9.00 - 20

Barum

14

7,50

9.00 - 20

Nokia

14

9,00

500 / 45 - 20

Alliance

Tab. 5-2

5.3.1.2

6,00

Tire pressures

Tightening torque Tightening torque of wheel lugs: 550 Nm Note!

Retighten the wheel lugs according to the inspection and maintenance schedule after each wheel change.

A 309 Litronic / 8720354

MJFCIFSS

5-9

Maintenance

Operating instructions

Lubricants and operating fluids

5.3.2

Filling with foam Note!

The running characteristics will be influenced by filling the tires with foam. Only LIEBHERR may fill the tires with foam.

5.4 Lubricants and operating fluids 5.4.1

General information to change lubricants and operating fluids Note!

The quantities given in the lubrication and operating fluid chart as well as on the lubrication chart in the cab are only guide values.

Check the level in the corresponding component after each oil change or refill.

Note!

Adhering to regulations for lubrication, level checks and changing of operating fluids guarantees a high degree of reliability and a long service life for the machine.

It is particularly important to adhere to the oil change intervals and use the specified type of lubricant.

Observe the following when using and checking lubricants and operating fluids:

Note!

Cleanliness is of the utmost importance when changing oil.

Clean all filler plugs, filler covers and drain plugs and their surroundings before opening.

If possible, drain the oil when it is at operating temperature.

Ensure that old oils are collected and disposed of in an environmentally acceptable manner, including removable oil filter cartridges.

5 - 10

MJFCIFSS

A 309 Litronic / 8720354

Operating instructions

Maintenance Lubricants and operating fluids

Danger!

When checking and changing lubricants and operating fluids, ensure that the following precautions are adhered to: Unless otherwise indicated, carry out all work on the machine on level, solid ground and with the engine shut down.

Whenever you access the engine compartment, always secure the cover and side doors to prevent them from accidentally falling back or closing.

Only refuel the machine when the engine is shut down, do not smoke and avoid open flames.

Turn the battery master switch to position 0 (off) and remove the ignition key.

A 309 Litronic / 8720354

MJFCIFSS

5 - 11

Maintenance

Operating instructions

Lubricants and operating fluids

5.4.2

Lubrication chart

Fig. 5-5

5 - 12

A 309 Litronic lubrication chart

MJFCIFSS

A 309 Litronic / 8720354

Operating instructions

Maintenance Lubricants and operating fluids

Symbol

Display

Quantity (liters)*

Diesel engine

15,5

Hydraulic tank

200,0

Swing gear

4,4

Transmission

3,3

Rigid axle

8,0

Steered rigid axle (option)

7,3

Rigid axle wheel head

2,1

Wheel head, steered rigid axle (option)

2,0

Steering axle

7,3

Wheel head, steering axle

0,8

General lube points Check oil level Oil change First oil change Lubrication Operating instructions

*Guide values

A 309 Litronic / 8720354

MJFCIFSS

5 - 13

Maintenance

Operating instructions

Lubricants and operating fluids

5.4.3

Lubrication chart

Description

Medium

Diesel engine

Engine oil

The information provided by the engine manufacturer applies (see Deutz operating instructions).

15,5

Hydraulic tank

Engine oil

API-CD, APICD+SF, CCMC-D4, CCMC-D5, ACEA-E1, ACEA-E3

SAE 10W SAE 10W-30 SAE 10W-40 SAE 15W-40 SAE 20W-20 SAE 30W

200,0

Swing gear (as parking brake)

Gear oil

API-GL-5 MIL-L 2105 B, C or D

SAE 80W-90 or SAE 90

4,4

Swing gear (as positioning swing brake)

Gear oil

API-GL-5 MIL-L 2105 B

SAE 90 LS

4,4

Steering axle

Gear oil

API-GL-5 MIL-L 2105 B ZF TE-ML 05

SAE 90 LS

7,3

Wheel heads of steering axle

Gear oil

API-GL-5 MIL-L 2105 B ZF TE-ML 05

SAE 90 LS

0.8 each

Rigid axle

Gear oil

API-GL-5 MIL-L 2105 B ZF TE-ML 05

SAE 90 LS

8,0 (7,3)

Rigid axle wheel heads

Gear oil

API-GL-5 MIL-L 2105 B ZF TE-ML 05

SAE 90 LS

2.1 each (2.0 each)

Transmission

Gear oil

ZF TE-ML 07

SAE 10W-30 SAE 10W-20

3,3

Race and teeth of swing ring, attachment bearing

Lubricating grease

High pressure grease KP2k or EP2

Consistency 2 NLGI grade

-

Hinges, joints, locks

Engine oil

-

-

-

-

Rubber seal on doors and covers

Silicon spray or talcum powder

-

-

-

-

Tab. 5-3

5 - 14

Symbol

Classification

Viscosity

Quantity (liters)*

Lubrication chart

MJFCIFSS

A 309 Litronic / 8720354

Operating instructions

Maintenance Lubricant and operating fluid specifications * = Guide values

5.4.4

Operating fluid chart

Description

Medium

Fuel tank

Commercially available Diesel fuel with sulphur content <= 0.5 %

200

Coolant

Anti-corrosion fluid and antifreeze

15,5

Window washer system

Commercially available window washer fluid or denatured alcohol

-

3,0

Refrigerant Air conditioning system

R 134 a

-

1,7 kg

Refrigerant oil in A/C compressor

PAG ZXL 100 PG

-

0,15

Tab. 5-4

Symbol

Quantity (liters)*

Operating fluid chart

* = Guide values

5.5 Lubricant and operating fluid specifications 5.5.1

Lube oil for the Diesel engine The information provided by the engine manufacturer applies (see Deutz operating instructions).

5.5.1.1

Oil change intervals for the turbocharged engine Conditions of use

Oil change interval dependent on oil viscosity: CH-4 CG-4 CF-4 E2-96 (D4)

E3-96 (D5) E4-98 E5-99

Climate normal to -10 °C

up to 0.5 % above 0.5 %

250 hrs.

125 hrs.

500 hrs.

250 hrs.

below -10 °C

up to 0.5 % above 0.5 %

125 hrs.

-

250 hrs.

125 hrs.

Tab. 5-5

A 309 Litronic / 8720354

Sulphur content in fuel

Oil change intervals for the turbocharged engine

MJFCIFSS

5 - 15

Maintenance

Operating instructions

Lubricant and operating fluid specifications

Oil change intervals for Diesel engine depend on the following criteria: at 500 operating hours when using initial fill oil of quality E3-96. every 500 operating hours. e zone, sulphur content in fuel and oil quality (see Tab. 5-5). and oil filter should be changed at least once a year.

5.5.2

Fuel Diesel fuels should meet the minimum requirements of the below listed, approved fuel specifications.

The sulphur content should not exceed 0.5 % . A higher sulphur content will affect the oil change intervals and the engine life.

5.5.2.1

Lubricity Decreasing sulphur content has raised the problem of Diesel fuel lubricity. It has been shown that Diesel fuels containing the maximum permitted European sulphur limit of 0.05 % can cause wear in the fuel injection system (particularly for distributortype injection pumps). ain lubrication additives in their additive package. The fuel lubricity must be < 400 µm according to the HFFR (60°) test.

Suppliers should supply the additives as the responsible party for the fuel quality. It is not recommended that customers add secondary lubricity additives.

5.5.2.2

Flow improvement by adding petrol (regular gasoline) When ambient temperatures are below approx. 0 °C, the flow properties of summer Diesel fuels can become insufficient due to paraffin separation.

The same also occurs in winter Diesel fuels used in temperatures below -15 °C. Frequently, Diesel fuels with additives with a use temperature of up to -20 °C are offered.

To avoid malfunctions, Diesel fuel must be mixed with normal gasoline or petroleum at lower temperatures.

Adding normal gasoline should be viewed as an emergency remedy and must not exceed 30 % by volume.

Super petrol (Super or premium gasoline) may not be used for mixing. Engine performance can be reduced depending on the additives mixed in for cold weather conditions. For this reason, additions to the mixture should be kept as low as possible by taking the current ambient temperatures into account.

Danger!

For safety reasons, mix fuel only in the fuel tank.

Note!

When refuelling, the specifically lighter additional fuel should be added before the Diesel fuel. Then run the engine until the mixed fuel is distributed through the entire fuel system.

5 - 16

MJFCIFSS

A 309 Litronic / 8720354

Operating instructions

Maintenance Lubricant and operating fluid specifications

Approved fuel specifications DIN EN 590 ASTM D 975 - 89a 1 D and 2

Mixing ratio Diesel fuel / regular gasoline Ambient temperature °C

Summer Diesel fuel %

Additive regular gasoline %

0 to -10

70

30

-10 to -15

50

50*

-15 to -20

-

-

-20 to -25

-

-

Tab. 5-6

Mixture ratio summer Diesel fuel / regular gasoline

Ambient temperature °C

Winter Diesel fuel %

Additive regular gasoline %

type -15 °C

type -20 °C

for type -15 °C

for type -20 °C

0 to -10

100

100

-

-

-10 to -15

100

100

-

-

-15 to -20

70

100

30

-

-20 to -25

50

70

50*

30

Tab. 5-7

Mixing ratio winter Diesel fuel / regular gasoline

* If an addition of 50 % is required, use only petroleum (no regular gasoline).

5.5.2.3

Additives to Diesel fuel (flow improver) Commercially available flow improvers can al cold weather conditions. When using them, follow the manufacturer dosage and usage requirements.

5.5.3

Hydraulic oil

5.5.3.1

Mineral oil Engine oils corresponding to the following specifications and regulations are specified:

A 309 Litronic / 8720354

MJFCIFSS

5 - 17

Maintenance

Operating instructions

Lubricant and operating fluid specifications

Single-grade oils:

API - CD / CCMC - D4 / ACEA - E1 Mercedes-Benz regulations, Page no. 226.0 and 227.0

Multi grade oils:

API - CD + SF / CCMC - D5 / ACEA - E3 Mercedes-Benz regulations, Page no. 227.5 and 228.3

Tab. 5-8

Specified engine oils for use as hydraulic oil

The engine oil for use as hydraulic oil can be selected according to the following chart.

Fig. 5-6

Engine oils for use as hydraulic oil

Warm-up guidelines At temperatures up to 10 °C below the given limit (black bar), the following warm-up guidelines apply: After starting the engine, regulate the Diesel engine only to approx. 1 / 2 of the rated speed. Operate the hydraulic cylinder and motors, move cylinder briefly against the stop. Warm-up duration approx. 10 minutes.

At even lower temperatures: Preheat the oil tank before starting the engine.

5.5.3.2

Environmentally friendly hydraulic fluids Note!

Mixing environmentally friendly hydraulic oils made by different manufacturers as well as mixing them with mineral oils must be avoided.

The environmentally friendly hydraulic oils recommended by LIEBHERR are limited to oils with a synthetic ester basis with a viscosity according to ISO VG 46.

The initial oil fill is carried out at the factory according to an approved list. Use of an environmentally friendly hydraulic oil must first be coordinated with LIEBHERR. Plant-based oils are not to be used due to their insufficient temperature properties.

The use of bypass filters is required.

5 - 18

MJFCIFSS

A 309 Litronic / 8720354

Operating instructions

Maintenance Lubricant and operating fluid specifications

5.5.3.3

Hydraulic oil monitoring Note!

Environmentally friendly hydraulic fluids should generally be checked at regular intervals through an oil analysis.

Oil analysis is recommended for mineral oils.

Machines in normal use: at least every 500 operating hours Machines in dust intensive use: at least every 250 operating hours LIEBHERR recommends that oil analyses be carried out by the WEAR CHECK Company and that oil changes are performed on the basis of the lab report (see also customer service and product information).

5.5.3.4

Hydraulic oil monitoring in normal use

Fig. 5-7

Taking an oil sample in normal use

hrs.operating hours

2

second oil sample

1

3

additional oil samples every 500 operating hours

first oil sample

Oil change according to analysis and lab report.

Change intervals for hydraulic oil return filter (10 µm): first after 500 operating hours, additional changes every 1000 operating hours.

5.5.3.5

Hydraulic oil monitoring in dust intensive use

Fig. 5-8

Taking an oil sample in dust intensive use

hrs.operating hours

2

second oil sample

1

3

additional oil samples every 250 operating hours

first oil sample

Oil change according to analysis and lab report.

Change intervals for hydraulic oil return filter (10 µm): first after 500 operating hours, additional changes every 500 operating hours.

A 309 Litronic / 8720354

MJFCIFSS

5 - 19

Maintenance

Operating instructions

Lubricant and operating fluid specifications

5.5.3.6

Notes on reducing hydraulicoil contamination in heavy dust use If the machine is generally operated with the hydraulic hammer, or if it is used under similar circumstances (heavy dust occurrence), there is the risk that the hydraulic oil will become contaminated more than usual.

To prevent early wear of hydraulic components, the oil change intervals (and intervals between oil samples) should be reduced and the following regulations should also be observed: hours. dges must be used instead of the usual 20 / 5 µm filter cartridges. must be replaced with a 2 µm fine filter (fineness of standard filter is 7 µm). every time the hydraulic oil is changed (every 500 operating hours).

Note!

Machines fitted with a hydraulic hammer at the factory and retrofitted hydraulic hammer kits feature these 10-µm filter cartridges and 2-µm breather filters.

5.5.4

Gear oil Gear oils must correspond to the specifications

.

Engine oils used in gears must correspond to the specifications .

For viscosity classes SAE 80 and SAE 90 according to MIL-L-2105 D, oil of viscosity class SAE 80W90 can also be used.

5 - 20

MJFCIFSS

A 309 Litronic / 8720354

Operating instructions

Maintenance Lubricant and operating fluid specifications

5.5.5

Lubricating grease and other lubricants Grease

Description / manufacturer

Lubricating grease for the swing ring / general lube points

The grease must correspond to specification KP2k, consistency 2 or NLGI grade according to DIN 51818 and DIN 51825 or EP 2 according to NF-T-60 132.

The grease must consist of a lithium complex and have a VKA value of at least 2300 N according to DIN 51350 and ASTM D 2596.

Contact spray for slip rings

Cramolin

Lubricant for pistons, piston nuts and piston bearing installations on hydraulic cylinders

Gleitmo 800

Special anti corrosion fluid for installation areas of sealingelements on hydraulic cylinders

Castrol-Tarp

Anti-corrosion grease for exposed piston rods (for cylinders that are not moved often or during transport)

-

Tab. 5-9

5.5.6

Lubricating grease and other lubricants

Coolant To improve coolant quality, water filter attachments are used for LIEBHERR Diesel engines.

Due to this measure, the coolant is filtered again in the bypass flow and is cleaned of dirt and rust particles, which could result in leaks on the coolant pumps.

Ambient temperature to

Part water in %

Part anti-corrosion fluid / antifreeze in %

-37 °C / -36.67 °C

50

50

-50 °C / -58 °F

40

60

Tab. 5-10 Mixture ratio water / anti-corrosion fluid / antifreeze The coolant must contain a minimum of 50 percent by volume of anti-corrosion fluid/ antifreeze all year. This corresponds to an antifreeze protection up to -37 °C and ensures sufficient protection from corrosion.

In case of coolant loss, it must be ensured, when adding coolant, that this amount does not fall short of 50 % by volume.

A 309 Litronic / 8720354

MJFCIFSS

5 - 21

Maintenance

Operating instructions

Lubricant and operating fluid specifications

Note!

Do not use more than 60 % anti-corrosion fluid/antifreeze!

At a higher percentage, the cooling effect and antifreeze protection would actually be reduced.

When carrying out maintenance work, the mixing ratio of the coolant must be checked.

Note!

2 years.

Before adding new coolant, make sure that the coolant system is clean and flush if necessary.

5.5.6.1

Regulations for fresh water quality To prepare the coolant, use clean water, which is not too hard. Often, but not always, drinking water meets these requirements. Sea water, brackish water, brine and industrial wastewater are not suitable.

Content

Quantity

Sum of alkaline earths (water hardness)

0.6 to 3,6 mmol / l (3 to 20 °d)

ph value at 20 °C

6.5 to 8.5

Chloride-ion content

max. 80 mg / l

Sum of chloride + sulphate

max. 100 mg / l

Tab. 5-11 Fresh water quality

5.5.6.2

Approved anti-corrosion fluid and antifreeze Concentrate, undiluted

Product description

Manufacturer

Country

Agip Antifreeze Plus

Agip Petrol S.p.A., Rome

I

Agip Langzeit-Frostschutz

Autol-Werke GmbH, Würzburg

D

Antigel DB 486

Sotragal S.A., St. Priest

F

Aral Kühlerfrostschutz A

Aral AG, Bochum

D

Avia Frostschutz APN (G48-00)

Deutsche Avia-Mineralöl GmbH, Munich

D

BP Antifrost X 2270 A

Deutsche BP AG, Hamburg

D

BP Napgel C 2270 / 1

BP Chemicals LTD., London

GB

Caltex Engine Coolant DB

Caltex UK Ltd, London

GB

Caltex Extended Life Coolant

Caltex UK Ltd, London

GB

Castrol Anti-Freeze O

Deutsche Castrol Vertriebs GmbH, Hamburg

D

Century F.L. Anti-Freeze

Century Oils, Hanley, Stoke-on-Tent

GB

5 - 22

MJFCIFSS

A 309 Litronic / 8720354

Operating instructions

Maintenance Lubricant and operating fluid specifications

Product description

Manufacturer

Country

Chevron DEX-COOL Extended Life Anti-Freeze / Coolant

Chevron Texaco, San Ramon, CA

USA

DEUTZ Kühlschutzmittel 0101 1490

Deutz Service International GmbH, Cologne

D

Esso Kühlerfrostschutz

Esso AG, Hamburg

D

Fircofin

Fuchs Mineralölwerke GmbH, Mannheim

D

Frostschutz Motorex (G48-00)

Bucher & Cie, Langenthal

CH

Frostschutz 500

Mobil Oil AG, Hamburg

D

Glacelf Auto Supra

Total Nederland N.V., Den Haag

NL

Glycoshell AF 405

Shell Deutschland GmbH, Hamburg

D

Glycoshell N

Shell Deutschland GmbH, Hamburg

D

Glysantin (G 48-00)

BASF AG, Ludwigshafen

D

Havoline XLC

Arteco, Gent

B

Havoline DEX-COOL Extended Life Anti-Freeze/ Coolant

Chevron Texaco, San Ramon, CA

USA

Igol Antigel Type DB

Igol France, Paris

F

Labo FP 100

Labo Industrie, Nanterre

F

Motul Anti-Freeze

Motul SA, Aubervilles

F

OMV Kühlerfrostschutzmittel

OMV AG, Schwechat

A

Organifreeze

Total Deutschland GmbH, Düsseldorf

D

OZO Frostschutz S

Total Deutschland GmbH, Düsseldorf

D

Total Antigel S-MB 486

Total Deutschland GmbH, Düsseldorf

D

Total Frostfrei

Total Deutschland GmbH, Düsseldorf

D

Veedol Anti-Freeze O

Deutsche Veedol GmbH, Düsseldorf

D

Wintershall Kühlerschutz

Wintershall Mineralöl GmbH, Düsseldorf

D

Tab. 5-12 Approved anti-corrosion fluid / antifreeze (concentrate, undiluted)

A 309 Litronic / 8720354

MJFCIFSS

5 - 23

Maintenance

Operating instructions

Diesel engine

50:50 premix (water: anti-corrosion fluid / antifreeze) Product description

Manufacturer

Country

Liebherr Anti-Freeze APN Mix Ident-Nr. 8611045

Liebherr

D

Caltex Extended Life Coolant Pre-Mixed 50/50 (ready-to-use-version)

Caltex UK Ltd, London

GB

Chevron DEX-COOL Extended Life Prediluted 50/50 Anti-Freeze/Coolant

Chevron Texaco, San Ramon, CA

USA

Havoline XLC, 50/50

Arteco, Gent

B

Havoline DEX-COOL Extended Life Prediluted 50/50 Anti-Freeze/Coolant

Chevron Texaco, San Ramon, CA

USA

Organicool 50/50

Total Deutschland GmbH, Düsseldorf

D

Tab. 5-13 Approved anti-corrosion fluid / antifreeze / 50:50 premix

5.6 Diesel engine 5.6.1

Check oil level Danger!

Danger of burning.

The engine oil is hot when at or near operating temperature.

Do not allow your skin to come into contact with hot oil or components containing hot oil.

The machine must be in level position.

Shut down the engine.

Wait for a short time until the oil has collected in the oil pan.

Fig. 5-9

Check oil level

Check the oil level in the engine.

The oil must leave a mark between the min and the max marks on the dipstick.

If necessary, add engine oil at the oil filler fitting (see arrow) until the level has reached the upper mark MAX.

5 - 24

MJFCIFSS

A 309 Litronic / 8720354

Operating instructions

Maintenance Cooling system

5.6.2

Changing the oil For oil change, see the Deutz operating instructions.

Note!

Change the oil only if the engine is warm.

5.7 Cooling system 5.7.1

Checking and cleaning the cooling system

Fig. 5-10

Cleaning the cooling fins

The machine is equipped with a combination oil / water cooler.

Optimum cooling can only be achieved if the cooler is kept clean.

Check the engine, fan and cooler for damage and clean if necessary.

Check the cooling system according to the maintenance schedule intervals.

If required, clean the cooling fins with compressed air or a steam jet (from inside to the outside, see arrow).

Check the condition and seals of the connector hoses between the radiator and engine the as well as the coolant hoses regularly.

In case of leaks, change the pressure relief valve 1 (expansion tank lock ring).

A 309 Litronic / 8720354

MJFCIFSS

5 - 25

Maintenance

Operating instructions

Cooling system

5.7.2

Checking the coolant level Danger!

Danger of burns due to hot coolant.

The engine cooling system is hot and pressurized when at or near operating temperature.

Avoid touching coolant or coolant-bearing parts.

Check the coolant level only when the engine has cooled off sufficiently.

Fig. 5-11

Expansion tank

Turn the cover (big arrow) a half turn.

In this position, relieve any pressure that may be present. After equalizing the pressure, slowly open the cap all the way.

The coolant must be at least at the MIN mark or above. When cold, do not fall below the MIN mark.

Add coolant if necessary.

Close the cap.

After adding coolant, allow the engine to run for a short time with the heater turned on and then recheck the coolant level.

5.7.3

Anti-corrosion fluid and antifreeze The system must be filled with antifreeze year round.

At delivery, the coolant contains antifreeze for temperatures up to -37 °C (this corresponds to approx. 50 % antifreeze).

When carrying out maintenance work, the mixing ratio of the coolant must be checked.

Quantity: see Lubrication Chart Note!

Do not use more than 60 % anti-corrosion fluid/antifreeze!

At a higher percentage, the cooling effect and antifreeze protection would actually be reduced.

5 - 26

MJFCIFSS

A 309 Litronic / 8720354

Operating instructions

Maintenance Cooling system

5.7.4

Changing water filters

Fig. 5-12

Water filter

The water filter must be replaced every 500 operating hours: Close the shut off valves (arrows) on the filter housing.

Unscrew the filter element.

Lubricate the seal ring on the new filter element lightly with oil.

Install the new filter element until the seal ring is touching on the filter head.

Note!

The filter element can be damaged.

Do not use any tools to tighten the filter element.

Tighten the filter element by hand a 1/2 - 3/4 turn.

Open the shut off valves again.

5.7.5

Changing the coolant Danger!

Danger of burns due to hot coolant.

Change the coolant only when the engine is cold.

When changing the coolant, observe the following points: ling circuit at least every two years. closed. rcuit after refilling. take place with the ignition key in the contact position.

A 309 Litronic / 8720354

MJFCIFSS

5 - 27

Maintenance

Operating instructions

Cooling system

5.7.5.1

Draining the coolant

Fig. 5-13

Drain valve

Open the cover of the expansion tank slowly.

Remove the cover plate on the underside of the engine.

Place a suitable container underneath.

Unscrew the cover of the drain valve 1 on the underside of the water cooler (see arrow) and attach the drain hose from the toolbox.

Fig. 5-14

Water taps on the Diesel engine

Open the water taps 2.

5.7.5.2

Refilling the coolant Remove the drain hose on the underside of the water cooler and close the valve.

Open the water taps 2.

Pour coolant into the expansion tank until the coolant is visible in the filler neck.

Turn the heater on and set it to its highest level; allow the Diesel engine to warm up.

Check the coolant level and add more coolant, if necessary.

5 - 28

MJFCIFSS

A 309 Litronic / 8720354

Operating instructions

Maintenance Fuel system

5.8 Fuel system Danger!

Danger of explosion!

Avoid open flames when working on the fuel system and when refuelling.

Do not smoke.

5.8.1 5.8.1.1

Refuelling Fuel tank cap

Fig. 5-15

Fuel tank cap

Unscrew tank cap 1 Add fuel via the strainer.

5.8.1.2

Electric refuelling pump (option)

Fig. 5-16

Electric refuelling pump

The electric refuelling pump is used to add fuel It is located behind the side door on the fuel tank.

A 309 Litronic / 8720354

MJFCIFSS

5 - 29

Maintenance

Operating instructions

Fuel system

For refuelling and storing hoses, proceed as follows: Connect the suction hose 1 and 2.

Insert the free end 3 of the suction hose into the fuel supply tank.

Open the shut off valve 4.

Use switch S25 (green) on the control unit 5 to turn the refuelling pump on and The pump turns off automatically as soon as the maximum fill level is reached.

The refuelling pump can be turned off at any time using switch S59 (red).

Caution!

Do not let the pump run dry.

Ensure that the fuel level does not drop below the suction level of the suction hose.

Close the shut off valve 4.

Make sure that there is no fuel in the suction hose 1 (2) before storing the hose.

Roll up the suction hose and place it in the storage compartment.

Close the cover again.

5.8.2

Draining the water from the fuel tank The condensation in the fuel tank and fuel system should be drained daily. If conditions of use and fuel quality permit, the maintenance interval can be increased to once a week.

Note To reduce condensation in the tank, keep the fuel level as high as possible.

Fig. 5-17 1

Fuel tank

Tank cap

2

Strainer

3

Drain plug

The bottom of the tank is equipped with a drain plug 3.

Open the drain plug 3 on the underside of the fuel tank by two turns.

5 - 30

MJFCIFSS

A 309 Litronic / 8720354

Operating instructions

Maintenance Fuel system

Drain off water until fuel emerges, close the plug again.

5.8.3

Emptying and cleaning the fuel tank To empty, remove the tank cap 1 and the drain plug 3 and allow the fuel to flow into a suitable container.

Clean the tank.

Check the tank and strainer2 regularly for contamination.

5.8.4

Draining off water at the preliminary fuel filter

Fig. 5-18

Fuel pre-filter

Turn in the shut off valve 1 slightly until the water flows off via the hose.

Drain the water visible in the glass container into a suitable container.

Close shut off valve 1.

5.8.5

Replacing the fuel prefilter cartridge Unscrew electrical cable 2.

Turn in shut off valve 1 slightly until fuel flows off.

Drain the fuel into a suitable container.

Remove sight gauge 4, unscrew filter cartridge 5.

Lubricate the seals on the filter head and the sight gauge (see arrows) lightly with oil.

Screw on new filter cartridge 5 and sight gauge 4.

Close shut off valve 1.

Install electrical cable 2.

Operate hand pump 3 until the sight gauge 4 is filled with fuel.

A 309 Litronic / 8720354

MJFCIFSS

5 - 31

Maintenance

Operating instructions

Dry air filter

Note The filter cartridge could be damaged if it is tightened too much!

Do not use any tools to tighten the filter.

5.8.6

Replacing the fuel filter cartridge (fine filter)

Fig. 5-19

Fuel fine filter

Unscrew fuel filter cartridge 1.

Lubricate the rubber seal ring on the new filter cartridge lightly.

Note The filter cartridge could be damaged if it is tightened too much!

Do not use any tools to tighten the filter.

Screw on the new filter cartridge and tighten by hand.

It is not necessary to bleed the fuel system after changing the fine filter.

5.9 Dry air filter Maximum engine protection against early wear due to dust is only possible if the dry air filter is serviced at regular intervals.

The dry air filter is designed to offer maximum protection and long maintenance intervals.

Washing the filter inserts is not recommended for safety reasons.

5 - 32

MJFCIFSS

A 309 Litronic / 8720354

Operating instructions

Maintenance Dry air filter

Fig. 5-20

Vacuum gauge

When the maximum intake pressure has been attained, the maintenance display on the purified air connection (see arrow) switches on and indicator light H13 (air filter contamination) illuminates.

Cleaning the dust discharge valve:

Fig. 5-21

Dust discharge valve extractor slot

Push the extractor slot up by hand once a week.

Dust falls out.

After that, accumulating dust and humidity cannot make the dust discharge valve stick.

5.9.1

Replace filter elements.

Caution!

Frequent removal and installation of filter elements can shorten the service life of the seals.

Do not replace the parts of the dry air filter more often than prescribed.

A 309 Litronic / 8720354

MJFCIFSS

5 - 33

Maintenance

Operating instructions

Dry air filter

Fig. 5-22

Assembling the dry air filter

1

Filter housing cover

4

Safety element

2 3

Filter housing Main element

5

Dust discharge valve

Stick to the change intervals: Replace main element 3, if, as a result of contamination, the maximum intake low pressure is exceeded.

Replace main element 3 at least once a year.

Only replace safety element 4 after every third change of main element 3, but in any case at least once a year.

Note!

Replace the safety element immediately in the event that a visual check has already shown that safety element 4 is very dirty.

Replace filter element(s): Remove the cover 1 with the engine switched off.

Take out filter elements 3 and 4.

Clean the interior of the air filter housing and the sealing surface in the housing using a damp cloth.

Caution!

Dirt could enter the engine intake!

Do not clean the housing by blasting out with compressed air.

Before installing a new filter element, clean the seal and the seal contact face in the housing carefully.

Insert a new filter element 3 with the old or new safety element 4, making sure it is sealed and positioned correctly.

Close the filter housing 2 with cover 1.

5 - 34

MJFCIFSS

A 309 Litronic / 8720354

Operating instructions

Maintenance Hydraulic system

5.9.2

Monitoring the filtered air line

Fig. 5-23

Filtered air line

Monitor the filtered air line 1 between the filter outlet and the engine intake pipe for damage and leaks each time the filter element is replaced.

Fig. 5-24

Not every tensioning clap should be tightened

Note!

Tensioning clamps with spring assemblies (3, see arrow) can themselves even out any changes in diameter that may arise. Retightening can affect their function.

Do not retighten tensioning clamps with spring assemblies.

If necessary, retighten the tensioning clamps 2.

5.10 Hydraulic system Maintenance work on the hydraulic system is restricted mainly to the hydraulic tank.

All other system components do not require special maintenance.

The pipe and hose network should be checked at regular intervals for leaks.

A 309 Litronic / 8720354

MJFCIFSS

5 - 35

Maintenance

Operating instructions

Hydraulic system

Note!

Strict cleanliness is of particular importance for the hydraulic system.

For this reason, the intervals given

5.10.1

Checking the oil level in the hydraulic tank The oil level is checked using the sight gauges on the hydraulic tank. The sight gauges are accessible when the engine hood is open.

Fig. 5-25

Sight gauges on the hydraulic tank

The lower eye - MIN - shows the minimum oil level if all cylinders are fully extended.

When checking the minimum oil level, the following prerequisites must be met: The hydraulic excavator must be standing on level ground.

The attachment must be fully raised and the adjustable boom cylinder, hydraulic cylinder, stick cylinder and bucket cylinder fully extended (stick and bucket curled in).

The blade and / or outrigger support must be fully extended or lowered.

The oil level may not fall below - MIN - level.

The upper eye - MAX - shows the maximum oil level if all cylinders are fully retracted.

When checking the maximum oil level, the following prerequisites must be met: The hydraulic excavator must be standing on level ground.

The attachment is placed on level ground, the stick and bucket cylinders are fully retracted.

The blade and / or outrigger support must be fully retracted or lowered.

The oil level may not exceed - MAX - level.

Check the oil level and add more oil, if necessary.

5 - 36

MJFCIFSS

A 309 Litronic / 8720354

Operating instructions

Maintenance Hydraulic system

5.10.2

Relieving the pressure in the hydraulic system Danger!

A fine stream of oil can penetrate the skin when under high pressure and cause serious injury.

Before working on the hydraulic system, always relieve the pressure.

Do not check for leaks with bare hands.

Note the following points: Place down the attachment Shut down the engine.

Move the pilot control devices (joystick and pedals) in all directions (with the ignition key in contact position).

Danger!

The hydraulic oil is hot when at operating temperature and could be pressurized.

Do not allow your skin to come into contact with hot oil or components containing hot oil.

Fig. 5-26

Relieving the pressure in the hydraulic system

Back out the breather filter 1 by a maximum of one turn.

The pressure in the hydraulic system is relieved.

The breather filter 1 can be turned manually if the safety pin 2 is inserted. An open end spanner can be used if the filter does not open easily.

A 309 Litronic / 8720354

MJFCIFSS

5 - 37

Maintenance

Operating instructions

Hydraulic system

5.10.3

Emptying and refilling the hydraulic tank

Fig. 5-27 1

Draining and refilling the hydraulic oil

Breather filter

2

Return filter

3

Drain valves

If possible, always fill and empty the hydraulic system using a filler unit.

To drain the oil: The pressure in the hydraulic system must be relieved.

Back out the breather filter 1 by a maximum of one turn.

The pressure in the hydraulic system is relieved.

Remove the cover of the return filter 2.

Install the drain hose to the drain valves 3 in the tank bottom and let the oil flow out into a suitable container.

To refill the hydraulic oil: Back out the breather filter 1 by a maximum of one turn.

The pressure in the hydraulic system is relieved.

Remove the cover of the return filter 2.

Refill the oil through the filter cartridge until the level reaches precisely the center mark on the sight gauge.

Tighten the breather filter 1.

Install the cover of return filter 2.

Caution!

After each hydraulic oil change, bleed the hydraulic pumps.

To drain the condensation: Drain the condensate regularly.

Place a suitable container underneath the tank.

Keep the drain hose on the drain valves 3 (see Fig. 5-27) until oil contains no more water.

Interval: see Maintenance schedule

5 - 38

MJFCIFSS

A 309 Litronic / 8720354

Operating instructions

Maintenance Hydraulic system

5.10.4

Return filter The return filter is located on the top of the hydraulic tank.

Fig. 5-28

Return filter

1 2

Cover Hex head screw

5 6

Magnetic plug Filter element

3

Gasket

7

Protective cylinder

4

Bypass cage

The magnetic rod 5 of the return filter must be cleaned at fixed intervals (see maintenance chart) and the glass fiber filter element 6 replaced.

Note!

When working in dust intensive conditions, please observe the special regulations for filter change.

To clean the magnetic rod or replace the filter element: The pressure in the hydraulic system must be relieved.

Unscrew the four screws on the filter cover and lift out the cover 1 and magnetic rod 5.

Carefully clean the magnetic rod to remove any dirt particles.

Remove the used filter cartridge 5 using the bracket.

Vertically insert the new filter cartridge into the tank, using the bracket and press down lightly. Then place the bracket on the side on the tank ring.

Caution!

Ensure that the filter cartridge is vertically positioned in the tank.

Center the cover unit and bypass cage 4 on the filter element 6 and set it on top.

When doing this, ensure that the gasket 3 is positioned correctly and is in good condition.

A 309 Litronic / 8720354

MJFCIFSS

5 - 39

Maintenance

Operating instructions

Hydraulic system

Note!

The filling hole of the hydraulic tank is equipped with a protective cylinder 7. This prevents objects from getting into the hydraulic tank. The protective cylinder can be removed from the filling hole, if required.

Note!

Each time you replace the filter element 6, also replace the pressure filter integrated in the servo oil unit.

5.10.5

Servo oil filter The pressure filter 8 is part of the servo oil unit 1 which is located on the rear of the hydraulic tank.

Fig. 5-29

Servo oil unit

1 2

Servo oil unit Pressure filter

5 6

Filter element seal ring Filter housing

3

Mounting stud

7

Filter housing seal ring

4

Filter element

8

Pressure accumulator

Note!

It is not permitted to clean the filter element.

Change the filter element each time the filter housing is opened.

To replace the filter element: The pressure in the hydraulic system must be relieved.

Unscrew the filter housing 6 from pressure filter 2 and remove filter element 4.

Clean the filter housing.

Oil the thread and sealing surfaces on filter housing 6 and on servo oil unit 1 as well as seal rings 5 and 7 with hydraulic oil.

Push the filter element 4 carefully onto the mounting stud 2.

Screw filter housing 6 on completely and tighten by hand.

5 - 40

MJFCIFSS

A 309 Litronic / 8720354

Operating instructions

Maintenance Hydraulic system

Note!

When replacing the filter element 4, also replace the filter element seal ring 5.

5.10.6

Servo circuit The joysticks do not require special maintenance.

Inspect the pipe network as well as connections on all components (pressure accumulator, pressure limiting valve, pressure filter etc.) regularly for leaks.

Danger!

The pressure accumulator 8 (see Fig. 5-29) ensures that the servo circuit has enough pressure for a few movements, even after the Diesel engine has been shut down.

Before working on the servo circuit, the control pressure must be relieved as follows: Place the attachment on the ground.

Shut down the engine.

Operate both joysticks (with ignition key in contact position).

5.10.7

Bleeding the hydraulic pump

Fig. 5-30

Hydraulic pump

After working on the pump or after changing oil in the hydraulic system, the hydraulic pump must be bled.

Loosen the fitting of the leak oil hose 1 slightly and allow the air to escape.

When hydraulic oil flows out, retighten the fitting.

Before using the pump for the first time or after repairs or replacement, the pump housing must be filled with hydraulic oil via the same connection.

A 309 Litronic / 8720354

MJFCIFSS

5 - 41

Maintenance

Operating instructions

Hydraulic system

5.10.8

Servicing the hydraulic cylinder

5.10.8.1

Checking the piston rod bearing

Fig. 5-31

Piston rod bearing

Note When a leak occurs on the piston rod bearing of a hydraulic cylinder (arrow), then the seal kit must be replaced by a LIEBHERR mechanic.

5.10.8.2

Protecting the piston rods

Fig. 5-32

Machine with piston rods retracted

When the machine is out of service for more than 4 weeks and particularly for transport by sea, the following measures must be taken: Position or transport the machine in such a way that the piston rods are fully retracted.

Cover any exposed piston rods with a thick layer of acid free anti-corrosion grease.

For sea transport, check the preservation of the piston rods again after loading.

Cover piston rods with anti-corrosion grease also if a cylinder is used with a low stroke for certain applications, and the piston rod is not regularly covered with hydraulic oil (e.g. cylinder on basic boom when working above ground).

Regularly check the condition of little moved hydraulic cylinders.

5 - 42

MJFCIFSS

A 309 Litronic / 8720354

Operating instructions

Maintenance Changing the oil on components

5.10.9

Replacing hydraulic hoses

Fig. 5-33

High pressure hose with SAE fitting

Danger!

A defective hydraulic hose can cause accidents and injuries.

Replace defective hydraulic hoses (bubbles, moisture, damaged top edge etc.) immediately.

Install new hydraulic hoses without torsion.

Ensure that the hydraulic hose is not twisted when mounting.

Installed high pressure hoses with SAE connections have a nominal diameter of 16, 20 or 25.

Tighten the mounting screws of SAE fittings with the following tightening torques. :

Screw

Grade

Torque

M10

10.9

68 Nm

M12

10.9

117 Nm

M14

10.9

185 Nm

Tab. 5-14 Tightening torques for SAE fittings

5.11 Changing the oil on components 5.11.1

General notes The machine must be in level position.

Shut down the engine.

Wait for a short time until the oil has collected in the oil pan.

If possible, drain the oil when it is at operating temperature.

A 309 Litronic / 8720354

MJFCIFSS

5 - 43

Maintenance

Operating instructions

Changing the oil on components

5.11.2

Swin gear - oil change

Fig. 5-34

Changing the oil on the swing gear

1

Drain valve

3

Oil container

2

Drain hose

4

Cap

To drain the oil: Remove the cap 4.

Unscrew the cover of the drain valve 1 via the opening on the base plate of the swing platform.

Screw the provided drain hose 2 on the drain valve and allow the oil to flow into a suitable container.

Remove the hose 2.

Reinstall the cover of the drain valve 1.

To add the oil: Add the oil via the tank 3 until the level reaches the MAX mark.

Reinstall cover 4.

5 - 44

MJFCIFSS

A 309 Litronic / 8720354

Operating instructions

Maintenance Changing the oil on components

5.11.3

Transmission - oil change

Fig. 5-35 1

Changing the oil in the transmission

Oil drain plug

2

Oil filling and oil filler plug

To drain the oil: Remove the oil filler plug 2.

Remove the oil drain plug 1.

Drain the oil into a suitable container.

Install the oil drain plug 1.

To add the oil: Add the oil until the oil level reaches bore 2.

Install the oil filler plug 2.

5.11.4

Steering and rigid axle - oil change

Fig. 5-36

Changing the oil on the steering axle and rigid axle

1

Oil drain plug

3

Oil level check

2

Oil filler plug

To drain the oil: Remove oil filler plug 2 and oil drain plug 1.

A 309 Litronic / 8720354

MJFCIFSS

5 - 45

Maintenance

Operating instructions

Drain the oil into a suitable container.

To add the oil: Screw in oil drain plug 1.

Remove plug 3.

Add the oil until the oil level reaches bore 3.

Screw in oil filler plug 2 and plug 3.

Fig. 5-37

Changing the oil on the wheel head (draining the oil, Fig. left, adding the oil, Fig. right)

To drain the oil: Turn the wheel head until the plug is located exactly vertically beneath the center of the wheel.

Remove the plug and drain the oil to flow into a suitable container.

Reinstall the plug.

To add the oil: Turn the wheel head until the level mark line is exactly horizontal.

Add the oil up to the bottom edge of the bore.

Reinstall the plug.

Check the wear on the multi-disk brake at least once a year.

The wear on the multi-disk brake can be checked without removing the planetary carrier or disks (see Service manual).

Check brake wear also in case of the following problems:

5 - 46

MJFCIFSS

A 309 Litronic / 8720354

Operating instructions

Maintenance Electrical system

5.13 Electrical system 5.13.1

Notes for electrical system Danger!

Danger of injury due to spark formation.

Avoid sparks and open flame when charging batteries or working on the batteries.

Always wear safety glasses and protective gloves. r correct function at regular intervals.

Burnt out fuses and bulbs must be replaced immediately after the cause of the defect has been rectified.

Fix any problems, such as loose connections, chaffed wires or incorrectly attached clamps immediately.

Disconnect the batteries when working on the electrical system or when carrying out electric arc welding on the machine.

Danger!

Danger of injury due to spark formation.

Disconnect the negative terminal (-) first and connect it last.

5.13.2

Battery master switch Caution!

Be especially careful with machines with built-in auxiliary heater.

Turn the battery master switch only off when the auxiliary heater's after-run is completed.

A 309 Litronic / 8720354

MJFCIFSS

5 - 47

Maintenance

Operating instructions

Electrical system

Fig. 5-38

Battery master switch

Before starting any work on the electrical system, including welding work on the machine, switch the battery master switch to position 0.

When washing the machine, cover the electrical components (particularly the alternator, generator, wiring, electronic components and transmitters) to prevent moisture penetrating.

When cleaning the engine with a water / steam jet, do not hit electric sensors such as oil pressure switches directly with water or steam.

Otherwise moisture could penetrate and lead to contact corrosion and the failure of the transmitters.

Oil pressure switches are not watertight due to the necessary membrane ventilation.

Note!

Battery can discharge if the machine is out of service for longer periods of time.

Before a longer down time, switch the battery master switch to position 0 (off).

5.13.3

Battery care The battery must always be kept clean to ensure proper function.

Especially the pole ends and battery terminals A must be cleaned regularly and then covered with a thick layer of acid free grease (see Fig. 5-39).

Danger!

Bent rubber hoses of central degasification increase the risk of explosion!

The hydrogen created in the batteries may not be allowed to build up in the battery compartment and must be able to escape through the rubber hoses. The hoses of the central degasification must be routed without kinks.

Check the condition of the hoses B regularly, especially after installing a battery (see Fig. 5-39).

The fluid level in the cells should be 10 to 15 mm above the top of the plate. Use only distilled water when refilling.

5 - 48

MJFCIFSS

A 309 Litronic / 8720354

Operating instructions

Maintenance Electrical system

Fig. 5-39

Battery care

From time to time, use an acid tester C to measure the acid concentration.

When the battery is fully charged, the unit weight is 1.28 kg/l (31.5° Bé).

If the acid tester displays a lower value, then the battery is more or less discharged and must be recharged, if necessary.

5.13.4

Slip ring assembly (option)

Fig. 5-40

Slip ring assembly

Slip ring assemblies are sensitive to moisture. An oxide layer can form on the conductive surfaces, which restricts the flow of current. Electrical users in the undercarriage will no longer be supplied sufficiently with current, which can lead to malfunctions.

To prevent this, it is recommended that the following work is carried out every 500 operating hours.

Unscrew the lock nuts 1.

Remove the slip ring housing 2.

Clean the oxidation off the slip ring assembly (use a cleaning spray if necessary).

Replace damaged (corroded) wire lugs.

Spray "Cramolin" contact spray on all slip ring elements.

Replace the housing 2.

Fasten the housing 2 evenly with lock nuts 1.

A 309 Litronic / 8720354

MJFCIFSS

5 - 49

Maintenance

Operating instructions

Heating system / heating and air conditioning system (option)

5.14 Heating system / heating and air conditioning system (option) 5.14.1

Fresh air filter

Fig. 5-41

Fresh air filter

The air flow in the heating and air conditioning system is reduced when the fresh air filter is dirty, which frequently results in the system icing up or shutting down. ing in dust intensive conditions. without these filters, since the heat exchanger will be blocked quickly.

Open clamp 1 and push cover 2 up.

Remove the fresh air filter 3.

Note!

Never wash the filter elements with hot water or a steam jet.

If damaged or in a bad condition, replace the filter elements.

Blow out the fresh air filter 3 with compressed air or clean in cold or luke warm water.

5 - 50

MJFCIFSS

A 309 Litronic / 8720354

Operating instructions

Maintenance Heating system / heating and air conditioning system (option)

5.14.2

Heating system

Fig. 5-42

Water taps on the Diesel engine

If the heater remains off for an extended period of time (e.g. in summer), close the water taps 2 on the Diesel engine.

Carry out the following maintenance work on the heating system annually before the start of the heating period: e coolant circuit, the hose connections on the heat exchanger, the seals on the shut off valves and the hose clamps. n fluid and antifreeze in the coolant.

Fig. 5-43

Heating / air conditioning unit

To check the heat exchanger / evaporator: Check the fins on the heat exchanger 1 and evaporator 2 (air conditioning system) annually for damage.

Blow out with compressed air if dirty.

Align the fins, if necessary.

5.14.3

Air conditioning system (option) Switch on the air conditioning system for approx. 10 minutes every 2 or 3 weeks, regardless of the season.

During the operating period, the following maintenance work must be carried out every 500 operating hours:

A 309 Litronic / 8720354

MJFCIFSS

5 - 51

Maintenance

Operating instructions

Heating system / heating and air conditioning system (option)

Fig. 5-44

Condenser

To check the condenser: If heavily contaminated, overpressure forms in the air conditioning circuit and the air conditioning system turns off automatically.

Remove cover 1.

Check the condenser 2 for contamination.

If necessary, blow out the condensor 3 with compressed air from the front through the mesh guard 4 of the fan motors. Remove the fan motors, if necessary.

Make sure that the condenser fins are clean.

To check the A/C compressor:

Fig. 5-45

A/C compressor

Tighten the mounting screws of the A/C compressor (see arrow) and retainer on the Diesel engine.

Check the condition of the compressor V-belt.

5 - 52

MJFCIFSS

A 309 Litronic / 8720354

Operating instructions

Maintenance Heating system / heating and air conditioning system (option)

Fig. 5-46

Dryer-accumulator unit

To check the dryer-accumulator unit: With the Diesel engine running and the air conditioning system turned on, check the refrigerant level in the sight gauge a of the dryer accumulator unit 5.

Note!

If there is insufficient refrigerant, the white floater ball 6 is at the bottom of the sight gauge.

If the cooling effect is diminishing, have the system refilled by a refrigeration technician.

Determine the degree of moisture of the desiccant in dryer accumulator unit 5.

To do this, check the color of the indicator pearl 7 in the sight gauge a.

If the pearl is blue, the degree of moisture in the air conditioning circuit is OK. If, however, the pearl is pink, then the dryer-accumulator unit is saturated with moisture.

Change dryer-accumulator unit 5 immediately.

Check the condition of the of dryer accumulator unit visually.

If you notice that the refrigerant collector is rusty or damaged (e. g. on the panel mounting, on the hose connection), replace the refrigerant collector (pressure tank).

In the last two cases and at least once a year, the dryer-accumulator unit 5 must be replaced by a technician trained in air conditioning systems.

The A/C circuit must be emptied, checked for leaks and refilled. Check the hose lines for abrasion, replace and, if necessary, retighten the hose connections.

Fig. 5-47

A 309 Litronic / 8720354

Fan motor on the heating /air-conditioning unit

MJFCIFSS

5 - 53

Maintenance

Operating instructions

Lubricating the machine

Additional maintenance work: The following maintenance work must also be carried out at least once a year by a technician trained in air conditioning systems: Check the function of the fan motor M65.

Check the function of the air flaps in the heating / air-conditioning system.

Check the electrical connections for tight seating (good contact).

Check the electrical lines for abrasions.

Check the defrost thermostat B295 (for function, correct positioning and for damage).

Check the function of the pressure switch B294 on the dryer-accumulator unit 9 (see Fig. 5-46).

5.15 Lubricating the machine Note!

When lubricating the machine with a manual grease gun, the required effort is reduced significantly if the grease is pumped in slowly.

5.15.1

Lubricating the swing gear

Fig. 5-48

Central lubrication, swing race / gears

Lubrication is carried out at the grease bar. The grease bar is located under the swing platform. Lubrication must be carried out daily in multi-shift operation.

To grease the swing race a, use the manual grease gun to pump two strokes of grease into grease fittings 1 and 2.

5 - 54

MJFCIFSS

A 309 Litronic / 8720354

Operating instructions

Maintenance Lubricating the machine .

Fig. 5-49

Pinion on swing gear

A housing (see arrow) which surrounds the swing gear pinion provides a virtually sealed grease reserve for gear lubrication on the swing ring. Lubrication ensures partial replacement of this reserve.

For partial replacement of the grease reserve, pump 20 strokes of grease into grease fitting 3 with the manual grease gun.

5.15.2

Lubricating the attachment Each lube point on the attachment must be lubricated every 10 to 50 operating hours (depending on use and multi-shift, daily or for each shift).

5.15.3

Lubricating the axles Lubricating the steering knuckle bearings:

Fig. 5-50

Lube points of steering knuckle bearing

Caution!

Do not use too much grease on the steering knuckle bearings.

Grease each bearing point with two strokes.

Grease the bearing points via the grease fittings with a manual grease gun.

A 309 Litronic / 8720354

MJFCIFSS

5 - 55

Maintenance

Operating instructions

Lubricating the machine

Lubricating the oscillating bearing: The bearing of the oscillating axle has two lube points.

Fig. 5-51

Lube points of oscillating bearing

Use a manual grease gun to grease the oscillating bearing via the grease fitting, until clean grease emerges on the bearing points.

5.15.4

Lubricating the digging tool / bucket tilt device The lubrication points on the digging tool or change over lever / connector link must be lubricated regularly. The corresponding lube points are marked in red.

Fig. 5-52

Lubrication of digging tool

In normal use, each lube point must be greased weekly until clean grease emerges on the corresponding bearing point.

In severe applications, for example when handling material that causes wear, when working under water or in multiple shifts, the lubrication must be made daily or for each shift.

5.15.5

Lubricating the grapple (option) The grapple must be lubricated regularly. The corresponding lube points are marked in red.

5 - 56

MJFCIFSS

A 309 Litronic / 8720354

Operating instructions

Maintenance Quick change systems

Fig. 5-53

Lubrication of grapple

In normal use, each lube point must be greased daily or per shift until clean grease emerges on the corresponding bearing point.

In severe applications, the lubrication interval should be shorted accordingly.

5.16 Quick change systems 5.16.1

Lubricate the mechanical quick change adapter (option) The mechanical quick change adapter is not lubricated via the central lubrication system. The bearing points must be greased using the grease gun.

Fig. 5-54

Lubrication of mechanical quick change adapter

Grease the bearing points via the grease fitting with a grease gun.

A 309 Litronic / 8720354

MJFCIFSS

5 - 57

Maintenance

Operating instructions

Quick change systems

Note!

If the mechanical quick change adapter is greased when the pin is extended, the hollow area between the locking pins fills with grease and the pins can no longer be retracted.

Make sure that the locking pins are retracted during the lubrication procedure.

5.16.2

Hydraulic quick change adapter (option) Lubricating the quick change adapter: The hydraulic quick change adapter is not greased via the central lubrication system.

The bearing points must be greased using the grease gun.

Fig. 5-55

Lubricating the quick change adapter

Grease the locking pins 1 via the grease fitting with a grease gun.

Note!

The hydraulic quick change adapter cannot be sufficiently greased if the locking pins are extended.

Make sure that the locking pins are retracted during the lubrication procedure.

Cleaning the strainer:

Fig. 5-56

5 - 58

Cleaning the strainer

MJFCIFSS

A 309 Litronic / 8720354

Operating instructions

Maintenance Quick change systems

The filter disc 12 in the fittings between the connecting hoses and the hydraulic cylinder must be checked for blockages and cleaned, if necessary, every 2000 operating hours.

Remove the cover 20 and the screws 21 from the quick change adapter.

Remove the fittings and hydraulic hoses from the hydraulic cylinder 10.

Screw out the outer mounting assembly 13 using a suitable tool (e g. a tack).

Remove the filter disc 12, check it and clean or replace it, if necessary.

Place the filter disc 12 on the inner mounting assembly 11 and mount the outer mounting assembly 13.

Connect the fittings and hydraulic hoses to hydraulic cylinder 10.

Attach the cover 20 with the screws 21 on the quick change adapter.

5.16.3

LIKUFIX (option)

5.16.3.1

Cleaning LIKUFIX The LIKUFIX hydraulic coupling system is mostly maintenance-free.

We recommend to clean the system at regular intervals and spray it with lubricant (see Service manual). This will prevent dirt adhering and icing up.

If the system is kept properly clean, the seals are very durable.

5.16.3.2

Replacing the seal ring

Fig. 5-57

Replacing the seal

If leaks occur at the coupler plugs (A, see arrows), replace the seal rings.

A 309 Litronic / 8720354

MJFCIFSS

5 - 59

Maintenance

Operating instructions

Parking and swing gear brake

Use a screwdriver to push down the seal plate on the coupler plug and lift out the defective seal ring with a pointed object (B).

Press the new seal ring together and place it on the seal plate with open side down (C).

Press down the washer as far as the groove, place the screwdriver in the middle of the seal ring and move your hand away (D).

Allow the seal ring to snap into the groove (E).

Remove the screwdriver (F).

The seal plate must move upwards. If necessary, press the seal ring down again until the seal plate is moveable.

5.17 Parking and swing gear brake Both the parking brake on the transmission and the swing gear brake are negative acting, wet multi-disk brakes.

They are vented hydraulically and are fully sealed and integrated in the transmission or swing gear.

Their usage purely as parking brakes makes them wear-free and therefore maintenance free.

5.18 General Maintenance points 5.18.1

Replacing wear parts In addition to the normal maintenance and service work, which have to be carried out in the given intervals, the following repairs can also be made by the machine operator or maintenance personnel:

tions of hydraulic components (but not on pressure relief valves which are sealed with a lead seal at the factory). tem can be replaced.

It should be noted that only original LIEBHERR spare parts are to be used.

This is particularly true for hoses and hydraulic lines, which must be preassembled at the factory. For all other repairs, particularly when removing the counterweight, factory or dealer mechanics must be consulted.

5.18.2

Replacing the teeth on the digging tool Determine the degree of wear of the teeth visually.

5 - 60

MJFCIFSS

A 309 Litronic / 8720354

Operating instructions

Maintenance General Maintenance points

With heavily worn teeth, considerably greater force will be required for the digging tool to penetrate the digging material. The teeth must be replaced in time to prevent damage to the tooth adapter.

Do not work with the machine if teeth on the digging tool are missing or are heavily worn.

To attach and remove teeth with wedge retainers:

Fig. 5-58

Replacing the teeth

Use a hammer and driver 1 to knock out the wedge 2 (A ).

Remove the old tooth.

Place a new rubber wedge retainer 3 on the tooth retainer (B).

Push the new tooth on the adapter.

Use the hammer to knock in the wedge 2 (C).

To attach and remove teeth with tension pin retainer:

Use a hammer and driver 1 to knock out the tension pin 2 (A).

Remove the old tooth.

Push the new tooth onto the adapter (B).

Knock in the tension pin 2 with the hammer (C).

5.18.3

Welding work on the machine Welding work on all main components serving for power transmission (such as the undercarriage frame, swing platform, attachment parts etc.) may only be carried out by the manufacturer or by an authorized workshop.

A 309 Litronic / 8720354

MJFCIFSS

5 - 61

Maintenance

Operating instructions

Inspection and maintenance schedule

Disconnect the battery before starting any electric arc welding work on the machine.

Always disconnect the negative terminal (-) first and reconnect it last.

Turn the battery master switch off!

Caution!

If high currents flow through the bearings or sealing elements, they could be burnt.

Move the grounding cable of the welding tool as close as possible to the welding area, so that the welding current cannot flow over parts, such as the swing ring, joints, bearings, bushings, rubber elements or seals.

5.19 Inspection and maintenance schedule Caution!

Careful maintenance can only be carried out when the machine is clean. In particular, visual inspections, such as for cracks, can only be made on a clean machine.

Clean the machine before starting any maintenance work (see also the chapter

Note!

The daily maintenance tasks, which the machine operator has to carry out, include a function check of the brakes (swing gear, operating and parking brake), steering and the electrical and hydraulic systems.

Additionally, a visual check must be made for leaks on the engine, hydraulic system, transmission and axles.

Maintenance / inspection at operating hours

WORK TO BE CARRIED OUT A 309 / A 311 Litronic By maintenance personnel (machine operator)

By authorized expert personnel

First and only interval Repeat interval Special interval every 250 hours

Note

First and only interval Repeat interval

DIESEL ENGINE Check oil level and oil pressure in engine Check coolant level and coolant temperature Check air filter via maintenance indicator Check and drain water separator on fuel filter Drain off water and sediment on fuel tank

5 - 62

MJFCIFSS

A 309 Litronic / 8720354

Operating instructions

Maintenance Inspection and maintenance schedule

Maintenance / inspection at operating hours

WORK TO BE CARRIED OUT A 309 / A 311 Litronic By maintenance personnel (machine operator) First and only interval Repeat interval Special interval every 250 hours

By authorized expert personnel

Note

First and only interval Repeat interval

Empty dust collector on air filter (shorten or extend interval as necessary) Check and clean cooler, pressure relief valve, coolant hose, fan Replace lube oil filter cartridge Replace engine oil

1)

Check oil, cooling and fuel system for leaks and condition Replace water filter cartridge (at least 1 x annually) Check and adjust throttle control Check anti-corrosion fluid / antifreeze in coolant (replace coolant every 2 years) Check condition and tension of the V-belt (using a testing device at operating temperature). (Replace every 2 years) Check / adjust valve clearance Check engine console and oil sump mounts, clamps etc.

Check flexible fuel leak oil line (change at least every 2 years) Check intake system and exhaust system for leaks and for condition Replace fuel fine filter cartridge (or as necessary)

4)

Replace fuel pre- filter cartridge (or as necessary)

4)

Replace main element of air filter (according to maintenance indicator / annually) Replace safety element of air filter (every third change of main element / annually)

Never clean!

Check clean air line (during filter maintenance) Check / adjust injection valves every 3000 hrs. (if performance diminishes) HYDRAULIC SYSTEM Check oil level in hydraulic tank Clean magnetic rod in return filter (daily during first 300 hrs.)

Replace filter element in return filter (first time at 500 hrs.)

2)

Replace filter unit on servo oil unit Check mounting of components

A 309 Litronic / 8720354

MJFCIFSS

5 - 63

Maintenance

Operating instructions

Inspection and maintenance schedule

Maintenance / inspection at operating hours

WORK TO BE CARRIED OUT A 309 / A 311 Litronic By maintenance personnel (machine operator)

By authorized expert personnel

First and only interval Repeat interval Special interval every 250 hours

Note

First and only interval Repeat interval

Clean hydraulic oil cooler (and as necessary) Drain off water in hydraulic tank (when using environmentally friendly fluids, max. 0.1 % part of water permissible, insert bypass filter, take oil sample) Check hydraulic system for leaks and function Check / adjust servo, primary and secondary pressures Replace hydraulic oil in tank (or optimize interval with oil analysis)

2), 3)

Replace breather filters on hydraulic tank

2)

ELECTRICAL SYSTEM Check indicator lights and displays when turning on Check lighting Check acid concentration and level and cable terminals and pole ends on batteries as well as all plug connections Spray slip rings on rotary connection (if present) with Cramolin contact spray Check function of entire system and components SWING GEAR Check oil level and look for leaks Check function and action of swing gear brake Check mounting of gear and oil motor Replace gear oil (first time at 500 hrs.)

SWING RING Renew lubrication on gear Renew lubrication on swing race Check mounting screws for tight seating and entry of swing gear pinion TRANSMISSION Check oil level and look for leaks Check function of gear shift and parking brake

5 - 64

MJFCIFSS

A 309 Litronic / 8720354

Operating instructions

Maintenance Inspection and maintenance schedule

Maintenance / inspection at operating hours

WORK TO BE CARRIED OUT A 309 / A 311 Litronic By maintenance personnel (machine operator)

By authorized expert personnel

First and only interval Repeat interval Special interval every 250 hours

Note

First and only interval Repeat interval

Check mounting of transmission, oil motor and drive shafts Replace gear oil (first time at 500 hrs.)

AXLES Check oil level and for leaks, check wheel lugs for tight seating.

Check mounting tightness of axles Lubricate steering knuckle bearing (weekly / monthly, depending on application) Replace oil of differential and planetary gear, front and rear (first time at 500 hrs.)

Check wear on multi-disk brake (1 x annually or as necessary) STEERING Check for leaks and function Check mounting tightness of components and steering parts OSCILLATING AXLE SUPPORT Check for leaks and function Check mounting tightness of cylinders BRAKE SYSTEM Check system for leaks Check function and action Check accumulator and brake pressure as well as control switch

Check / refill washing fluid in windshield washer system container Check function of heater (before start of winter) Check heating system for leaks Check door and window hinges as well as locks

A 309 Litronic / 8720354

MJFCIFSS

5 - 65

Maintenance

Operating instructions

Inspection and maintenance schedule

Maintenance / inspection at operating hours

WORK TO BE CARRIED OUT A 309 / A 311 Litronic By maintenance personnel (machine operator) First and only interval Repeat interval Special interval every 250 hours

By authorized expert personnel

Note

First and only interval Repeat interval

Check water inlet valve for function and dirt, clean if necessary AIR CONDITIONING SYSTEM Turn on air conditioning system regularly (at least 1 x every 14 days) Check condenser for contamination, blow out if necessary Check mounting screws and compressor drive belt Check dryer collector unit (moisture, fill and condition), replace if required (at least every 2 years) Clean fresh air filter (at least 1 x monthly, weekly for dust intensive use) Replace fresh air filter (shorten change interval for dust intensive use) Check mounting of air conditioning system, hose connections and electrical contacts (at least 1 x annually) UNDERCARRIAGE + UPPERCARRIAGE + ATTACHMENTS Lubricate bearing points on attachment Grease swing bearing Visually check wear condition of teeth Lubricate bearing points on undercarriage (depending on application, daily in mult-shift operation) Check parts for cracks Check mounting tightness of counterweight and tank Check tight seating of attachment pins

400 Nm

Check line and screw connections for tight seating Check cover hinges, quick connections and gas cylinders on hoods Point out appropriate use of attachment Have machine lubricated according to lubrication schedule by the machine operator and point out any operating errors.

HYDRAULIC QUICK CHANGE ADAPTER Check function of visual and acoustic warning devices Check extended position of locking pins visually

5 - 66

MJFCIFSS

A 309 Litronic / 8720354

Operating instructions

Maintenance Inspection and maintenance schedule

Maintenance / inspection at operating hours

WORK TO BE CARRIED OUT A 309 / A 311 Litronic By maintenance personnel (machine operator) First and only interval Repeat interval Special interval every 250 hours

By authorized expert personnel

Note

First and only interval Repeat interval

Check condition of hydraulic hoses and of wiring harness Lubricate locking pins Clean strainer MECHANICAL QUICK CHANGE ADAPTER Check extended position of locking pins visually Lubricate locking pins Tab. 5-15 Inspection and maintenance schedule 1 2 3 4

A 309 Litronic / 8720354

Engine oil change intervals can be shortened depending on temperature, fuel and oil quality.

Observe shortened maintenance intervals in dust intensive application.

When using environmentally friendly hydraulic fluids, the maintenance interval is to be determined by regular analysis.

Shorten the maintenance interval depending on application (e.g. dust intensive application, barrel refuelling).

MJFCIFSS

5 - 67