Service Manual

Swing System

SWING SYSTEM
SWING SYSTEM...................................................................................................................
..................1
1Schematic.....................................................................................................................
................4
1.1Electric....................................................................................................................
...............4
1.2Hydraulic...................................................................................................................
.............6
2Location of components........................................................................................................
........9
3Functional description........................................................................................................
.........12
3.1System control..............................................................................................................
.......12
3.2TCV valve...................................................................................................................
.........13
3.3Pumps.......................................................................................................................
...........14
3.4Motors......................................................................................................................
............14
3.5Replenishing................................................................................................................
........15
3.6Swing brake.................................................................................................................
........15
4Troubleshooting...............................................................................................................
...........15
5Adjusting.....................................................................................................................
................16
5.1Specifications..............................................................................................................
.........16
5.2Procedures..................................................................................................................
.........17
6Detailed component description................................................................................................
..23
6.1Swing pump A4 VG 180......................................................................................................23

6.3Hydraulic fixed displacement motor FMF with discharge....................................................35

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Swing System

The hydraulic swing circuit on Liebherr hydraulic excavators R 996 is a closed circuit.
The most important components of this circuit are:
-The electro hydraulic pilot control system
-4 hydraulic pumps A4 VG 180
-2 Torque control valves
-4 replenishing and positioning pumps HY Z GGS 11/38
-2 pressure limiting valves LV1
-4 hydraulic motors FMF 250
-4 swing gears SAT 450 / 207 with integrated disk brakes
-1 swing ring ROD 4004 DJ (triple race roller bearing with inner tooth)
Technical data
Swing pumps
A4 VG 180
Swing pumps outputkW900
4180
Max. displacementcm3
Max.
Max

flowl/min

operating

Secondary

pressurebar350

pressurebar400

Replenishing and positioning pumps

Pumps

HY Z GGS 11/38
3

displacementcm

Pumps

4400

flowl/min

438
480

Replenishing and positioning pressurebar30

Hydraulic motors
Motors

FMF 250
3

displacementcm

Working

256

pressurebar350

TorqueNm

41239

Flowl/min

4388

RPMt/min1470
Swing gears

SAT 450 / 207

TorqueNm

445482

RPMt/min38,44
Number

of

Swing ring

teeth13
ROD 4004 DJ

TorqueNm2112024
RPMt/min3,24
Number

of

teeth154

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1 Schematic
1.1 Electric

Swing System

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Swing System

A 1006Printplate
A 1018Printplate
FA 1009Fuse (+24V)
GND LeitGround from acces ladder
+24V no movementSignal +24V if ladder or service trap not locked in there uppermost position
K 100Relay
K 101Relay
U 21Left joystick
P1Potentiometer swing left
P2Potentiometer swing right
XP-Proportional signal joystick moved to the left
XS-Logical output joystick moved to the left
XP+Proportional signal joystick moved to the right
XS+Logical output joystick moved to the right
SliLogical signal joystick moved to the left (=XS-)
SreLogical signal joystick moved to the right (=XS+)
X 418Connector on A 1006
X 426Connector on A 1006
X 435Connector on A 1006
X 441Connector on U 21
Y 150Solenoid valve swing left / right on PP1
Y 151Solenoid valve swing left / right on PP2
Yr 150Regulation solenoid valve swing left on PP1
Yr 151Regulation solenoid valve swing left on PP2
Yr 155Regulation solenoid valve swing right on PP1
Yr 156Regulation solenoid valve swing right on PP2

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1.2 Hydraulic

Swing System

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Swing System

GS
GS
GS
GS

1Swing
2Swing
3Swing
4Swing

gear
gear
gear
gear

front
rear
rear
front

right
right
left
right

MS
MS
MS
MS

1Swing
2Swing
3Swing
4Swing

motor front right

motor rear right
motor rear left
motor front left

SU 1 / P6Servo oil pressure - PP1

SU 2 / P6Servo oil pressure - PP2
TCV 1Torque control valve - PP1
TCV 2Torque control valve - PP2
Y 150Solenoid valve swing left / right on PP1
Y 151Solenoid valve swing left / right on PP2
Yr 150Regulation solenoid valve swing left on PP1
Yr 151Regulation solenoid valve swing left on PP2
Yr 155Regulation solenoid valve swing right on PP1
Yr 156Regulation solenoid valve swing right on PP2

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Swing System

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Swing System

2 Location of components

Swing pumps PS

Servo oil unit

Positioning and replenishing pumps P10

Limiting valve

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Tor q ue control valve TCV 1

Swing System

Torque control valve TCV 2

Platine A 1018 with relay K100 & K101 and potentiometer P1 & P2

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Swing System

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Swing System

3 Functional description
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 servo control lever.
The left servo control lever U21 delivers different electrical signals (proportional as well logical signals)
depending on its momenteanous deflection.
The pilot control units have two proportional outputs and one logical output for each direction. For the
swing movements the different outputs are:
Xp+Proportional output for Yr 155 (swing right)

Xs+Logical signal for swing right

Xp-Proportional output for Yr 150 (swing left)

Xs-Logical output for swing left

the torque control valves (TCV).
The logical outputs signals are used to command the two potentiometer P1 and P2 on A1018.
The hydraulic part of the swing control system consists of the servo oil circuits (i.e. of pumps P9.1.2 &
P9.2.2, servo oil units SU1, SU2) which supplies the servo pressure to the regulation solenoid valves
The solenoid valves Y150 and Y151 are used to supply the TCV (1 and 2) with positioning pressure

To protect the swing gears and swing ring teeth, the electrical swing system is equipped with two
potentiometer P1 and P2.
The potentiometer are used to avoid the shock who exist in the gears due to the play between the
teeth in case of counter rotation (if uppercarriage turn in one direction and moving the joystick to the
opposite direction to have maximum hydraulic braking).
The functioning principle is as following:
-If the joystick is moved to the left; the signal Xs- (Sli) is send to A1018 and the
uppercarriage turn in left direction.
-If the operator release the joystick in neutral position; the signal Xs- (Sli) and the
closes and the uppercarriage movement is decelerate.
-If the operator moved the joystick direct to the right (after moved to the left); the signal
Xs- (Sli) is equal to 0V and at the same time the signal Xs+ (Sre) is send to A1018. In
this case the solenoid valves Yr 150 and 151 are immediately closed but there is a
temporisation of approximately 400 ms between the moment where Xs+ is send and
where the solenoid valves Yr155 and 156 receives the proportional current Xp+ and
teeth of the swing ring and the swing gears.

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Swing System

Xst

Xs+
t

Yr150
r150 (151)
t

Tempo
Y r155 (156)
t

3.2 TCV valve

The torque control function in the fine control range, is realised by comparison of control pressure on
one side and working pressure on the other side of the control spool (16.4). Maximum pressure is
controlled by a pressure sequence valve (16.1).
Torque control below maximum pressure setting works with the following principle:
-Control pressure Y1 (or Y2), that is given by the proportional solenoids (YR 155 or YR 150),
pilots the control spool in the defined direction.
-Servo pressure X1 or (X2) is connected to one side of the control piston (S.2) of the pump. The
other side of the control piston X2 (or X1) is released to the tank.
-If system pressure X5 (or X6) becomes more than 16 times higher than control pressure Y1 (or
Y2), the control spool (16.4) will be moved back so that the pump will be stopped in swivelling
out or swivels back to maintain a working pressure, that corresponds to the control pressure.
Maximum torque (pressure) control is realised by a pressure sequence valve (16.1) and two checks
valves (S8, S9) that are integrated in sandwich plates in the outlet of the back pumps. The function is
as follows:
-Both pressure ports A and B of the swing pumps are fitted with a sandwich plate. The both
plates contains a check valve (S8, S9) each, and have their port MS connected together, so that
maximum working pressure from side A or B is available on ports MHA, MHB of the plates.
-Port MHB of one sandwich plate is connected to the port MHB of the torque control valve to
supply the maximum pressure signal to the pressure sequence valve 16.1. Port MHA of the
other sandwich plate is connected to port MHA of the torque control valve. This line is used for
oil supply.
-In the tank line, before the outlet, there is an orifice mounted (16.2).
-If maximum working pressure either from side A or B (line MHB) is higher than the setting of the
pressure sequence valve, line MHA will be switched, by the pressure sequence valve, to the
tank line of the torque control valve. This increased oil flow will produce a back pressure in front
of the orifice.
-The back pressure works as a counter pressure to the side of the control cylinder that is
normally connected to the tank and stops the pump in swivelling or swivels the pump back. For
example, if the pump is swivelled out by servo pressure connected to X1, the back pressure will
be connected to X2 to stop the pump or to swivel it back.
-The check valves (16.3) in the control valve unit has safety function: if the spool of the torque
control valve gets no or only low servo pressure on Y1, and system pressure will be in the range
that the pressure sequence valve is working, the working pressure is also available at X5, so

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Swing System

that the spool will be switched to left position. In this case, back pressure will be connected to
X1 and the pump will swivel out instead of swivelling back. With the integrated check valves
(16.3), in that worse case, both sides of the control piston are on the same pressure level, so
that the pump swivels back by the force of the internal springs.

3.3 Pumps
The 4 hydraulic pumps A4 VG 180 are variable displacement axial pumps in swash plate design. The
there 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.
The 4 pumps are linked 2 by 2 (PS1.2 with PS2.1 and PS1.1 with PS2.2) and each group works with
one TCV.

3.4 Motors
The pumps feeds the hydraulic constant volume motors FMF who are directly fixed on the swing gear
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.
The pumps PS2.1 and PS1.2 feeds the hydraulic motors MS2 and MS3 and the pumps PS1.1 and
PS2.2 feeds the hydraulic motors MS1 and MS4. The two hydraulic motors circuit are independant.

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3.5 Replenishing
control valve) and for replenishing the hydraulic swing circuit to avoid cavitation on the suction side.
This cavitation is create from a loss of oil (leakage and discharge valve on hydraulic motors) in the
circuit.

3.6 Swing brake

The swing braking is done 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 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.
Optional equipment: swing brake controlled in semi automatic
With this equipment, the function of the push button is not to 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
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 81 down and reduce the
when the uppercarriage is quite immobile, the brake will apply.
Emergency stop of the uppercarriage swing motion: The swing brake can be applied independently of

Perform this braking via button S17 only in emergency cases, since it causes fast abrasion of the
brake discs.

4 Troubleshooting

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Swing System

5 Adjusting
5.1 Specifications

Replenishing and positioning pressure LV1Bar30

Replenishing and positioning pressure LV2Bar30
High pressure relief valves (secondary valves) (S3 & S4)Bar400
Wo r k ing pre ssur e on T C V 1 (1 6.1)

Bar

30

Wo r k ing pre ssur e on T C V 2 (1 6.2)

bar

30

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Swing System

5.2 Procedures
5.2.1 Swing pumps positioning and replenishing
pressure check / adjustment
5.2.1.1 Replenishing and positioning pressure for LV1
on powerpack.
LV1Replenishing pressure relief valve for powerpack
and positioning pressure relief valve for PS2.1 and
PS1.2.
Remove cap on test point MP and install 60 bar pressure
gauge.
Bring diesel engine to high idle, check pressure on
pressure gauge and compare it with pressure given on

Fig. 1

Apply swing brake (*), move the left joystick U21 to the left
and right and measure the pressure again.
If necessary readjust the replenishing pressure relief valve
LV1:
-Remove the protective cap at the relief valve LV1,
loosen the counternut 6 and turn the adjustment screw x
until reaching the prescribed value.
-Turn clockwise to increase replenishing and positioning
pressure.
-Turn counterclockwise to reduce replenishing and
positioning pressure.
After adjustment, retighten the counternut 6, reinstall the
cap, remove pressure gauge and close off test point MP on
powerpack.
Fig. 2

(
*
) To keep the swing brake applied even through the swing
pumps are swivelled out, you must disconnect the solenoid
valve Y7 on the control valve console, see fig. 3.

Fi g . 3

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5.2.1.2 Replenishing and positioning pressure for LV2

on powerpack .
LV2Replenishing pressure relief valve for powerpack
and positioning pressure relief valve for PS2.2 and PS1.1.
Remove cap on test point MP and install 60 bar pressure
gauge.
Bring diesel engine to high idle, check pressure on
pressure gauge and compare it with pressure given on

Fig. 4

Apply swing brake, move the left joystick U21 to the left
and right and measure the pressure again.
If necessary readjust the replenishing pressure relief valve
LV2:
Remove the protective cap at the relief valve LV2, loosen
the counternut 6 and turn the adjustment screw x until
reaching the prescribed value.
Turn clockwise to increase replenishing pressure.
Turn counterclockwise to reduce replenishing pressure.
After adjustment, retighten the counternut 6, reinstall the
cap, remove pressure gauge and close off test point MP
on powerpack .
5.2.2 High pressure relief valves (secondary valves)

Fig. 5

Fig. 6

Notice: The high pressure relief valves S.3 and S.4 are
factory adjusted and leaded. There is no possibility to
adjust the values on site so that wrong adjustment by
inexperienced people is not possible.
Do not check the function of the secondary valve on the
machine, because it does not withstand the maximum flow
of the pump. If you are in doubt, that the valve does not
work correctly, please replace it by a new one and check
the setting of the old one on test bench.

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Swing System

5.2.3 Adjustment of swing pumps working pressure

control
MA
MB
16.1
torque control valve TCV1 (for pumps PS2.1 &
PS1.2).
16.2
torque control valve TCV2 (for pumps PS1.1 &
PS2.2).
Valves 16.1 resp. 16.2 reduce control pressure to swing
right / left, and thus limit, via the torque control valves
TCV1 & TCV2, the high pressures on connections A and B
of the pumps PS2.1 & PS1.2, resp. PS1.1 & PS2.2.
5.2.3.1 Working pressure for PS2.1 & PS1.2
Remove caps on test points MA and MB on powerpack
and connect 600 bar pressure gauge.
Start the diesel engines, bring them to rated Rpm and
apply the swing brake.
Fully actuate the joystick for the swing gear to the left, read
high pressure on pressure gauge MB and compare with
prescribed working pressure, see pressure specification.
Repeat test for swing right while reading pressure on
gauge MA.
If necessary, readjust the working pressure. Therefore
remove cap on valve 16.1 of TCV1, loosen lock nut and
turn adjustment screw until the correct pressure is reached.
Turn clockwise to increase working pressure.
Turn counterclockwise to reduce working pressure.
After adjustment, retighten lock nut while countering
adjustment screw.
Remove pressure gauges and close off test points.
5.2.3.2 Working pressure for PS1.1 & PS2.2
Remove caps on test points MA and MB on powerpack
and connect 600 bar pressure gauge.
Start the diesel engine, bring them to rated Rpm and apply
the swing brake.
Fully actuate the joystick for the swing gear to the left, read
high pressure on pressure gauge MB and compare with
prescribed
workingpressure.
pressure.
prescribed working
Repeat test for swing right while reading pressure on
gauge MA.
If necessary, readjust the working pressure. Therefore
remove cap on valve 16.2 of TCV2, loosen lock nut and
turn adjustment screw until the correct pressure is reached.
After adjustment, retighten lock nut while countering
adjustment screw. Remove pressure gauges and close off
test points.

Fig. 7

Fig. 8

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Fig. 9

Fig. 10

Fig. 11

Swing System

5.2.4 Check mechanical neutral position

The mechanical neutral position is factory adjusted and
does not need to be adjusted under normal conditions.
However, should the uppercarriage turn or have tendency
to turn, the neutral position can be checked and if
necessary adjusted.
Prior to making the adjustment, check if the uppercarriage
turns even through the servo lines are without pressure
(example: disconnect servo lines on connection X1 and X2
of TCV1 and TCV2 and the solenoid valves Y150 and
Y151).
Install test point on PS1.1.
Start powerpack and bring to high idle.
Attach a 60 bar pressure gauge to test point MA, MB of the
pumps PS1.1 and PS2.1.
The two pressure (MA and MB) of each pump must be the
same and approximately equal to the replenishing
pressure.
If there is a difference between the pressure MA and MB
of each pump, loosen lock nut 10 of this pump and
carefully turn the adjustment rod 2 with an Allen wrench
clock or counterclockwise until the two pressure are the
same.
After the adjustment is completed, tighten lock nut while
holding the adjustment rod 2.
After this adjustment, stop powerpack . Install test point
on PS1.2. Start powerpack and bring to high idle.
Do the same operation for PS1.2 and PS2.2

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5.2.5 Adjust hydraulic neutral position

The hydraulic neutral position is factory adjusted and does
not need to be adjusted under normal conditions.
Checking or adjustment is only necessary if it is found that
the high pressures on test points MA and MB have
different values with the joystick for the swing fully
deflected. Before making adjustments, it must be certain
that the servo pressure on connection Y1 and Y2 is equal
and approximately within the required servo pressure
value.
5.2.5.1 Adjustment of TCV1
Remove caps on test points MA / MB on the pump PS2.1
and install 600 bar pressure gauges.
Apply swing brake, start the diesel engine 1 and bring to
high idle.
Adjust the working pressure for TCV1 to 200 bar (see

Fig. 12

Fully actuate the joystick for the swing gear to the left, read
high pressure on pressure gauge MB.
Fully actuate the joystick for the swing gear to the right,
read high pressure on pressure gauge MA.
If there is a difference between MA and MB, loosen the
lock nut 17 (near the outlet X5) on the regulator valve of
TCV1 and turn the adjustment screw 15 until the high
pressure MA (swing right) on test point is equal to the high
pressure MB (swing left) on test point.
After the adjustment is completed, tighten lock nut while
holding the adjustment screw.
Readjust the working pressure for TCV1 to the prescribed
5.2.5.2 Adjustment of TCV2
Remove caps on test points MA / MB on the pump PS2.2
and install 600 bar pressure gauges.
Apply swing brake, start the diesel engine 2 and bring to
high idle.
Adjust the working pressure for TCV2 to 200 bar (see

Fig. 13

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Swing System

Fully actuate the joystick for the swing gear to the left, read
high pressure on pressure gauge MB.
Fully actuate the joystick for the swing gear to the right,
read high pressure on pressure gauge MA.
If there is a difference between MA and MB, loosen the
lock nut 17 (near the outlet X5) on the regulator valve of
TCV2 and turn the adjustment screw 15 until the high
pressure MA (swing right) on test point is equal to the high
pressure MB (swing left) on test point.
After the adjustment is completed, tighten lock nut while
holding the adjustment screw.
Readjust the working pressure for TCV2 to the prescribed

Fig. 14

Fig. 15

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Swing System

6 Detailed component description

6.1 Swing pump A4 VG 180
The swing pump is a variable displacement axial piston pump in swash plate design. She supply the
closed loop swing circuit.
The displacement volume is in proportion to the input RPM and infinitely variable. The flow increases

6.1.1 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.
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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Swing System

When the swash plate 4 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 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 reversing
direction.

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Swing System

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 (TCV) which may be externally mounted and serve to control the
displacement of several swing pumps A4 VG.

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Swing System

6.2.1 Function
and swing movements of the machine, proportionally to the deflection of the servo control levers and
pedals.
Each servo control unit delivers different electrical signals (proportional as well logical signals)
depending on its momentaneous deflection.
control valve blocks and distributor block on the attachment, and swing pumps via the torque control
regulators (TCV).
The logical outputs of the servo control units are used to elaborate the switching logic determining the
priorities in the summation of the different hydraulic pump flows. This switching logic is used to
valves Yr.
6.2.2 Pilot control units (Joystick and pedal transmitters)
Both electronic and mechanical remote control components are integrated in each pilot control unit.
6.2.2.1 Mechanical components
Joysticks:The mechanical component consists of a joystick, which can be deflected, in any
direction. A spring returns the hand lever to its center (neutral) position.
other which provide the input signals for the electronic components.
The hand lever is moved through a gate, which ensures that full diagonal deflection
results in full x- and y- axis movement.
Pedals:The mechanical component consists of a foot plate, which is movable around an axis.
A spring returns the foot plate to its center (neutral) position.
The deflection of the foot plate is transmitted to a stroke sensor, which provides the input
signal for the electronic components of the pedal transmitter.

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The electrical part of the pilot control system

consists of the 24 volts batteries, the
j oysticks and pedals U20 to U24 in the cab,
the print plates A1006 and A1009, the spool
valves switching box E1011 and the
valves console and on the torque control
valves for the swing pumps.

Swing System

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Swing System

6.2.2.2 Electronic components

In each pilot control unit (joystick or pedal), the output signal of each stroke sensor is applied, through
a matching circuit, to a pulse duration modulator (PDM).
The modulator signal is amplified by an output amplifier so it is sufficient strength to supply the
regulating solenoide valves on the control valve console (attachment and travel movements) and on
the torque control valves for the swing pumps (swing movements).
Since the regulating solenoid valves are driven with impressed current, the influence of resistance
changes in the coils (for example, due to temperature differences) is suppressed.
6.2.2.3 Function
the control unit are electrically energized as follows:
proportionally to the joystick or pedal deflection.

These logical outputs are used in the printplate A 1006 to elaborate the switching logic which
determines the priority for the different pump flows in case of simultaneity of movements via the

The hydraulic part of the system consists of the

servo oil circuit (i. e. of pumps P9.1.2 & P9.2.2,
servo oil units SU1, SU2, and SU3) which
supplies the servo pressure to the regulating

For servo pressure value and detailed description

of servo oil circuit, refer to chapter: Attachment /
Travel sy stem

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6.2.3.1 Characteristic curves and adjustment

Characteristic curve for
regulating solenoide valves on
control valve console

Characteristic curve for

joystick & pedals
(mA)

(mA)

1000

1000

800

800

600

600

400

400

200

200

0
0102030405060708090100 35 30
25
20
15
10
Lever displacement (%)
Regulating pressure (bar)

0
5

I 90% adjusted by
Imax potentiom.

I 10% adjusted by
potentiom. Imin

Control unitMoved toActuated movementImin (mA)Imax (mA)

U20

X+Open

Shovel flap pedal

shovel

X-Close

U21

X+Swing

Left joystick

X-Swing

flap400700

shovel

right250700
left250700

Y+Stick

cylinder

Y-Stick

cylinder

U22

X+Bucket

Right joystick

X-Bucket

flap400700

extend400700
retract400700

cylinder

retract400700

cylinder

Y+Boom

cylinder

Y-Boom

cylinder
right

extend400700

retract400700
extend400700

U23

Y+Travel

Right travel pedal

Y-Travel

right

backwards400700

U24

Y+Travel

left

foreward400700

Left travel pedal

Y-Travel

left

foreward400700

backwards400700

Service Manual

Swing System

6.2.3.2 Shovel flap pedals U20

FS t-WE-14.20-L-2-4ESe/128
58
Anschlu
belegung

Stecker

X- (L )

I
max

Connector /
pin on
control unit

Signal

I
min

1+24V
2Xs3Xp-

X+( R)

6Xp+
7Xs+
80V

I
max

Connector
/ pin on
printplate
A1006

X446
2Xs-Logical output left shovel flap pedal moved3
3Xp-Proportional signal left shovel flap pedal moved4

6Xp+Proportional signal right shovel flap pedal moved6

7Xs+Logical output right shovel flap pedal moved5
80VEarthing
shovel
flap
pedals2

I
min

Service Manual

Swing System

6.2.3.3 Left joystick U21

S t-WE-L-WE-4xy-8Ese/85 FL 100I
Anschlu
belegung
Stecker
Busche

X
+-

1Xs+1+24V
2Xs-20V
3Xp+3
4Xp-4WW

I
I
max I
min
max I
min

Y
+-

I
max I
min I
max I
min

9Yp-9S3
10Yp+10
11Ys-11
12Ys+12

Connector /
pin on
control unit
X441X440

Connector / pin
on print plate
A1006

Signal

1+24V24V

supply

joystick

stick

and

swingX426-1

20VEarthing joystick stick and swing2

4WW24V supply push buttons top of handle5
5WS1Output signal push button left4
6WS2Output signal push button right3
7S124V supply push rocker switch14
8S2Output signal rocker switch tilted down13
9S3Output signal rocker switch tilted up12
1Xs+Logical output joystick moved to the right6
2Xs-Logical output joystick moved to the left9
3Xp+Proportional signal joystick moved to the right8
4Xp-Proportional

9Yp-Proportional

signal

joystick

signal

moved

joystick

to

moved

the

left11

backward17

10Yp+Proportional signal joystick moved foreward20

11Ys-Logical output joystick moved backward15
12Ys+Logical

output

joystick

moved

foreward18

Service Manual

Swing System

6.2.3.4 Right joystick U22

S t-WE-L-WE-4xy-8Ese/85 FL 100r
Anschlu
belegung
Stecker
Busche

X
+-

1Xs+1+24V
2Xs-20V
3Xp+3
4Xp-4WW

I
max I
min
I
max
I
min

Y
+-

I
max I
min
I
max
I
min

9Yp-9S3
10Yp+10
11Ys-11
12Ys+12

Connector /
pin on
control unit
X443X442

Signal

Connector / pin
on print plate
A1006

1+24V24V supply joystick boom and shovel tiltX425-1

20VEarthing joystick boom and shovel tilt2
4WW24V supply push buttons top of handle5
5WS1Output signal push button left4
6WS2Output signal push button right3
7S124V supply push rocker switch14
8S2Output signal rocker switch tilted down13
9S3Output signal rocker switch tilted up12
1Xs+Logical output joystick moved to the right6
2Xs-Logical output joystick moved to the left9
3Xp+Proportional signal joystick moved to the right8
4Xp-Proportional signal joystick moved to the left11

9Yp-Proportional signal joystick moved backward17

10Yp+Proportional signal joystick moved foreward20
11Ys-Logical output joystick moved backward15
12Ys+Logical output joystick moved foreward18

Service Manual

Swing System

6.2.3.5 Right travel pedal U23

FS t-WE-L-4Ese/120
58 r
Anschlu
belegung
Stecker

1+24V
20V
3Ys+
4Ys5Yp+
6Yp-

I
max

I
min

Connector/p
in on control
Signal
unit

Connector/pin
on printplate
A1006

X445
1+24V24V

supply

right

travel

pedalX427-1

20VEarthing right travel pedal2

3Ys+Logical output right travel pedal moved foreward5
4Ys-Logical output right travel pedal moved backward3
5Yp+Prop. signal right travel pedal moved foreward6
6Yp-Prop. signal right travel pedal moved backward4

6.2.3.6 Left travel pedal U2

FS t-WE-L-4Ese/120
58 r
Anschlu
belegung
Stecker

1+24V
20V
3Ys+
4Ys5Yp+
6Yp-

I
max

I
min

Connector/p
in on controlSignal
unit

Connector/pin
on printplate
A1006

X445
1+24V24V

supply

20VEarthing

right
right

travel

pedalX427-1

travel

pedal2

3Ys+Logical output right travel pedal moved foreward5

4Ys-Logical output right travel pedal moved backward3
5Yp+Prop. signal right travel pedal moved foreward6
6Yp-Prop. signal right travel pedal moved backward4

Service Manual

Swing System

6.3 Hydraulic fixed displacement motor FMF with discharge

1.1.1 General data
MachineR

995R

994B

and

996

Hydraulic motor..............................................TypeFMF 165FMF 250

3
Max. oil volume..............................................Cm
/U165250

Max. permissible leak oil quantity

(without discharge at 300 bar).......................L/min811
Discharge quantity
(at aP=12 bar).............................................
L/min1111
Tightening Torque
Allen head screws 14.....................................Nm540540
Tightening Torque
Discharge two way check valve 191..............Nm70-10070-100
Tightening torque

Tightening Torque
Inductive impulse transmitter 51....................Nm10-1210-12

Service Manual

Swing System

1.1.2 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.
1.1.3 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 angular 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 while 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 returned 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 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 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.

1.1.4 Maintenance and repairs

Liebherr
hydraulicmotors
motorsare
aremaintenance
maintenance
free.
Liebherr hydraulic
free.

Service Manual

Swing System

2Roller bearing
3Drive
4Cylinder
5Piston
5.1Glide shoe
6Swash plate
7Return plate
8Return ball

14Allen head screw

15End ring
16Shaft seal
17O-ring
18O-ring
19O-ring
22Lock ring
23Lock ring

8.1Spring

25Spacer

9Control plate

26Needle bearing

10Stop pin

27Washer

12Housing

191Discharge two way check valve

13Connector plate

192Discharge pressure regulator

Service Manual

Swing System

13Connector plate
Discharge two way check valve

192.1Piston

191.1Piston

192.2Flow regulator

191.2Spring

192.3Spring

191.3Bushing

192.4Bushing

Service Manual

Swing System

1.1.5 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
at actuation
actuationthe
thepressure
pressurerises
rises
connection
on the
motor,
the pressure
on on
connection
A onA the
motor,
the pressure
P actsP on the piston
A
surface A
surface
SSand moves the piston against the preload of spring 191.2.
Pressure B
Pon 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
is
P applied on L.
A
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.
1.1.6 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.

Service Manual

Swing System

1.1.7 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.

2Roller bearing
3Drive shaft
4Cylinder
5Piston
5.1Glide shoe
6Swash plate
7Return
plate
7Return plate
8Return
ball
8Return ball

15End ring
16Shaft seal
17O-ring
18O-ring
19O-ring
22Lock ring
23Lock
ring
23Lock ring
25Spacer
25Spacer

8.1Spring
9Control plate
10Stop pin
12Housing
13Connector plate
14Allen head screw

26Needle bearing
27Washer
51Impulse sending unit
52O-ring
191Two way check valve with discharge
192Discharge pressure