SUB GROUP INDEX 11.01 Travel Gear - Chart R902 - R942 Litronic / 101 > 11.05 Travel Gear "Trasmital” R900 Litronic / 101 > R902 LC Litronic / 101 > R912 LC Litronic / 101 > R912 HD-SL Litronic / 101 > R922 HD-SL Litronic / 101 > 11.10 Travel gear - Liebherr "FAT" . with crosswise rollers bearing R912HD-S Litronic / 101 > R942 Litronic/ 101 > 11.15 Travel gear- Liebherr "FAT" a with segmented rollers bearing R912HD-S Litronic / 01.92 > R932 Litronic / 101 > 11.16 Travel gear- Liebherr "FAT" with segmented rollers bearing R942 Litronic / 01.92 > 11.17 Travel gear- Liebherr "FAT" with flanged cover and ball bearing R902 Litronic / 3001 > R912 Litronic / 3001 > R922 Litronic / 3001 > R932 Litronic / 3001 R 942 Litronic / 3001 11.20 Travel brake R900 - R 942 Litronic / 101 > 11.21 Travel brake R 902 Litronic / 3001 > R912 Litronic / 3001 > R 922 Litronic / 3001 > R 932 Litronic / 3001 > R 942 Litronic / 3001 > 11.25 Slipring seal R900 - R 942 Litronic / 101 > Benennung/Description/Dénomination ve R900-R942 Model Type Litrenic LIEBHERR Travel Gear ‘Ab/from/a partir de 101 Datum/Edition/Date Blatt/Page/Feuille 11. 12.94900 to F TRASMITAL LIEBHERR FAT Litronicupto seri imber “| 709c3B | 713caB | 350/012 | 400/013 | 400/023 | 450/064 Description, see sub group |__11.08 11.0 11.10 vito [4.4 1116 Weight (ka) 180 280 220 320. 240 337 it quanti titres) 3.0 0 9 20 10 BS on SAE 80 or SAEBO W 90 ‘API - GL 4-80 or API-GL-5-90 Olt qual Gear ratio [128.122 971078] 107.9 | 1138: 1292 | 118,2 | 1004 143,5 ‘Mounted in Machines 900 (358/101) |X 902 (3647101) x 902 (35470592-]] X 912LC G46 101) x (346 1289) Pix (417 2001-5) x S1ZEW 379/101) x (0791 1289-») x (484 2001) x o2std aero | | ix (416 1289) x (482 2001) x g12stds aero || 2 1x (476 11285->) fi (483 /2001-+) x SIZLCS 2/101) x (485 / 2001») x S1ZHD (4967/2001) x S1ZHD-S (380/101) x (G80 03:91) x (481 /2001-») x (481 /01-92-) x 912 HD-SL 87/101) x 922 HD-SL (aso 101) 932 HD-SL (365/101) x 932HD-S G81/101~) x 932 HD-W (405/101) x (942 HD-SL (366/101) x (366/258) x 942 HD-S (382/101 x (382/258) x Benennung/Description/Denomination R900 to R 942 Litrenic typ Mode! Type LIEBHERR Travel Gear Chart ‘Absfrom/a partir de Datum/Edition/Date Blatt/Page/Feuile 11.01.01Chart of Travel gears R900 to R 942 Litronic / from Serial Number 3001 Travel Gear FAT 350 / 032) FAT 350 /022| FAT 400 / 063 | FAT 400/073 Description, see sub group, 11.17 11.17 wW.17 1.17 Gear ratio 90.1 102 102 113.3 Mountedin Machines 902 Std (3647 3001-») x 912Std (491 /3001-) x Q12HD-S (483 /3001-+) x 912 HD-SL_(417/3001-») x 912 HD-EW (611 /3001-») x 922 HD-SL_ (480 / 3001-+) x 932HD-SL_(572/3001-») x 932 HD-S _ (571/3001-) x 942 HD-SL (574 3001-+) x 942HD-S —(573/3001-») x 11.01.01Construction of travel gear The three stage planetary gear is driven by the attached hydraulic oil motor. It moves the track chain via the sprocket wheel, which is attached to the gear. The wet disc brakes, which are integrated in the gear are applied directly onto the gear. The brakes are used as spring applied brakes and are hydraulically vented, i.e. if there is no brake pressure, the discs are pressed together by springs, the brake is held closed mechanically. Benennung/Description/Dénomination Typ See page 11 Model «sub group index” Type “Subatoup LIEBHERR Travel Gear Trasmital ‘Abitrom/a parti de Datumieitionibate slatvPagerfeuile 11.05.01 10.99Function and power flow, see diagram on page 11.05.05 The input torque is transferred from the oil motor 62 via the splined shaft fitting 1 to the sun gear 32. The sun gear 32 drives the sun gear 40 via planetary gear 26 and planetary carrier 35, with the oil motor speed reduced by planetary stage ! The sun gear 40 drives the sun gear 41 via planetary gear 25 and planetary carrier 18 with the oil motor speed reduced by planetary stage Il The sun gear 41 drives the gear housing 50 via planetary gears 14 and the sprocket wheel, which is mounted to the gear housing via the oil motor speed reduced by planetary stage Il. The total gear ratio - see data on page 11.05.02 - is combined by the three planetary stages. ‘The output torque increases in the same ratio as the output speed is reduced. Gear maintenance ‘The gear has to be checked regularly, in intervals given on the maintenance guidelines in section 3, Check the oil level, for leaks, the mounting tightness of the gear, the sprocket wheel and the oil motor. The gear oil has to be replaced in given intervals. Repair of travel gear See “Repair Instructions for Trasmital travel gear”, issued separately.GENERAL DATA Gear typ 709 C3B “a |" 709C3B | 713G3B Input RPM max. mint || 2694 3050 3050 2940 2940 2155 Oil Quality API-GL-4(MIL-L-2105) Travel brake Release pressure, max. Disk brake, hydr. vented ‘Axial play and torque values to be noted at installation A) Axial play-Fitting 1 B) Torque Screw 2 ©) Torque Screw 22 D) Torque Screw 42 £) Torque Screw 43, mm 30+? bar 07-12 0,7-1,2 | 0,7-1,2 215 215 215 85 385, 85 70 70 70 555 555 555 07-12] 0, 310 620 8s 85 70 70 555 1000 Note : Repairs on the gear (ring 6, ball 7, and housing 50) should only be done by the manufacturer ! LIEBHERR Datumieaition/Date 01.92 Benennung/Description/DEnomination Travel gear “Trasmital” BP.) seepagert 0101 Abitrom/a partir de BlatuPagerFeuile 11.05.02CAUTION: Observe all safety guidelines before working on the gear. Make sure the machine is parked on flat, solid ground, or properly secured when working on an incline. Relieve hydraulic and brake pressure. Removal of Travel Gear 1. Park the machine on flat, solid ground. Release the ‘track and remove it, see description on page 12.12.01 2. Turn the gear so that plug 39 points down to the ground. Remove plug 38 and drain the gear oil Reinsert the plug. 3. Remove screws 68 and take off the protective cover 67 4. Disconnect hydraulic, leak oll and brake lines on hy- draulic motor and gear. 5. Remove screws 65 and take off sprocket wheel 64 6. Secure the gear with appropriate lift. Remove screws 63 and complete gear 60 from gear carrier / undercarriage. Installation of Travel Gear 1. Set gear 60 into the gear carrier/undercarriage (make sure it is seated correctly!) and install screws 63 Torque to 620 Nm. 2. Mount the sprocket wheel_with screws 65 onto the gear, torque screws 65 to 620 Nm. 3. Connect brake, leak oil and hydraulic lines to the oil motor 62 and gear 60. 4. Attach cover 67 and insert screws 68 with snap rings 69, torque to 130 Nm. 5. Turn gear 60 so plug 38 (to check oil level) is in hori- zontal position and the other plug 38 (oil filler plug) is ‘on top. Remove both plugs and refill with gear oil until the oil level shows on the horizontal bore hole. 6. Install the chain, see description on page 12.12.01To seal the gear Note: The drawings on this page are part of diagram on page 11.05.05. Important : Clean and check all parts carefully before installation 1. Drive Remove plug 38 (oil drain) and drain gear oil. Insert plug 38 with seal 37. Remove screws 2 and pull oil motor 62 from gear. Pull off O-ring 61 Lightly grease a new O-ring 61 and install on oil motor 62. Set oil motor into gear. Tighten screws 2, torque to 105 Nm Remove plug 38 (oil filler plug and oil level checky. Fill with gear oil until the lower edge of the bore hole Insert plug 38 with seal ring 37. 2. Cover s2 Remove gear from side frame, see “Removal of Gear” Remove countersunk screw 42 and cover 52 Remove O-ring 56 from hub 4 Lightly grease the new O-ring 56 and pull it on hub 4 Set cover 52 carefully with half of the lifetime seal onto hub 4 and secure with screws 42. Torque to 70 Nm Mount the gear to the undercarriage, see “Installation of Gear” BenennungiDescription/Dénomination LIEBHERR Travel Gear Trasmital DatumiEdionDate 10.89 rye See page 11 Modet ub group index Mode! “subgroup ‘Abrfromia partir de BlatuPagerFeuile 11.05.03* | = ce cn Dee a Lifetime seal 5 Remove the gear and take apart, see “Removal of gear" and paragraph 2. Remove the lifetime seals 5 from cover $2 and gear housing 50. Insert new seals as described on page 11.25.01, using mounting tool, into cover 52 and housing 50 (lightly grease O-ring 56) Reassemble the gear and insert into the under- carriage, see paragraph 2 and “Installation of gear” . Brake Remove the oil motor, see pararaph "1, Drive” Imporant: The support ring 55 is psring loaded! It is necessary to use tool no. 130 to remove this support ring! Insert support ring 55, using tool. Release lock ring 3 and remove the tool. Pull support ring 55, piston 54 with spring 46 form hub 4, Remove spacer 9 Remove spiral ring 47, 48 and O-rings 49, 51 from hub 4 and remove spacer 9 Insert the new seals 47, 48, 49, and 51, make sure they are positioned correctly. Lightly lubricate the O- rings. Insert spacer 9, piston 54 with spring 46 as well as support ring 55 carefully into hub 4. Insert spacer ring 55, using tool no. 130 and lock lock ring 3 (make sure it is seated correctly!), remove tool. Insert oil motor 62, see paragraph “1. Drive” Note: Brake repairs described in section 11.20. Cover 36 Remove plug 38 and drain gear cil Remove screws 22 and carefully take off cover 36 Remove O-ring 39 from cover 36. Lightly grease new O-ring 39 and pull onto cover 36. Carefully push cover 36 over the planetary gears 26 onto the housing 50. Insert screws 22 and torque to 85 NmBrake1 Fitting/Disc carrier 2 2 Hex head screw 2 3 Snap ring 23 4 Hub 2 5 Lifetime seal 25 6 Bearing ring 26 7 Ball Bearing 27 8 Bearing spacer 28 9 Spacer 29 10 Outer Disc 30 11 Inner Disc 31 12 Spacer 32 13 Washer 33 14 Planetary gear 34 15 Planetary pin 35 16 Roller bearing 36 17 Centering ring 37 18 Planetary carrier 38 19 Planetary pin 39 20 Washer LIEBHERR DatumiEdition/Date 10.89 BenennungDescription/Dénomination Roller bearing Allen head screw Washer Snap ring Planetary gear Planetary gear Washer Planetary pin Lock ring Washer Thrust washer Sun gear Centering ring Snap ring Planetary carrier Cover Seal Plug O-ring Travel Gear Trasmital 40 a a2 43 44 45 46 a7 49 50 51 52 53 54 55 56 7 59 Sun gear Sun gear Countersunk screw Allen head screw Planetary carrier Bushing Spring Spiral ring Spiral ring O-ring Gear housing O-ring Cover Spacer Piston Support ring O-ring Snap ring Spacer Mes Seepage 1 joel Sub group index Type grou ‘Abitromia partir de BlatuPagerteuille 11.05.04Somvauneun " 13 14 15 16 ”7 18 19 20 21 22 23 24 25 26 7 28 29 30 31 Fitting/Disc carrier Hex head screw Snap ring Hub Lifetime seal Bearing ring Ball Bearing Bearing spacer Spacer Outer Dise Inner Disc Spacer Washer Planetary gear Planetary pin Roller bearing Centering ring Planetary carrier Planetary pin Washer Roller bearing Allen head screw Washer Snap ring Planetary gear Planetary gear Washer Planetary pin Lock ring Washer Thrust washer 32 33 34 35, 36 37 39 a 42 43 45 46 a7 48 49 50 51 52 53 54 55 56 57 59 60 61 62 Sun gear Centering ring Snap ring Planetary carrier Cover Seal Plug Oring Sun gear Sun gear Countersunk screw Allen head screw Planetary carrier Bushing Spring Spiral ring Spiral ring O-ring Gear housing Oring Cover Spacer Piston Support ring Oring Snap ring Spacer Travel gear, complet O-ring Fixed displacement oil motor Adjustment Values and Torques A,B,C, D,E See diagram on page 11.05.05 and General Data on page 11.05.022 61 4 56 5 3 55 48,51 10,11 12 16 14 13 15 19 20 16 25 22 24 23 26 \ \ ant 1 | / / Py A ON NAN AN 7 50 8 59 54 9 47,49 46 45 44 43 41 BenennungyDescriptionénomination Fahrwerksgetriebe Trasmital Tye. See page 11 | =sub group index LIEBHERR Travel gear Trasmital ee DatuméditoniDate Mécanisme de translation Trasmital BiatvPagerreuile 1089 1.05.05Construction of Travel Gear The three stage planetary gear is driven by a FMF hydraulic oil motor. It moves the track chain via the sprocket wheel, which is connected to the gear. The integrated wet disc brakes are directly applied to the gear. The brakes are spring applied brakes and are hydraulically vented, ie. if there is no brake pressure, the discs are pressed together by springs; the brake is held closed mechanically. Benennung/Description/Dénomination yp See page 1? Moge! Sub group index LIEBHERR Type Travel Gear "FAT" ‘Abrtromia partirde DatumfEdition/Date blatuPagerreuile 10.89 11.10.01Function and Power Flow, see diagram on page 11.10.05 The input torque is transferred from the oil motor 96 via the splined shaft fitting to sun gear 5. Sun gear § drives sun gear 6 via planetary gear 11 and planetary carrier 16, with the oil motor speed reduced by planetary stage I Sun gear 6 drives sun gear 7 via planetary gear 11 and planetary carrier 16 with the oil motor speed reduced by planetary stage It The sun gear 7 drives the gear housing 17 via planetary gear 12 with the oil motor speed reduced by planetary stage ill. The sprocket wheel, which is connected with the gear housing 17 turns the track chain and thus transfers the torque of the gear to the chain Gear Maintenance ‘The gear has to be checked regularly, in intervals given on the maintenance guidelines in section 3. Check the oil level, for leaks, the mounting tightness of the gear, the sprocket wheel and the oil motor. The gear oil has to be replaced in given intervals. Sealing and Repair of the gear See “Repair Instructions for FAT 350-450 Travel Gear", issued separately.GENERAL DATA Machine Mode! R912HD-SLitronic | R942 Litronic Serial Number See pageno. 11.01.01 | Seepage no. 11.01.01 Gear Type FAT 350/012 FAT 400/013 Input RPM, max. mint | 3100 2720 Output RPM, max. mint | 27,7/24,0 2B Output torque, max. Nm | 32500 51500 Gear Ratio 113,8/129,2 118,2 Weight kg | 218 318 il quantity in gear | 50 7.0 Oil Viscosity SAE 80 SAE 80 Oil quality API-GL-4/SAE80 API-GL-4/SAE 80 Brake Disc brake, hydr. vented Venting pressure, min bar | 16 20 Release pressure, max. bar | 35 35 ‘Axial play and torque values to be noted at installation : A) Axial play- sun gears mm } 05-17 05-1,7 (via adjustment nut 48) 8) Pretension- Roller bearing 58 on new gear mm | 0,05 0,05 onthe outer diameter of adjustment ring2 mm | 35 39 onused gear mm | 0,025 0,025 ‘onthe outer diameter of adjustment ring2 mm | 17 20 ©) Torque screws 60 nm | 72 n D) Torque- screws 61 nm | 210 425 E) Torque- screws 95 Nm | 310 620 Torque - screws 98 nm | 130 130 Torque - screws 99 nm | 310 620 Torque - screws 100 Nm | 310 620 yp Model See page 11.0101 Type Benennung/Description/Dénomination LIEBHERR Abffrom/a partirde Travel Gear "FAT DatumitdivoniDate BlawwPagerFeuile 11.10.02 07.93CAUTION: Observe all safety guidelines before working ‘on the gear. Make sure the machine is parked on flat, solid ground, or properly secured when working on an incline. Relieve hydraulic and brake pressure. Removal of Travel Gear 1 Park the machine on flat, solid ground. Release the track and remove it, see description on page 12.12.02 ‘Turn the gear so that drain plug 62 points down to the ground. Remove plug 38 and drain the gear oil into appropriate container. Reinsert plug 62. Remove screws 98 and take off the protective cover 402. Disconnect hydraulic, leak oil and brake lines on hy- draulic motor and gear. Remove screws 99 and take off sprocket wheel 105 Secure the gear with appropriate lift Remove screws 100 and complete gear 92 from gear carrier/undercarriage. Installation of Travel Gear 1 Set gear 92 into the gear carrier/undercarriage (make sure it is seated properly!) and install screws 100. Note torque values on previous page. Mount the sprocket wheel with screws 99 to the gear. Note torque values on previous page . Connect brake, leak oil and hydraulic lines to the oil motor 96 and gear 92. Attach cover 102 and insert screws 98 with snap rings 101. Note torque values on previous page Turn gear 92 so plug 62 (to check oi! level) is in horizontal position and the other plug 62 (oil filler plug) is on top. Remove both plugs and add gear oil (See General Data) until the oil level reaches the lower edge of the bore hole. Install the chain, see description on page 12.12.02 1 1aTo Seal the Gear Note : The drawings on this page are part of diagram on page n° 11.10.05. Important : Clean and check all parts carefully before reinstallation. 1. Drive Turn the gear until the outermost plug 62 (oil drain) on the gear housing 17 is on the bottom. Remove plug 62 (oil drain) and drain gear oil into appropriate container. Reinsert plug 62 Remove screws 95 and pull oil motor 96 from gear. Pull off O-ring 97. Lightly lubricate a new O-ring 97 and install on oil motor 96. Set oil motor into gear. Tighten screws 95, torque to values given on page 11.10.02 Remove plug 62 (oil filler plug and oil level check). Add gear oil until the lower edge of the bore hole. Insert plug 38 with seal ring 37. 2. Seal 91 Remove gear from undercarriage, see “Removal of Gear” Remove oil motor 96, see paragraph 1. “Drive” Remove screws 60 and list off housing 1 complete with brake housing 25 from inner gear 20. Remove lifetime seal 91 and O-rings 83/84. Lightly grease the new lifetime seal 91 as described on page 11.25.01 and install into housing 1 and adjustment ring 2, using mounting tool. Lightly grease O-rings and pull O-rings 83 and 84 onto the inner gear 20 Carefully install complete housing 1 with brake housing 25 and install screws 60 with lock washers 65. Torque to values given on previous page. Install oil motor 96, see § 1 " Drive” and mount the gear into the undercarriage, see “Installation of Gear” Benennung/Description/Dénomination LIEBHERR Travel Gear DatumiEdivon/Date "FAT" 10.89 yp Seepage 11 Model Seepage |! tee ub group index ‘Abrfromi partir de BlatuPagerFeuile 11.10.033. Brake See section 11.20 for description of Travel brake. 4. O-ring 85 Remove the complete gear, see paragraph “Removal of Gear” and remove the oil motor, see paragraph 1. " Drive.” Remove the lock pins 57 between adjustment ring 2 and housing 17: 4. Possibility: Punch lock pins 57 into the bore hole. This method requires that the adjustment ring and housing 17 are rebored after repair. 2. Possibility: Lay one of the washers - in the seat kit - onto the lock pins 57 and weld them together on the inside. Weld a screw head from a M10 screw onto the washer. Remove the lock pins off with a puller. With this method, the lock pin bore holes between adjustment ring and housing can be reused. Remove Allen head screws and housing 1 complete with brake housing 25 from the inner gear. Check and note the play between adjustment ring 2 and housing 17 with a depth gauge. Install mounting tool, special tool No. 140, with screws on the inner gear 20. insert pinion shaft of tool into sun gear § and turn with SW 30 wrench until the pin of the tool enters the groove of the adjustment ring. Continue to turn the pinion shaft clockwise until the adjustment ring is, turned by out one turn, Make some covers out of metal or cardboard to cover are between adjustment ring and roller bearing 58 to protect it from dirt and contamination Remove adjustment ring completely and remove mounting toolPull O-ring 85 onto adjustment ring 2. Grease threads and sealing surface of adjustment ring 2 and housing 17 ‘Screw in adjustment ring 2 with mounting tool, special aoe es tool No. 140, until the previously noted play is reached. Bore the lock pin bore holes into the adjustment ring 2 and housing 17 or align them. Punch lock pins 57 into the bore holes (42 mm deep) and remove mounting tool. Install lifetime seal 91 into housing 1 and adjustment ring 2. Replace O-rings 83/84. Set complete housing with brake housing 25 onto the inner gear and mount with screws 60 (with lock washers 65) Note torques on page no. 11.10.02 Mount the oil motor 96, as described in paragraph 1 “Drive” Install the complete gear into the undercarriage, see paragraph " Installation of complete gear” denennung Description Dénomination ye, seepage LIEBHERR pe Subgroup index Travel Gear "BAT" ‘Abitromia parti de Datumn/Edition/Date BlatuPagerreuille ae 11.10.04Housing Adjustment ring Sun gear Sun gear ‘Sun gear Planetary gear Planetary gear Planetary gear Planetary carrier Planetary carrier Housing Inner gear Brake housing Ring piston End ring Seal Inner disc Outer disc Disc carrier Spring (large) Spring (small) Retainer Retainer Adjustment nut 57 58 60 6 62 65 66 70 n nR 2B 7 82 83 84 85 88 89 ” 95 96 7 Lock pin Roller bearing Allen head screw Allen head screw Plug Lock washer Lock washer Snap ring Snap ring Snap ring Snap ring Prop ring O-Ring O-Ring O-Ring O-Ring O-Ring Grooved ring Grooved ring Lifetime seal Hex head or Allen head screw FMF oil motor O-Ring NOTE ADJUSTMENTS AND TORQUES A,B,C, D,E See diagram on page 11.10.05 and General Data on page 11.10.0240 15 20 16 46 7 yf ee {| / | | \ eon eee i oA 82 89.73.83 2 85 91 35 70 77 10 5 11 71 72 62 Benennung/Description/Dénomination See page 11 Sub group index LIEBHERR Fahrwerksgetriebe FAT Travel gear Fat Réducteur de translation FAT ‘Abstrom/a partirde DatumveditioniDate BlarvPagerreuille 07.89 ruPageFeuil 11.10.05Construction of Travel Gear The three stage planetary gear is driven by a FMF hydraulic oil motor. Itmoves the track chain via the sprocket wheel, which is connected to the gear. The integrated wet disc brakes are directly applied to the gear. The brakes are spring applied brakes and are hydraulically vented, i.e. if there is no brake pressure, the discs are pressed together by springs; the brake is held closed mechanically. Typ Model See page 11.01.01 Type Benennung/Description/Dénomination LIEBHERR Travel Gear "FAT" with segmented roller bea ‘Abrtromia partir de DatumfEdiion/Date BlatuPagerFeuille 11.15.01 01.92Function and Power Flow, see diagram on page 11.15.04 The input torque is transferred from the oil motor 96 via the splined shaft fitting to sun gear 5. Sun gear 5 drives sun gear 6 via planetary gear 11 and planetary carrier 16, with the oil motor speed reduced by planetary stage | ‘Sun gear 6 drives sun gear 7 via planetary gear 11 and planetary carrier 16 with the oil motor speed reduced by planetary stage I! ‘The sun gear 7 drives the gear housing 17 via planetary gear 12 with the oil motor speed reduced by planetary stage Ill. The sprocket wheel, which is connected with the gear housing 17 turns the track chain and thus transfers the torque of the gear to the chain, Gear Maintenance The gear has to be checked regularly, in intervals given on the maintenance guidelines in section 3. Check the oil level, for leaks, the mounting tightness of the gear, the sprocket wheel and the oil motor. The gear oil has to be replaced in given intervals. Sealing and Repair of the gear ‘See “Repair Instructions for FAT 350-450 Travel Gear with segmented roller bearing", issued separately. naseGENERAL DATA Gear Type Liebherr FAT 400/023 Input RPM, max. mint | 2405 ‘Output RPM, max. mint | 24 Output torque. max. Nm | 43700 Gear Ratio 100,4 Kg | 242 L]7 SAE 80 Oil quality API-GL-4/SAE 80 Brake Disc brake, hydr. vented Venting pressure, min. bar | 20 Release pressure, max. bar | 35 Axial play and torque values to be noted at installation : A) Axial play- sun gear 5 Control measure from top of sun gear 5 to mounting face of hydraulic motor mm } 1115995 ©) Torque - screws 60 Nm | 120 D) Torque- screws 61 Nm | 480 E) Torque - screws 95 Nm 620 Torque - screws 99 nm | 620 Torque - screws 100 nm | 620 enennung/Descrption’Dénomination Ty LIEBHERR Maat seepage rt 0101 Travel Gear ‘oromiaparurde DawumiEdtionDate "FAT" slatuPagerFeuille 01.92 with segmented roller bea enonCAUTION: Observe all safety guidelines before working on the gear. Make sure the machine is parked on flat, solid ground, or properly secured when working on an incline. Relieve hydraulic and brake pressure. Removal of Travel Gear 1 Park the machine on flat, solid ground. Release the track and remove it, see description on page 12.12.02 Turn the gear so that drain plug 62 points down to the ground. Remove plug 38 and drain the gear oil into appropriate container. Reinsert plug 62. Remove screws 98 and take off the protective cover 102. Disconnect hydraulic, leak oil and brake lines on hy- draulic motor and gear. Remove screws 99 and take off sprocket wheel 105 Secure the gear with appropriate lift Remove screws 100 and complete gear 92 from gear carrier/undercarriage. Installation of Travel Gear 1 Set gear 92 into the gear carrier/undercarriage (make sure it is seated properly!) and install screws 100. Note torque values on previous page Mount the sprocket wheel with screws 99 to the gear. Note torque values on previous page. Connect brake, leak oil and hydraulic lines to the oil motor 96 and gear 92. Attach cover 102 and insert screws 98 with snap rings 101. Note torque values on previous page. Turn gear 92 so plug 62 (to check oil level) is in horizontal position and the other plug 62 (oil filler plug) is on top. Remove both plugs and add gear oil (see General Data) until the oil level reaches the lower edge of the bore hole. Install the chain, see description on page 12.12.02 ni 1s02To Seal the Gear Note : The drawings on this page are part of diagram on page 11.15.05. Important : Clean and check ail parts carefully before reinstallation. 1. Drive Turn the gear until the outermost plug 62 (oil drain) on the gear housing 17 is on the bottom. Remove plug 62 (oil drain) and drain gear oil into appropriate container. Reinsert plug 62. Remove screws 95 and pull oil motor 96 from gear. Pull off O-ring 97. Lightly lubricate a new O-ring 97 and install on oil motor 96. Set oil motor into gear. Tighten screws 95, torque to values given on page 11.15.02, Remove plug 62 (oil filler plug and oil level check). ‘Add gear oil until the lower edge of the bore hole Insert plug 38 with seal ring 37. 2. Lifetime seal To replace the Lifetime - seals 91 of the travel gears “FAT” described in this sub group (execution with segmented roller bearings) it is necessary to disassemble completly the gear (planetary stages, housing 17 and bearing segments must be removed). For detailled description. see "Repair Instructions for FAT 350 - 450 travel gear with segmented roller bearing", issued separately 3. Brake See section 11.20 for description of Travel brake Benennung/Description/Dénomination Model See page 1101.01 LIEBHERR a Travel Gear "EAT" with segmented roller bearing ‘Absfromia partirde Datumedition/Date BlatvPagerFeuile one 11.15.03FAT travel gear with segmented roller bearing ‘Sun gear ‘Sun gear ‘Sun gear Planetary gear Planetary gear Planetary gear Planetary carrier Planetary carrier Housing Bearing ring Inner gear Brake housing Ring piston End ring Seal Inner disc Outer disc Disc carrier Spring (large) Spring (small) Retainer Retainer 50 55 60 61 62 65 66 70 n 2 3 82 84 85 86 88 89 1 95, 96 97 Roller cage Cylinder roller Allen head screw Allen head screw Plug Lock washer Lock washer Snap ring Snap ring Snap ring Snap ring O-Ring O-Ring O-Ring O-Ring Grooved ring Grooved ring Lifetime seal Hex head or Allen head screw FMF oil motor O-Ring NOTE ADJUSTMENTS AND TORQUES A,C,D,E See diagram on page 11.15.04 and General Data on page 11.15.02 aiseConstruction of Travel Gear The three stage planetary gear is driven by a FMF hydraulic oil motor. It moves the track chain via the sprocket wheel, which is connected to the gear. The integrated wet disc brakes are directly applied to the gear. The brakes are spring applied brakes and are hydraulically vented, i.e. if there is no brake pressure, the discs are pressed together by springs; the brake is held closed mechanically. Benennung/DesciptonDénomination emer LIEBHERR Type ‘Sub Group index’ Travel Gear Trem pana GatumiEaiionbave "BAT" 0192 with segmented roller bearing Blaturagereuile 11.16.01Function and Power Flow, see diagram on page 11.16.04 The input torque is transferred from the oil motor 96 via the splined shaft fitting to sun gear 5. Sun gear 5 drives sun gear 6 via planetary gear 11 and planetary carrier 16, with the oil motor speed reduced by planetary stage |. ‘Sun gear 6 drives sun gear 7 via planetary gear 11 and planetary carrier 16 with the oil motor speed reduced by planetary stage Il The sun gear 7 drives the gear housing 17 via planetary gear 12 with the oil motor speed reduced by planetary stage Ill. The sprocket wheel, which is connected with the gear housing 17 turns the track chain and thus transfers the torque of the gear to the chain. Gear Maintenance The gear has to be checked regularly, in intervals given on the maintenance guidelines in section 3. Check the oil level, for leaks, the mounting tightness of the gear, the sprocket wheel and the oil motor. The gear oil has to be replaced in given intervals. Sealing and Repair of the gear See “Repair Instructions for FAT 350-450 Travel Gear with segmented roller bearing", issued separately. tearGENERAL DATA Gear Type Liebherr FAT 450/064 Input RPM, max. mint | 2720 Output RPM, mai mint | 189 Output torque, max. Nm | 82000 Gear Ratio 143.5 Weight kg Oil quantity in gear wfz Oil viscosity SAE 80 Oil quality API-GL-4/SAE80 Brake Disc brake, hydr. vented Venting pressure, min bar | 20 Release pressure, max, bar | 35 ‘Axial play and torque values to be noted at installation : A) Axial play- sun gear Control measure from top of sun gear 5 to mounting face of hydraulic motor mm | 11,7405 ©) Torque - screws 60 Nm | 310 D) Torque - screws 61 Nm | 425 E) Torque - screws 95 Nm | 620 Torque - screws 99 Nm | 620 Torque - screws 100 Nm | 1060 Benennung/Description/Dénomination hyp. See page 11 Sub Group index” LIEBHERR Travel Gear "FAT" with segmented roller bearing ‘Abitrom/a parti de DatumveaiioniDate BlattPagerteuile 11.16.02 01.92CAUTION: Observe all safety guidelines before working on the gear. Make sure the machine is parked ‘on flat, solid ground, or properly secured when working onan incline. Relieve hydraulic and brake pressure. Removal of Travel Gear 1 Park the machine on flat, solid ground. Release the track and remove it, see description on page 12.12.02 Turn the gear so that drain plug 62 points down to the ground. Remove plug 38 and drain the gear oil into appropriate container. Reinsert plug 62 Remove screws 98 and take off the protective cover 102 Disconnect hydraulic, leak oil and brake lines on hy- draulic motor and gear. Remove screws 99 and take off sprocket wheel 105. Secure the gear with appropriate lift Remove screws 100 and complete gear 92 from gear carrier/undercarriage. Installation of Travel Gear 1 Set gear 92 into the gear carrier/undercarriage (make sure it is seated properly!) and install screws 100. Note torque values on previous page Mount the sprocket wheel with screws 99 to the gear. Note torque values on previous page. Connect brake, leak oil and hydraulic lines to the oil motor 96 and gear 92. Attach cover 102 and insert screws 98 with snap rings 101. Note torque values on previous page. Turn gear 92 so plug 62 (to check oil level) is in horizontal position and the other plug 62 (oil filler plug) is on top. Remove both plugs and add gear oil (see General Data) until the oil level reaches the lower edge of the bore hole. Install the chain, see description on page 12.12.02 neuTo Seal the Gear Note: The drawings on this page are part of diagram on page n° 11.15.08. Important : Clean and check all parts carefully before reinstallation, 1. Drive Turn the gear until the outermost plug 62 (oil drain) on the gear housing 17 is on the bottom. Remove plug 62 (oil drain) and drain gear oil into appropriate container. Reinsert plug 62, Remove screws 95 and pull oil motor 96 from gear. Pull off O-ring 97. Lightly lubricate a new O-ring 97 and install on oil motor 96. Set oil motor into gear. Tighten screws 95, torque to values given on page 11.15.02. Remove plug 62 (oil filler plug and oil level check) ‘Add gear oil until the lower edge of the bore hole. Insert plug 38 with seal ring 37. 2. Slipring seals 91 Remove gear from undercarriage, see "Removal of gear” Remove snap ring 74 Caution : Snap ring 74 and seal housing 3 are under the axial preload of the slipring seals 91 To remove the snap ring 74, the seal housing 3 must first be pushed down using three devices (see fig. 4, pos. A) evenly positioned around the gear circumference and fixed to the thread bores of the inner gear 20. After snap ring removal, loosen the compression devices Install new slipring seals into seal housing 3 and bearing ring 18. Using the special mounting device (see instructions on page no. 11.25.01. Install a new o-ring 83 onto the inner gear 20 (slightly grease o-ring before installation). Set the seal housing 3 onto the gear. Set the snapring 74 around the inner gear 20, attach the compression devices to the inner gear and push the housing 3 down so that the snapring 74 can be inserted in its grove. Slowly loosen and remove the compression devices. 3. Brake See section 11.20 for description of Travel brake. BenennungiDescription/Dénomination LIEBHERR Travel Gear Dawmitanonbate "EAT" 01.92 with segmented roller bearing Kis Seepage 11 Model -subdroup Index ype ‘Abriromia partir de BlatuPage/Feville 11.16.03FAT travel gear with segmented roller bearing Seal housing Sun gear ‘Sun gear Sun gear Planetary gear Planetary gear Planetary gear Planetary carrier Planetary carrier Housing Bearing ring Inner gear Brake housing Ring piston End ring Seal Inner disc Outer disc Disc carrier Spring (large) Spring (small) Retainer disk Retainer disk Retainer disk 50 55. 60 61 62 65 66 70 n R B 74 76 82 83 85 86 88 89 1 95 96 7 Roller cage Cylinder roller Allen head screw Allen head screw Plug Lock washer Lock washer Snap ring Snap ring Snap ring Snap ring Snap ring Notch nail O-ring Oring Oring O-ring O-ring Grooved ring Grooved ring Lifetime seal Hex head or Allen head screw FMF oil motor O-Ring NOTE ADJUSTMENTS AND TORQUES A,C, D,E See diagram on page 11.16.04 and General Data on page 11.16.02 ate96 43/4 307880 eyes 40 5 6 Benennung/Description/Dénomination Voir feuille 11. LIEBHERR Type ‘soutgroupest Fahrwerksgetriebe FAT “Abiiromis particde Datum/ditionDate Travel gear Fat Réducteur de translation FAT BlatuPagerreuille et 11.16.041, CONSTRUCTION OF TRAVEL GEAR The three stage planetary gear is driven by a FMF or FMV hydraulic oil motor. it moves the track chain via the sprocket wheel, which is connected to the gear. The integrated wet disc brakes are directly applied to the gear. The brakes are spring applied brakes and are hydraulically vented, i.e. if there is no brake pressure, the discs are pressed together by springs; the brake is held closed mechanically. Benennung/Description/Dénomination yp See page 11 Mode! ee LIEBHERR Model sup groupindex Travel Gear FAT ‘Abifroma partir de with flanged cover and ball bearing Datumn/Edition/Date lat/Page/Feuille fate Blatt/Pags 11.17.01Function and Power Flow, see diagram on page 11.17.04 The input torque is transferred from the oil motor 96 via the splined disc carrier 55 to the input shaft 35 at the gear. The input shaft 35 drives the sun gear 25 via planetary gear 32 and planetary carrier 30, with the oil motor speed reduced by planetary stage |. ‘The sun gear 25 drives the sun gear 15 via planetary gear 22 and planetary carrier 20 with the speed reduced by planetary stage Il. ‘The sun gear 15 drives the inner gear 10 via planetary gear 5 with the speed reduced by planetary stage Ill ‘The sprocket wheel, which is connected with the inner gear 10 turns the track chain and thus transfers the torque of the gear to the chain. Gear Maintenance The gear has to be checked regularly, in intervals given on the maintenance guidelines in section 3. Check the oil level, for leaks, the mounting tightness of the gear, the sprocket wheel and the oil motor. The gear oil has to be replaced in given intervals. Sealing and Repair of the gear See the separately issued Repair Instructions “Travel gear FAT ...”, concerned gear type. 11.17.01GENERAL DATA Gear Type FAT 350/032| FAT 350/022 | FAT 400 / 063 | FAT 400/073, Output RPM max permissible mint | 43. 38 285 285 ‘Output torque max permissible Nm | 35000 35000 60000 60000 Gear ratio 90.1 102 102 1133 il motor Type | FMV75/31.5| FMV75/31.5| FMV90/39.9| FMV 90/3929 Torque constant Nm/bar | 1.20 1.20 1244 1244 (at max. oil volume of oil motor) Weight kg | 180 180 305 305 Oil quantity in gear L}s 5 65 65 Oil quality APL-GL-5 Oil vicosity SAE 90 or SAE 80 W 90 Brake Disk brake, hydr. vented Brake torque static Nm | 46800 53000 90000 90000 Venting pressure, mit bar | 18 18 18 18 ‘Axial play and torques values to be noted at installation : A) Control measure for axial play, driving side (top of sun gear 5 to mounting face of hydraulic motor) mm | 93.541 935+1 11st0s | 111.5405 B) Control measure for axial play, planetary gears side (from end of diving shaft 35 ‘to mounting face of cover 40) mm | 3.5+1 35t1 3541 3541 ©) Torque- Threaded pin 1.4 Nm | 410 410 410 410 D) Torque: Screws 46 Nm | 69 69 69 69 E) Torque - Screws 95 Nm | 310 310 620 620 (Motor) Torque - Screws 99 nm | 620 620 620 620 (Sprocket) Torque - Screws 100 Nm | 620 620 620 620 (Gean) ‘Benennung/Description/Denomination LIEBHERR AT" with flanged cover and ball bearing Travel gear “ Datum Edition 12.94 Date 7 Wedel Type See page no. 1101.01102 — 98 3. REMOVAL AND INSTALLATION OF TRAVEL GEAR AA AUTION : Observe all safety guidelines before working on the gear. Make sure the machine is parked on flat, solid ground, or properly secured when working on an incline. Relieve hydraulic and brake pressure. 3.1 Removal of Travel Gear 1. Park the machine on flat, solid ground. ‘Turn the gear so that one drain plug 48 points down to the ground, Remove plug 48 and drain the gear oil into appro- priate container. Reinsert plug 48. 2. Release the track and remove it, see description on sub - group 12.12. 3. Remove screws 99 and take off sprocket wheel 105 4, Remove screws 98 and take off the protective cover 102. 5. Disconnect hydraulic lines 106, leak oil and servo lines 107 1108 on hydraulic motor. Disconnect brake line 109 on gear. Close off all connections. 6. Remove screws 112 and remove Brake valve 110 and connector flange 111 from oil motor 96. 7. Remove oil motor 96 from gear. 8, Secure the gear with appropriate lift. Remove screws 100 and complete gear 92 from gear cartier/undercarriage. Notice the mounting position of the gear (as an exemple the position of the brake connection). 3.2. Installation of Travel Gear 1. Set gear 92 into the gear carrier/undercarriage (make sure itis seated properly!) and install screws 100. 2. Install the oll motor 96 and install screws 95. + 3, Install the brake valve 110 and connector flange 111. 4. Connect brake line 109 on gear and leckoil- servo- and hydraulic oil lines 108/107/106 on oil motor 96. 5. Attach cover 102 and insert screws 98 with lock washers 101 6. Check that one plug 48 points down to the ground, Remove one plugs of the top (oil level and filler plug) and add the prescribed gear oil (see § 2.) until the oil level reaches the lower edge of the bore hole. 7. Install sprocket weel on gear and install screws 99. 8. Install the chain, see description on sub group 12.12, Data”! + Note torque values on §2 “Techni 19.17.024, TO SEAL THE GEAR [XEP™ Important : Clean and check all parts carefully before reinstallation. 4.1 Sealing in the area of hydraulic motor Remove oil motor 96, see § 3.1 (point 1 and 4 to 7). Slightly lubricate a new o-ring 97 and install on oil motor 96. Seat oil motor 96 into the gear, see § 3.2 (points 2 to 6). 4.2 Sealing in the area of the slipring seals 95 Remove snap ring 76. Caution : Snap ring 76 and seal housing 75 are under the axial preload of the slipring seals 70. To remove the snap ring 76, the seal housing 75 must first be pushed down using three devices (as three sprocket, mounting screws 105 underlayed with washer or sockets) evenly positioned around the gear circumference and fixed to the thread bores of the gear carrier 1. Remove the snap ring 76 and loosen the compression devices. Pull off the seal housing 75, the o-ring 71 and the slipring seals 70. Install new slipring seals 70 into the seal housing 75 and the inner gear 10 (see instructions in sub group 11.25) with the special mounting device. Install a new o-ring 71 onto the gear carrier 1 (slightly grease o-ring before installation). Set the seal ring 75 with slipring seal onto the gear. Set the seal housing75 onto the gear. Set the snap ring 76 around the gear carrier 1, attach the ‘compression devices and push the seal housing 75 down so | 96 that the snapring 76 can be inserted in its grove. Slowly and evenly loosen and remove the compression devices, c WIN 43. Sealing in area of travel brake See section 11.21. for description of Travel brakes. Rn 75 Benennung/Description/Dénomination 7 See Page no. LIEBHERR Hecate oer Travel Gear FAT z,, yatum ' : Depuis eaten 42.94 with flanged cover and ball bearing a Date foes, = 11.17.0312 13 14 Vouw 10 5 20 2 22 2B 25 30 eT 32 33 35 36 38 Travel Gear FAT with flanged cover and ball bearing Gear carrier End plug Lock pin Threaded pin Snap ring Supporting ring Planetary gear Snap ring Plug Inner gear Steel ball Sun gear Planetary carrier Supporting ring Planetary gear Snap ring Sun gear Planetary carrier Supporting ring Planetary gear Snap ring Input shaft Snap ring Ball retainer Cover a an Bs 51 52 55 56 7 61 62 63 70 n nm 75 16 95 7 Supporting ring Leting O-ring Allen head bolt Plug Pressure ring Inner dise Outer disc Disc car r Grooved ring Grooved ring 1g piston Spring (large) Spring (small) End ring Snap ring Slipring seal O-ring Lock pin Seal housing Snap ring Hex head or Allen head screw Oil motor FMV O-ring 11.17.03,45 48 25 30 31 NOTE ADJUSTMENTS AND TORQUES A, B, C, D and E !! See "General Data” on page no. 11.17.02 Benennung/Description/Dénomination See page LIEBHERR No.11.01.01 Travel Gear FAT Datum with flanged cover and ball bearing fain 42.94 bate Blatt/Page/Feuille 11.17.04Design and Function of Travel Gear Brake System fm ay 43/44 7 36/37 1, Disk brake, see fig. 1 ‘The brake is integrated into the travel gear and is applied to the gear drive. The brake disks 10/11 are spring applied brakes and are hydraulically vented, i.e. if there is no brake pressure, the disks are pressed together by springs. The brake is held closed mechanically and released by applying servo pressure to the brake piston 54 2. Oil Rotary Connection 72, see fig. 2 The single oil rotary connection 72 is set onto the § way oil rotary (high pressure) connection. They are special connections from the upper to the undercarriage and are located in the center of the swing ring. For a description of the oil rotary connections, see section 7.60. 3. Solenoid valve 73, see fig. 3 ‘The solenoid valve 73 - integrated in compact block 80 on the tank, releases servo oil to the disk brake (to release the brake) and closes off the connection (to apply the brake). BenennungiDescription/Dénomination Typ see page 1? Mode! bie Sub group index LIEBHERR Travel Brake ‘Abitromia partie de DatumedioniDate BlotvPagerFeuille 11.20.01 10.89| Button $17, see fig. 4 [in] (ef contol thesolencidvlve 3 eS = a If button $17 is pressed, current flows via relay K8 to actu Prt} fe ate the solenoid valve 73, and the brake is released. oO ete Seni enue root el 6 # Be Fo} ea) Function of Travel Brake When button 516 is pressed, the solenoid valve 73 is moved. Oil from the servo control/hydraulic system actuates piston 54 via rotary connection 72 and brake connection/gear. The piston is pushed towards spring 46 and the brakes are released. The red indicator light in button $16 turns off When button $16 is pressed to apply the brake, solenoid valve 73 moves into neutral position. The oil in the brake piston area flows via rotary connection 72 and solenoid valve 73 into the tank. The springs 46 move the piston 54 via preload force against the brake discs, which results in the necessary braking action to secure the excavator on an incline. The indicator light in button $16 lights up. For safety and longer brake life, the servo pressure to servo controls 87 and 88 is also closed off , which ‘means that the excavator cannot travel The accumulator in the travel brake also serves as a safety function. If the Diesel engine fails, the brake is applied automatically, since no oil is available via the servo control to keep the brake released. Sealing and Repair on the Travel Brake Separately issued repair instructions, “Travel Gear FAT 350-450" or “Trasmital Gear” are available. 1. Fitting/inner disc carrier Bot eeaecicnt (50*) 4 Hub 81 Pressure relief valve (30 bar)- rr) oe eaters 82. Servo oil filter (52*) ala 83 Check valve (53%) 46 Spring 84 Accumulator (sa*) a een 85 Test point//servo contro (a2") 62 Oil motor /travel drive-left (200%) Bis ereanli ani oeae 63 Oil motor /travel drive- right (201*) left with foot pedal (82*) 72. Single rotary connection 251") 88 Servo control / travel gear - 73. Solenoid valve/trvel brake system (57*) right with foot pedal (83*) 77 Hydraulic tank ay Fo Fuse7 58 78 Gear pump (30*) enone S16 Button / travel brakes * = Positions corresponds at hydraulic scheme, see group 6. napeNote: The disk brake in the FAT Gear is as view in section 9.20 - Swing Brake Benennung/Description/Dénomination yp See page 11 LIEBHERR Sub group index ‘Abitrom/a partirde Travel Brake Datum/edition/Date BlarvPagerreuile a 1.20.02Repair of Brake (Sealing the brake and replacing the brake discs) If a lot of noise can be heard in the brakes, the brake pads are worn. The outer discs should be replaced immediately. The brake also has to be replaced if the braking action decreases. (EP IMPORTANT! Before repairing the brakes,rmake sure all appropriate safety procedures are for machine and personnel are observed, as parking the machine on level ground, securing the machine if working on an incline, relieving the brake pressure. ‘The brake can be repaired without removing the gear. ‘The following drawings are part of diagram on page 11.05.05 and 11.10.05. Trasmital Travel Gear 1. Disassembly Remove plug 38 (oil drain valve) and drain gear oil Insert plug 38 with seal 37, Remove screws 68 and remove cover 67 Remove screws 2 and pull the oil motor 62 with connected hydraulic lines from the gear. Remove the brake lines from the gear. [NEP CAUTION: Support ring 55 is under spring pressure. Insert support ring 55, using tool No. 130. ee Release snap ring 3, loosen the tool and remove it. S Se Remove support ring 55, piston 54 with springs 56 as well as spacer 9 from hub 4. Pull off fitting/disc carrier 1 from sun gear shaft 32 and remove discs 10/11 Remove O-rings 49 and 51 from spacer 9 and hub 4. Special too! n° 130 GenennengbeiptonDevoninaven tp, seepage LIEBHERR Mode! Subgroup index Travel Brake Abtioni paride Datumiedivon/Date BlatuPagerreuille 10.89 11.20.03Special tool 2. Assembly IMPORTANT: Carefully clean and check all parts for wear before installation. Push disc carrier 1 onto the sun gear shaft 32. Insert a outer disc 10 onto the hub, then a inner disc 11 onto the disc carrier, ete Insert spiral rings 48 and O-rings 51 into the hub 4. Insert spiral ring 47 and O-ring 49 into the spacer 9. [JEP Note: Mount the spiral rings opposite the pres- sure side. Lightly lubricate the O-rings before installation. Set spacer 9 on piston 54, make sure it is seated correctly and push both parts into hub 4. Note: When inserting spacer 9 and piston $4, make sure the O-rings and spiral rings in the hub are seated correctly, Insert springs 46 into piston 54. Use tool no. 130, push the support ring 55 in. Insert snap ring 3 (watch that it is seated correctly), remove the tool. Push oil motor 62 into the hub 4 and fitting 1 (watch the O-ring) and mount with screws 2 Torque to 205 Nm Connect the brake lines to the gear. Attach the housing 67 and mount with screw 68. Insert plugs and open oil plug, Fill with gear oil until the lower edge of the bore hole. Check the brake for function, see description of function2. Liebherr Travel Gear FAT Disassembly Remove plug 62 (oil drain) and drain gear oil. Reinsert plug 62. Remove screws 98 and take off cover 99, Remove screws 95 and pull oil motor 96 with connected hydraulic lines from the gear. Remove brake lines from gear. Remove Allen head screws 61 and take off brake housing 25 from connector housing 1 Replace O-ring 97 (on the oil motor) and 86 (on the brake housing), grease it lightly before installation CAUTION: End ring 31 and piston 30 are under spring pressure. Push piston 30 with tool no. 125 and two M16x120 or M16 x 140 screws down, Release the snap ring 73, loosen tool and remove it. Remove springs 43/44 and pull O-rings 82 and grooved ring 88 (with support rings) from brake housing 25 Push end ring 31 from piston 30 and pull off grooved ring 89 (with support ring) Brake housing 25 rotated from 90” Remove front ring 35, brake discs 36/37 and rear ring 35 from inner gear 20 SenennungiDescriptoniDénomination ty See page 11 Mode! ie Sub group index. LIEBHERR bes Travel Brake ‘Abstrom/s partir de DatumEdition/Date alatuPagerreuile 11.20.04 10.89Assembly Bit i eas Important: Before assembly, clean and check all parts carefully for wear. Set the rear ring 35 into the inner gear 20 and install the outer and inner discs 37/36 as follows: Outer disc - inner disc - outer disc etc. Set the front ring 35 onto the last outer disc. Install the grooved ring 89 with support ring into the end ring and the grooved ring 88 with support ring as well as O-rings into the brake housing. [Dugp- Note: Mount the support rings opposite the pressure side. Lightly lubricate the grooved ting before installation. Set the O-rings 82 and 86 onto the brake housing 25, lightly lubricate them before installation. Push the end ring 31 into piston 30. Insert the springs 43/44 and push the piston 30 onto the brake housing 25. With tool No. 125, push the piston 30 down, Insert snap ring 73 (watch that it is seated correctly), remove the tool Push the brake housing 25 into the connector housing 1 and tighten screws 61 with washer 66. For torque values, see page 11.10.02, Push the oil motor 96 into sun gear 5 and brake hosing 25 and secure with screws 95 ( for torque values, see page 11.10.02). Connect the brake lines to the gear. Install the housing 99, and secure with screws 98. Insert the drain plug 62 and open the oil plug. Fill with gear oil until the lower edge of the bore hole. Check for brake function, see description of function.1. CONSTRUCTION OF TRAVEL BRAKE Disc brake ‘An hydraulically vented wet disc brake is integrated in each travel gear and acts on the gear drive. If chamber "C*,connected to the brake control connection is at tank pressure, the brake piston 60 presses the discs 51 / 52 together with the preload of the springs 61 / 62. The resulting brake torque acts on the drive shaft of the hydraulic motor 200 / 201 via the disc carrier 55 with inner and outer teeth. If control pressure is applied to chamber “C” the piston 60 is pushed against the force of the springs 61 / 62 toward the end ring 63. The axial preload on the discs is relieved and the resulting brake torque is anuled. Brake valves 205 Abrake valve 208 is flanged to each travel motor 200 / 201. Each valve brake 205 comprises : - an hydraulic braking piston 206 preventing the travel motor from overspeeding, - the two ways check valve 207 and the pressure reducing valve 208, which generate the necessary brake control pres- sure to vent, via connection “Br* of brake valve, pressure hose 109 and chamber “C" the mechanical multi disc brake in the travel gears, For description of the brake valve 205, refer to sub group 7.98. Benennung/Description/Dénomination LIEBHERR Travel Brake Datum Edition 12.94 Date 7 ose see pageno. 11. ry Bia Page. 11.21.012. FUNCTION OF THE TRAVEL BRAKE The high pressure at connection "A" (respec "B*) of a travel motor 200 / 201 builds up, via two way check valve 207 and pressure reducing valve 208, at the port "Br" of the brake valve 205. ‘As a consequence the brake is relieved automatically as soon as the pressure appearing at connection (respec "B") at travel actuation becomes higher than the pressure necessary to vent the disc brake. Due to the "A - B - T" connection at neutral position of the travel spool valves 103 and 105 (see sub group “Hydraulic System") the pressure difference between connections "A" and “B" is relieved as soon as travel pedals are returned to neutral. The pressure at connection "b2", connected to tank via a restrictor decreases and the disc brake applies. 129 130 131 132 200 201 202 203 Sec. pressure relief valve / Travel left Sec. pressure relief valve / Travel left Sec. pressure relief valve / Travel right Sec. pressure relief valve / Travel right Travel motor left Travel motor right Positioning piston Control piston / travel motor displacement 205 206 207 208 209 250 251 Brake valve complete Hydraulic brake piston 2-Ways check valve - brake control pressure Pressure reducing valve- brake control pressure Travel brake Rotary connection Rotary connection / Travel brake 11.21.01Jenennung/Description/Dénomination Sieh Dat LIEBHERR |” an Ese See page no 1 Fahrwerksbremse = VowrFeutten tt Boa Travel Brake coms Edition 12.94 Frein de translation Blate c Fein 11.21.023. REPAIR OF TRAVEL BRAKE (Sealing the brakes and replacing the brake discs) tf a lot of noise can be heard in the brakes, the brake pads are worn. The outer discs should be replaced immediately. The brake also has to be replaced if the braking action decreases. A important! Before repairing the brakes, make sure all appropriate safety procedures for machine and personnel are observed, as parking the machine on level ground, securing the machine if 1g on an incline, relieving the brake pressure. The brake can be repaired without removing the gear. Disassembly Drain gear oil and pull the oil motor 96 from the gear, see page no 11.17.02, § 3.1 (points 1 and 4to 7). Remove the disc carrier 55 from the input shaft 35. A cautions ‘The end ring 63 and the ring piston 60 are under spring pressure, Press down the end ring 63 with special tool no. 129 and two screws 95 (fastening screws for oil motor 96). Release the snap ring 64, loosen the special tool and remove it. Remove end ring 63 and ring piston 60 complete with springs 61 / 62 from brake housing and pull off grooved rings 56 / 57 (with support rings) from brake housing 1 Pull off the front pressure ring 50, the inner / outer discs 51 / 52 and the rear pressure ring 50 from the inner gear of brake housing 1. Assembly DEF Important : Before assembly, clean and check all parts carefully for wear. Set the rear ring 50 into the inner gear 1 and install the outer and inner discs 52 / 51 as follows: Outer disc inner disc- outer disc etc. Set the front ring 50 onto the last outer disc 52. Set the grooved rings 56 and 57 with support rings into the brake housing 1 DEF Note: Mount the support rings opposite the pressure side. Slightly lubricate the grooved rings before installation. 11.21.02Mount the springs 61 / 62 and the ring piston complet 60 into the groove of brake housing 1. Insert the disc carrier 55 into the toothing of the input shaft 35 and the discs. Insert end ring 63 into piston 60 and push the it down with special too! no.129. Insert snap ring 64 (watch that it is seated correctly), and remove the tool. Replace the o-ring 97 on oil motor 96; slightly lubricate the o- ring before installation. Push the oil motor 96, see page no. 11.17.02, § 3.2 (points 2to 6) and contro! the axial play "A". in of function. Check for brake function, see desi Benennung/Description/Denomination LIEBHERR Travel Brake Datum Edition 12.94 bate S SS S prt) Nu my iS = is 7 Mode Type me From Bepuis See page no. 11.Handling and installation instructions for slipring seals Slipring seals are precision components made out of chilled cast iron, Therefore sharp knocks and blows should be avoided! Installation instructions 1. Do not remove slipring seals from protective packing until they are ready to be used. Protect the polished seal faces 1 from damage and dirt. New slipring seals should only be installed per pair, as wraped 2. The seal housings 2 (receiver parts) must be clean and free of burrs and machining residues. All edges in the housing bore must be smooth and chamfered. 3. Install slipring seals with special installation tool 3 (fig. 2). This consists of two half shells that are closed around the seal ring. Pressure is applied evenly around the circumference of the elastomeric part 4 For easier assembly, moisten the bore in the housing and the co-ting 4 with a 1:1 mixture of water and spirit. Seal face (sliding surface) Seal housing Installation tool O-ring (elastomer) Seal ring BenennungiDescription/Dénomination LIEBHERR Slipring seal DatumiEartionDate 01.92 Typ Mode! Type ‘Abrtcomia partir de BlatuPagerFeuille 11.25.01“oe Press the slipring seal into the housing Take care that afterwards the seal face lies parallel with the housing surface. To verify the correct installation, measure the distance A at three points evenly positioned around the slipring circumference (see fig. 3) The o-rings must not sit wave-like in the housing bore or bulge partially looped out of the bore (fig. 4) Note: ~ Before assembly of both seal rings, wait for complete evaporation of water-spirit mixture. If necessary, blow out o-rings and seal housings with pressure air. ~ Slipring seals of greater size as employed in. travel gears FAT should not be installed Using a rope wound around the o-ring 4 as. described page 12.15.01 Before assembling the slipring seals, apply a thin oil film to the seal faces 1, using a soaked chamois leather cloth. Take special care to do not apply oil to the elastomeric rings or to the housing bores. reso