08 Swing System

Service Manual
Chapter 8 - Swing system

Swing System.................................................................................................................................................... 8-2
Adjustment........................................................................................................................................ 8-2
1.1 Specifications ......................................................................................................................... 8-2
LFR/en/version: 08 / 2007
R 9250 from 13466
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R 9250 from 13466
Service Manual
Swing System
8 Swing System
The hydraulic swing circuit on Liebherr hydraulic excavators R 9250 is a closed circuit. The most important
components of this circuit are :
The electro hydraulic pilot control system.
2 hydraulic pumps A4 VG 125
2 hydraulic motors FMF 250
2 swing gears SAT 450 / 257 with integrated disk brakes
1 swing ring ROD 1304 DJ 001-001 (triple race roller bearing with inner both)
Technical data
A4 VG 125/125
Swing pumps
Swing pumps output
kW
2 220
Max. displacement
cm
2 125
l/min
2 353
Max. flow
Max. operating pressure
bar
350
Secondary pressure
bar
400
Hydraulic motors
2 FMF 250
Motor displacement
cm
256
Working pressure
bar
320
Torque
Nm
2 1239
Flow
l/min
2 391
RPM
t/min
1481
Swing gears
2 SAT 450 / 257

Nm
Torque
2 56000
13
Number of teeth
Swing ring
ROD 1304 DJ
114
Number of teeth
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Schematic
8.1 Schematic
8.1.1 Electric
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Schematic
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Schematic
FSG plate
E1005
Cabin connection box
E1038
Connection box regulation
F32
15A Fuse
U21
Left joystick
X88
Connector 18 poles / A1020 FSG
X96
Connector 4 poles / A1020 FSG
X122
Connector 70 poles / E1005 elevation
X300
Kl31 electronic ground E1005
X450
Connector 2 poles / Y150
XR450
Connector 2 poles / YR150
X455
Connector 2 poles / Y155
XR455
Connector 2 poles / YR155
X461
Connector 12 poles / U21
X755
Connector / Rotating deck
X858
Connector 24 poles / E1038
Y150
Solenoid valve swing left
YR150
Regulation solenoid valve - Swing left
Y155
Solenoid valve swing right
YR155
Regulation solenoid valve - Swing right
24V
Supply
0V
Ground
4 - 20X
4 - 20mA handle swing
4 - 20Y
4 - 20mA handle crowd
Kl31
Ground
SWL1
Regulation solenoid valve - Swing left supply
SSWL1
Solenoid valve - Swing left sypply
SWR1
Regulation solenoid valve - Swing right supply
SSWR1
Solenoid valve - Swing right supply
A1020
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Swing System
Schematic
8.1.2 Hydraulic
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Schematic
Lower collecting pipe - support control valves
CP3
Collecting pipe power pack
Test point
GS1
Swing gear left
GS2
Swing gear right
MA
Test point / high pressure - swing right
MB
Test point / high pressure - swing left
MH
Test point
MS1
Left swing motor
MS2
Right swing motor
P5.1
Rear swing pump
P5.2
Front swing pump
SP
Suction pipe
SU1
Servo oil unit
Y150
Solenoid valve - swing left
YR150
Regulation solenoid valve - swing left
Y155
Solenoid valve - swing right
YR155
Regulation solenoid valve - swing right
CP2
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Swing System
Location of components
8.2 Location of components
Swing pumps P5.1 and P5.2
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Connection regulation box E1038
Servo oil unit
Cabin connection box E1005 with A1020
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Swing System
FSG plate A1020
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Functional description
8.3 Functional description

8.3.1 System control
The purpose of the electro-hydraulic swing control system is to activate swing movements of the machine proportionally to the deflection of the joystick (see joystick and pedal transmitters).
The left joystick U21 delivers an electrical signal (between 4 and 20 mA) depending on its momenteanous deflection.
The FSG plate amplifies the signal in order to supply the solenoid valves.
Joystick
U21
4-20 mA
FSG plate
A1020
Solenoid
valves
0-1 A
The graphic shows the signal delivered to the solenoid valves as a function of the joystick deflection.
* The values of the current delivered to the solenoid valves are default values to adjust.
The functioning range of the joystick corresponds to a deflection included between 10% and 90%.
The logical valves are closed for a deflection included between 0 and 10%. They are opened for a deflection
included between 10 and 100%.
Concretely, the swing movement occurs for a joystick deflection value of 10%. A maximum swing movement
is achieved for a joystick deflection value of 90%.
The solenoid valves Y150, YR150, Y155 and YR155 are normally activated (+24V) except if there is no current
on 24V movement (if ladder or service trap is not locked in upper position).
The switching solenoid valves (Y150 and Y155) and the regulating solenoid valves (YR150 and YR155) are
mounted in torque control valves (TCV) on the front swing pump P5.2. These switching and regulating solenoid
valves control the swing pumps.
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In this range, the opening of the corresponding regulation solenoid valve is proportional to the joystick deflection.
Service Manual
Swing System
8.3.2 Pumps
The 2 linked hydraulic pumps A4 VG 125 are variable displacement axial pumps in swash plate design, the
displacement volume and the flow increases as the pumps are shifted from the O or neutral position to their
maximum outputs.
When the swash plate is shifted from one angle via the neutral position to the other angle, the direction of flow
changes, while the direction of pump rotation remains the same, meaning that the pressure side becomes the
suction side and vice versa. In this way, it is possible to change the direction of the swing motor in the closed
loop circuit.
8.3.3 Motors
The pumps feeds the hydraulic constant volume motor FMF who are directly fixed on the swing gear SAT. The
FMF fixed displacement motor is used to drive the excavators swing gear. The axial piston motor is designed
as a swash plate type motor.
Axial piston motors are energy converters : they transform hydraulic energy into mechanical energy by their
axially directed pistons in cylinder housing.
The pistons with glide shoes rotate on the swash plate. Because of the inclination of the gliding surface, a piston
stroke in the cylinder is created; and thus the constant flow volume of the oil motor.
The pumps PS1 and PS2 feeds the hydraulic motors MS1 and MS2, which are linked.
8.3.4 Swing brake
The swing braking is achieved with disk brakes who are integrated in the swing gears SAT. The disk brakes
act directly on the gear drive. They are used as a spring applied brake and are vented hydraulically, i.e. if there
is no brake pressure, the disks are pressed together by springs and the brake is mechanically closed.
The brake is negatively acting, hydraulically actuated and serves as a holding or parking brake.
When working, the swing can be locked in any position with this brake.
The swing brake is actuated via the push button S17. When the brake is applied, the red indicator light lights
up. When the push button indicator light is off, the brake is released.
Apply the brake only when the uppercarriage is not moving. In order to stop the uppercarriage when working
on a slope, first stop its movement with the left joystick U21. Then apply the brake via push button S17 and
move joystick U21 to neutral position.
To check the swing brake : apply the swing brake via push button S17. Then move the left joystick U21 to the
right and then to the left to stop. The brake is working properly if the uppercarriage does not move.
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Optional equipment : swing brake controlled in semi automatic
With this equipment, the function of the push button is not apply and release the brake as described before,
but to preselect the operating mode of the mechanical swing brake, as follows :
In one position the brake remains always applied.
In the other position, the brake is in semi automatic mode and is controlled via the rocker switch S57 mounted to the right joystick lever U22 as follows :
With the rocker switch tilted down, the brake is applied, respectively it applies as soon as the uppercarriage speed gets lower than a limit value.
With the switch tilted up, the brake remains released.
Notice : the red control light in the button S17 lights up each time the brake is applied.
If this light does not go out when the rocker switch 81 is tilted up, the button must first be pushed to preselect
the semiautomatic mode.
The brake only applies when the uppercarriage is near standstill and if no swing motion is actuated via the joystick!
In order to stop the uppercarriage when working on a slope, tilt the switch 57 down and reduce the uppercarriage speed by braking with joystick U21. Move the joystick U21 back to O position. The brake will apply only
when the uppercarriage will be quite immobile.
Emergency stop of the uppercarriage swing motion : the swing brake can be applied independently of the uppercarriage RPM by switching the button S17 from position semi-automatic into position applied.
Perform this braking via button S17 only in emergency cases, since it causes fast abrasion of the brake discs.
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Swing System
Troubleshooting
8.4 Troubleshooting
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Adjustment
8.5 Adjustment
8.5.1 Specifications
Bar
30
Swing brake
Bar
30
High pressure relief valves (secondary valves)
Bar
400
Working pressure on TCV
Bar
350
Replenishing and positioning pressure
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Swing System
Detailed component description
8.6 Detailed component description

8.6.1 Swing pumop A4 VG 125
The swing pump is a variable displacement axial piston pump in swash plate design. It supplies the closed loop
swing circuit.
The displacement volume is in proportion to the input RPM and infinitely variable. The flow increases as the
pump is shifted from the O or neutral position to its maximum output.
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8.6.1.1 Rotary group
In the pump housing 1, parellel to the input shaft 5, are nine circular arranged pistons 7. The pistons move axially in the cylinder barrel 8, which in turn is firmly connected to the input shaft 5 via splines. The end of the pistons
are shaped in a ball joint which in turn is mounted in a ball socket / glide shoe 2. The glide shoes are held
against the variable, but non-rotating swash plate 4 by the retainer plate 84.
The swash plate 4 may be shifted from the neutral position to both sides by the guide pin 81.
The regulation of the pump via the guide pin 81 is performed by the positioning piston 10.2, located in the pump
housing and controlled by the torque control valve.
With the swash plate in the neutral position, which means vertical in relation to the input shaft, the piston stroke
and the pump flow is theoretically zero.
The higher the pressures difference between the two surface areas of the positioning piston 10.2, the further
the positioning piston is moved against spring pressure and the steeper the angle of the swash plate 4 will be.
When the swash plate 4 is shifted from one angle via the neutral position to the other angle, the direction of the
flow changes, while the direction of pump rotation remains the same, meaning that the pressure side becomes
the suction side and vice versa. In this way, it is possible to change the direction of the swing motor in a closed
loop circuit.
The control of the pump is via kidney shaped ports in the control lens 6 and the pump head 3. During the revolution of the cylinder 8, oil corresponding to the area and stroke of the piston 7 is sucked in by four pistons
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Depending on the angle of the swash plate 4, the nine pistons have a certain stroke, which in turn determines
the output (pump flow) of the swing pump.
Service Manual
Swing System
through the kidney shaped control ports on the return oil side of the closed circuit. Four pistons supply the oil
via kidney shaped control ports to the pressure side and push the oil via the pressure port into the closed loop
circuit. The ninth piston is at dead center, which means reversing direction.
8.6.1.2 Pump displacement
The oil flow of the pump is depending on the stroke of the pistons 7.
When the positioning piston 10.2 is shifted from its neutral position to one side, it swivels out the swash plate
4 via the guide pin 81 and the pump flow is increased correspondingly.
The shifting of the positioning piston is achieved while connecting one port X1, X2 of the piston to a control
pressure, called positioning pressure, while the other port is connected to the tank at the same time.
Usually the replenishing pressure for the swing circuit is also used as positioning pressure.
The regulation of the pressure connected to X1, X2 between tank pressure and positioning pressure is achieved by the torque control valve which may be externally mounted and serve to control the displacement of several swing pumps A4 VG.
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Service Manual
8.6.2 Hydraulic fixed displacement motor FMF with discharge

8.6.2.1 General data
Machine
R9250
Hydraulic motor
Type
FMF 250
Max. oil volume
Cm/U
250
Max. permissible leak oil quantity (without discharge at 300 bar)
L/min
11
Discharge quantity (at a p = 12 bar)
L/min
11
Nm
540
Tightening torque - discharge two way check valve 191
Nm
70 - 100
Tightening torque - discharge pressure - flow regulator 192
Nm
90
Inductive impulse transmitter 51
Nm
10 - 12
Tightening torque - allen head screws 14
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8.6.2.2 Description
The FMF fixed displacement motor is used to drive the excavators travel or swing gear. The axial piston motor
is designed as a swash plate type motor.
Axial piston motors are energy converters : they transform hydraulic energy into mechanical energy by their
axially directed pistons in a cylinder housing.
The pistons with glide shoes rotate on the swash plate. Because of the inclination of the gliding surface, a piston
stroke in the cylinder is created, and thus the constant flow volume of the oil motor.
8.6.2.3 Function of oil motor

Housing 12 contains nine pistons, which are located parallel to the output shaft 3. The pistons are contained
in cylinder 4, which is connected by gears to the output shaft 3.
The end of each piston 5 is designed as a ball joint, which is mounted in glide shoe 5.1. They are held against
the fixed and angulator mounted swash plate 6 by the retainer plate 7 and the return ball 8.
The hydrostatic support (oil film) between the glide shoes 5.1 and the fixed swash plate 6 (due to drillings in
piston 5 and glide shoes 5.1) reduces surface pressure between the glide shoe and the swash plate.
In a no load or pressureless condition, the cylinder 4 is pressed against the control lens 9 by spring 8.1, which
is installed in return ball 8. As the system pressure increases, cylinder 4 and control lens 9 are so well balanced
by hydraulic forces that even at high loads an oil film is maintained on the surfaces of the control lens as well
as on the glide shoes. At the same time, leak oil is kept to a minimum. Part of the leak oil is used for lubrication
of all moving parts and then returns to the tank via an external line.
If pressurized oil enters at connection A or B, four pistons 5 are pressurized via kidney shaped inlets in the
control lens 9. On the opposite side, four more pistons 5 push the low pressure return oil through kidney shaped
inlets in control lens 9 and connection A or B to the tank. A ninth piston is at dead center, which means at the
point of reversing direction.
Once the oil pressure reaches the four pistons on the pressure side, a certain force is created by oil pressure
and piston surface.
This force is transferred via piston 5 and glide shoe 5.1 onto the swash plate 6.
This radial force, which uses cylinder 4 as a lever, creates the torque, which is tranferred via cylinder 4 to the
output shaft 3. The amount of torque is in direct proportion to the system pressure, which means high pressure
= high torque. By applying oil to the opposite port (connection A or B), the torque and direction of the hydraulic
motor is reversed (right or left turn).
During a complete revolution of cylinder 4, pistons 5 perform a dual stroke from the lower dead center to the
top dead center and reverse. This stroke depends on the inclination of the swash plate 6 and influences the oil
quantity.
The displacement of the hydraulic motor remains the same until the oil supply from the variable flow pumps
changes.
8.6.2.4 Maintenance and repairs

Liebherr hydraulic motors are maintenance free.

For resealing and repair work, see Repair instructions for Liebherr fixed displacement oil motors FMF.
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Roller bearing
14
Allen head screw
Drive
15
End ring
Cylinder
16
Shaft seal
Piston
17
O-ring
5.1
Glide shoe
18
O-ring
Swash plate
19
O-ring
Return plate
22
Lock ring
Return ball
23
Lock ring
8.1
Spring
25
Spacer
Control plate
26
Needle bearing
10
Stop pin
27
Washer
12
Housing
191
Discharge two way check valve
13
Connector plate
192
Discharge pressure regulator
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13
Connector plate - discharge two way

check valve
191.1
Piston
191.2
Spring
191.3
Bushing
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192
Discharge pressure - flow regulator
192.1
Piston
192.2
Flow regulator
192.3
Spring
192.4
Bushing
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8.6.2.5 Function of discharge valves in connector plate

The discharge valves 191 and 192 allows a small amount of oil from the low-pressure connection on the motor
to escape into the motor housing.
This small amount of discharge quickly replaces the oil in the motor housing which was lost to leakage by the
new motors, keeping the motor cool.
Two way check valve 191.
The two ends of the piston 191.1 are connected via bore holes in the connector plate via kidney shaped slits
in the control plate 9.
If at actuation the pressure rises on connection A on the motor, the pressure PA acts on the piston surface SA
and moves the piston against the preload of spring 191.2.
Pressure PB on connection B on the motor now reaches via internal bores in the valve sleeve 191.3 into the
ring shaped chamber L, where it actuates the replenishing pressure regulator.
However, if high pressure is applied on connection B of the motors, piston 191.1 is pushed into the opposite
direction and low pressure PA is applied on L.
Discharge pressure regulator 192.
Valve 192 functions as a restricted, pilot controlled pressure relief valve.
Pressure on L, via a restrictor bore hole in the flow regulator 192.2, actuates the main piston 192.1 and, when
the minimum pressure is reached, moves it towards the force of spring 192.3.
The oil can now reach chamber T via the restrictor bore hole and internal bores in valve sleeve 192.4 and flows
from there via a connector bore in connector plate 13 into the pump housing.
8.6.2.6 Repairs and adjustments on discharge valves

The repairs in valves 191 and 192 are limited to checking easy movement and resealing.
The discharge quantity is set at the factory and cannot be readjusted. If problems occur, replace the complete
valve.
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8.6.2.7 Variation with integrated impulse transmitter
The hydraulic fixed displacement motors FMF for the swing gear in machines with a closed loop circuit have
an additional impulse sending unit 51 for the control of the automatic swing brake.
2
3
4
5
5.1
6
7
8
8.1
9
10
12
13
14
Roller bearing
Drive shaft
Cylinde
Piston
Glide shoe
Swash plate
Return plate
Return ball
Spring
Control plate
Stop pin
Housing
Connector plate
Allen head screw
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15
16
17
18
19
22
23
25
26
27
51
52
191
192
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End ring
Shaft seal
O-ring
O-ring
O-ring
Lock ring
Lock ring
Spacer
Needle bearing
Washer
Impulse sending unit
O-ring
Two way check valve with discharge
Discharge pressure
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R 9250 from 13466

08 Swing System

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Service Manual

Chapter 8 - Swing system

R 9250 from 13466

R 9250 from 13466

2 SAT 450 / 257

R 9250 from 13466

R 9250 from 13466

R 9250 from 13466

Cabin connection box

Connection box regulation

Connector 18 poles / A1020 FSG

Connector 4 poles / A1020 FSG

Connector 70 poles / E1005 elevation

Kl31 electronic ground E1005

Connector 2 poles / Y150

Connector 2 poles / YR150

Connector 2 poles / Y155

Connector 2 poles / YR155

Connector 12 poles / U21

Connector / Rotating deck

Connector 24 poles / E1038

Solenoid valve swing left

Regulation solenoid valve - Swing left

Solenoid valve swing right

Regulation solenoid valve - Swing right

4 - 20mA handle swing

4 - 20mA handle crowd

Regulation solenoid valve - Swing left supply

Solenoid valve - Swing left sypply

Regulation solenoid valve - Swing right supply

Solenoid valve - Swing right supply

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R 9250 from 13466

Lower collecting pipe - support control valves

Collecting pipe power pack

Swing gear left

Swing gear right

Test point / high pressure - swing right

Test point / high pressure - swing left

Left swing motor

Right swing motor

Rear swing pump

Front swing pump

Servo oil unit

Solenoid valve - swing left

Regulation solenoid valve - swing left

Solenoid valve - swing right

Regulation solenoid valve - swing right

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8.2 Location of components

Swing pumps P5.1 and P5.2

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Connection regulation box E1038

Servo oil unit

Cabin connection box E1005 with A1020

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FSG plate A1020

R 9250 from 13466

8.3 Functional description

R 9250 from 13466

8.3.4 Swing brake

R 9250 from 13466

Optional equipment : swing brake controlled in semi automatic