Service Manual

Chapter 8 - Swing system

Swing system..........................................................................................................................8.00
1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.00.3
2 Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.00.5
2.1 Electric. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.00.5
2.2 Hydraulic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.00.6
3 Location of components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.00.7
4 Functional description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.00.11
4.1 System control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.00.11
4.2 Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.00.13
4.3 Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.00.13
4.4 Swing brake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.00.13
5 Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.00.17
6 Component description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.00.19
6.1 Swing pump DPVG 250 - 280 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.00.19
6.2 Hydraulic fixed displacement motor FMF with discharge . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.00.22
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 Service Manual Swing system
Technical data

8.00: Swing system

The hydraulic swing circuit of the excavator is a closed circuit. The most important components of this
circuit are:
– the electro hydraulic pilot control system
– 1 hydraulic pump DPVG 280
– 2 hydraulic motors FMF 250
– 2 swing gears SAT 400 / 256 with integrated disk brakes
– 1 swing ring ROD 1354 DJ (triple race roller bearing with internal teeth)

1 Technical data

Components Units Technical data

Swing pump Type DPVG 280
Swing pump output kW 389
3
Maximum displacement cm 283
Maximum flow l/min 643
Maximum operating pressure bar 350
Secondary pressure bar 420

Hydraulic motors Type 2 x FMF 250

Motors displacement cm3 257
Working pressure bar 345
Torque Nm 2 x 1340
Flow l/min 2 x 299
RPM min-1 1085

Swing gears Type 2 x SAT 400 / 256

Torque Nm 2 x 35930
-1
Maximum RPM min 38,8
Number of teeth 13

Swing ring Type ROD 1354 DJ

Torque Nm 678577
-1
RPM min 4,1
Number of teeth 124
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Technical data

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Schematic

2 Schematic

2.1 Electric

Fig. 1 Electrical scheme

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A161 Electrical plate / E1005 U21 Left joystick

A167 Electrical plate Y150 Solenoid valve swing left
A61 Electrical output module Y155 Solenoid valve swing right
A64 Electrical output module YR150 Adjustment solenoid valve swing left
L Left YR155 Adjustment solenoid valve swing
right
R Right

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Schematic

2.2 Hydraulic

Fig. 2 Hydraulic scheme

ETB Back oil expansion tank POF Piloting oil filter

ETF Front oil expansion tank ROF Replenishing oil filter
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GSB Rear swing gear SU1 Servo Unit 1

GSF Front swing gear Y150 Solenoid valve swing left
MSB Rear right swing motor Y155 Solenoid valve swing right
MSF Front right swing motor Y7 Solenoid valve swing brake
P5 Swing pump YR150 Adjustment solenoid valve swing left
P9 Pilot oil pump YR155 Adjustment solenoid valve swing
right
P10 Replenishing oil pump

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Location of components

3 Location of components

Fig. 3 Pumps installation

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P5 Swing pump
P9 Pilot oil pump
P10 Replenishing oil pump

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Location of components

Fig. 4 Servo oil unit SU1

Fig. 5 Solenoid valves

Y150 Solenoid valve swing left YR150 Adjustment solenoid valve swing left
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Y155 Solenoid valve swing right YR155 Adjustment solenoid valve swing
right

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Location of components

Fig. 6 Electrical modules A61

1 Cab elevation A64 Electrical output module

A61 Electrical output module A167 Electrical plate
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Location of components

For electrical components locations on the cab connection box E1005, you can refer to:
– the Operating Manual
– the chapter "Electrical System" of this Service Manual

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Functional description

4 Functional description

4.1 System control

The control system of the machine operates the swing movements on the basis of the related joystick
movement (also refer to the section "Joystick and pedal transmitters").
Thus, the left joystick U21 supplies an electrical control signal which depends on its momentarily
movement. The A167 plate amplifies this control signal in order to supply the solenoid valves with the
related current set value.
The swing movements are possible only if there are all the initial conditions that follow:
– The safety lever S7 is down.
– The operating and control elements are in neutral position.
– The access ladder and the service trap are locked in upper position.

Fig. 7 Control signal supplied by the joystick

Astart Angle start position of joystick Iend End current

Aend Angle end position of joystick Imax Maximum current
I Current intensity Istart Start current
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Functional description

Fig. 8 Set value supplied to the solenoid valves

T Time

The graphic above shows the set value supplied to the solenoid valves, which depends on the control
signal of the joystick.
For a joystick movement included between 0% and Astart (Angle start) position, the outputs module
do not send any current to the solenoid valves Yxx and Yrxx. Thus, they are closed and there is no
movement.
For a joystick movement included between Astart and Aend (Angle end) positions, the outputs mod-
ules send a current included between Istart and Iend to the solenoid valves. This current is based
on the control signal of the joystick. The switching solenoid valves Yxx is opened and the regulation
solenoid valve Yrxx is opened on the basis of the control signal: the speed of the movement is based
on the movement of the joystick. The lstart and lend values are adjusted during the machine assem-
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bly.
For a joystick movement included between Aend and 100%, the output modules send a current in-
cluded between Iend and Imax to the solenoid valves. Yrxx are at this time fully opened: the move-
ment has the maximum speed.

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4.2 Pumps
The hydraulic pump DPVG is a variable displacement axial pump in swash plate design, the displace-
ment volume and the flow increases as the pump is shifted from the "O" or neutral position to its max-
imum output.
When the swash plate is shifted from one angle via the neutral position to the other angle, the direc-
tion of flow changes, while the direction of pump rotation remains the same, meaning that the pres-
sure 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.

4.3 Motors
The pump supply the hydraulic constant volume motors FMF which are directly installed on the swing
gear SAT. The FMF fixed displacement motor is used to drive the swing gear of the excavator. 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 sur-
face, a piston stroke in the cylinder is created; and thus the constant flow volume of the oil motor.
The pump P5 supplies the hydraulic motors MSB and MSF, which are linked.

4.4 Swing brake

4.4.1 Mechanical swing gear brake

The swing braking is got with disk brakes which are integrated in the swing gears SAT. The disk
brakes operates 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. When the solenoid valve Y7 (connected on the servo oil unit SU1) is
activated, swing brakes are closed.
The uppercarriage can be locked in any position using a multi disk brake integrated in the swing gear.
The brake is negatively acting, hydraulically actuated and serves as a holding or parking brake.

Caution!
Damage to the machine.
Only lock the mechanical swing gear brake when the uppercarriage is stationary.

Press "Swing brake" button on the keyboard.

Swing brake is engaged.
Uppercarriage is locked.
First LED in the button comes on.
Press button again.
Swing brake is released.
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Uppercarriage is unlocked.
First LED in the button goes out.
The swing brake is engaged if the safety lever is up and the access ladder (if installed) or the service
trap (if installed) are down.

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Caution!
The brake only applies when the uppercarriage is near standstill and if no swing motion is actuated
with the joystick.

To stop the uppercarriage when working on a slope:

Use the joystick to reduce the uppercarriage speed.
Press "Swing brake" button to operate the swing brake.
Move the joystick back to "0" position only after the brake operates.

4.4.2 Semi-automatic swing brake control (optional)

Make sure that the swing brake does not operate.

Tilt down the rocker switch S57 on the right joystick handle.
The semi-automatic control of the swing brake is on.
When the semi-automatic control of the swing brake is on:
– When the uppercarriage speed is less than a limit value:
• The swing brake is applied.
• The first and the second LEDs in the "Swing brake" button come on.
• The swing brake symbol shows on the monitoring display.
– When the uppercarriage speed is more than the limit value:
• The swing brake is released.
• The first and the second LED in the "Swing brake" button go off.
• The swing brake symbol disappears from the monitoring display.
Tilt up the rocker switch S57.
The semi-automatic control of the swing brake is off.
The swing brake is released.

Caution!
The brake only applies when the uppercarriage is near standstill and if no swing motion is actuated
with the joystick.

To stop the uppercarriage when working on a slope:

Tilt down the rocker switch S57.
Use the joystick to reduce the uppercarriage speed.
Move the joystick back to "0" position only after the brake operates.

4.4.3 Emergency stop of the uppercarriage swing motion

The swing brake can be applied independently of the uppercarriage RPM by pushing "Swing brake"
button into position "applied".
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Caution!
Perform this braking with the "Swing brake" button only in case of emergency as it causes fast abra-
sion of the brake discs.

4.4.4 Check of the mechanical swing gear brake

Uppercarriage must be stationary.

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Press "Swing brake" button.

Swing gear brake is engaged.
LED in switch comes on.
Push the left joystick to the right and then to the left to stop.
Uppercarriage must not turn.
Swing gear brake function is operational.
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Adjustment

5 Adjustment
For adjustment instructions, refer to the section "Adjustment procedure R9200" in chapter 3
"Technical Data" of this manual.
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Adjustment

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Component description

6 Component description

6.1 Swing pump DPVG 250 - 280

Fig. 9 Swing pump

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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Component description

6.1.1 Rotary group

Fig. 10 Rotary group

In the pump housing 1, parallel 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.
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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.
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.

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Component description

When the swash plate 4 is shifted from one angle via the neutral position to the other angle, the di-
rection 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 di-
rection 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 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 revers-
ing direction.

6.1.2 Pump displacement

Fig. 11 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 DPVG.
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6.2 Hydraulic fixed displacement motor FMF with discharge

6.2.1 General data

Technical data Unit Value

Hydraulic motor Type FMF 250
Maximum oil volume cm3 250
Maximum permissible leak oil quantity (without discharge at 300 l/min 11
bar)
Discharge quantity (at a p = 12 bar) l/min 11
Tightening torque - socket head screws 14 Nm 540
Tightening torque - discharge two ways check valve 191 Nm 70 - 100
Tightening torque - discharge pressure - flow regulator 192 Nm 90
Inductive impulse transmitter 51 Nm 10 - 12

Fig. 12 Displacement motor

6.2.2 Description
The FMF fixed displacement motor is used to drive the excavators travel or swing gear. The axial pis-
ton motor is designed as a swash plate type motor.
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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 sur-
face, a piston stroke in the cylinder is created, and thus the constant flow volume of the oil motor.

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.

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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 drill-
ings 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 sur-
faces 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 centre, 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 transferred 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 centre
to the top dead centre 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.

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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Fig. 13 Section of displacement motor

2 Roller bearing 14 Socket head screw

3 Drive 15 End ring
4 Cylinder 16 Shaft seal
5 Piston 17 O-ring
5.1 Glide shoe 18 O-ring
6 Swash plate 19 O-ring
7 Return plate 22 Lock ring
8 Return ball 23 Lock ring
8.1 Spring 25 Spacer
9 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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Fig. 14 Section of discharge two ways check valve

13 Connector plate - discharge two way 192.1 Piston

check valve
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191.1 Piston 192.2 Flow regulator

191.2 Spring 192.3 Spring
191.3 Bushing 192.4 Bushing
192 Discharge pressure - flow regulator

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.

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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.

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.

6.2.7 Variation with integrated impulse transmitter

The hydraulic fixed displacement motors FMF for the swing gear in machines with a closed loop cir-
cuit have an additional impulse sending unit 51 for the control of the automatic swing brake.

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Fig. 15 Section of displacement motor

2 Roller bearing 15 End ring

3 Drive shaft 16 Shaft seal
4 Cylinder 17 O-ring
5 Piston 18 O-ring
5.1 Glide shoe 19 O-ring
6 Swash plate 22 Lock ring
7 Return plate 23 Lock ring
8 Return ball 25 Spacer
8.1 Spring 26 Needle bearing
9 Control plate 27 Washer
10 Stop pin 51 Impulse sending unit
12 Housing 52 O-ring
13 Connector plate 191 Discharge two way check valve
14 Socket head screw 192 Discharge pressure regulator
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