Service Manual Hydraulic Excavator Swing Gear SUB GROUP INDEX R900 B-R 944 9.10. Swing Gear "SAT" A/ R 9008 / 6001 -» ‘AI R904 / 6001 —> AA/R9%4//6001 > AR 924 /6001 > A/R934/ 5001 R944 / 5001 9.20. Swing Brake See cecteeteetene . ‘AJR 9008 / 6001 > A/R904/ 6001 > A/R914/ 6001 > A/R924/ 6001 > ‘A/R934/ 5001 > R944 / 5001 > AIR 900 B -A/R 924 / 6001 > LIEBHERR 9.00.00 AIR 934-R944/ 5001 > Issue : 12/2001Service Manual Hydraulic Excavator Swing Gear 1. CONSTRUCTION OF SWING GEAR The two stage planetary gear is driven by the attached HMF (914 - 924) or FMF (900 B - 904 - 934 - 944) hydraulic oil motor. It moves the uppercarriage via the output shaft and the internally geared swing ring. The integrated disk brake acts directly on the gear drive. It is used as a spring applied brake and is vented hydraulically, ie. if there is no brake pressure, the disks are pressed together by springs and the brake is mechanically closed.) A housing around the output pinion of the swing gear contains all the necessary lubrication reserve for the lubrication of the output pinion and swing ring teeth. Lubricating the gear partially replaces this reserve. A/R 900B and 904 A/R914 and 924 ‘AIR 900 B -A/R 924 / 6001 ~ LIEBHERR 9.10.01 AJR 934-R944/ 5001 > Issue : 12 / 2001Service Manual Hydraulic Excavator 2, TECHNICAL DATA Swing Gear Litronic Machine Model A/R 9008 AJR904 A/ROIG Serial number 6001 6001 6001 —— Gear Type SAT 225/220 | SAT225/220 | saT250/231 Max. Speed 2400 min-t 2400 min 2172 mint Max. Torque 4850 Nm 4850 Nm 8500. Nm Gear Ratio 1:31,7 1:31.7 1:37 Weight 108kg 108k 154k Oil Quantity in Gear 4.4 Ite. attr. 5.5 itr. Oil Quality API-GL-5 API-GL-5 API-GL-5 Oil Viskosity SAE90W SAE 90W SAE90W or saesow90 | sAzsow90 | saesows0 (orf swing brake actuated via foot pedal) SAE SOLS SAE 90 LS SAE 90 LS Brake Disk brake hydr. vented Air pressure min. 20 bar 20bar 28 bar Air pressure max. 35 bar 35 bar 35 bar Axial play and Torques A) Measurement of control of sun gear 5 93,5+05mm | 93,5+05mm | 9,0 +05 mm (measured from mounting surface ) 8) Friction of tapered roller bearing 57/ 58 20-25 Nm 20-25 Nm 35-40 Nm ©) Torque screw 60 49.Nm 49Nm 49m D) Torque screw 61 135Nm 135m 210 Nm 8) Torque screw 63 86Nm 86Nm 210Nm F) Torque screw 101 310Nm 310Nm 310Nm H) Torque screw 104 310Nm 310Nm 310Nm 9.10.02 LIEBHERR Issue : 12/2001Service Manual Hydraulic Excavator TECHNICAL DATA, Swing Gear Litronic Machine Model ASR924 AIR934 R944 Serial number 6001 5001 5001 Gear Type $AT275/233 | SAT275/222 | SAT300/213 Max. Speed 2172min-t 1943 min 1550 mint Max. Torque 9000 Nm 10500 Nm 13460 Nm Gear Ratio 1:36 1:317 1:37 175kg 200kg 260kg it i 6.0 ltr 6,0ltr. 8.0 It @ itaustir api-ct-s | api-ct-s | api-ct-s Oil Viskosity SAE SOW SAE9OW SAE 90W or SAE80W90 | SAE80W90 | SAESOW90 (or if swing brake actuated via foot pedal) SAE SOLS SAE 9015 SAE 90 LS Brake Disk brake hydr. vented Air pressure min. 28bar 20 bar 20bar Air pressure max. 35 bar 35 bar 35 bar Axial play and Torques : ‘A) Measurement of control of sun gear 9,0+05 mm 93,5 mm 11,7 mm e ( measured from mounting surface ) 8) Friction of tapered roller bearing 57/58 35-40 Nm 45-50 Nm. 55-60 Nm ©) Torque screw 60 49 Nm 49m 49.1Nm D) Torque screw 61 135m 210Nm 210Nm £) Torque screw 63 210Nm 210Nm 210Nm F) Torque screw 101 310Nm 310Nm 620 Nm H) Torque screw 104 310Nm 310 Nm 620 Nm saps sss NNN NANNIES NAAN NA NNN SASNNHHANSNNNNNS AJR 900 B -A/R 924 / 6001 —> AIR 934-R944/ 5001 > WEBHERR 9.10.03 Issue : 12/2001Service Manual SSSI NSH NHHNNN NSIS ANAND NAEEAASAASNSSASSNNASOSNNNNHHNANNN 9.10.04 Hydraulic Excavator Swing Gear 3. FUNCTION AND POWER FLOW, see also § 6. ‘The input torque is transferred to the sun gear 5 by the hydraulic oil motor 190. ‘The sun gear 5 drives the sun gear 6 via the planetary gears 10 and the planetary carrier 15 with the reduced speed by planetary stage | ‘The sun gear 6 drives at the same time via planetary gear 11 and the planetary carrier 16 the output shaft 17 with the reduced speed by planetary gear I! The gear ratio - see also § “Technical Data". is combined by both planetary gears. The output torque increases in the same ratio as the output speed is reduced. Function of lubrication system The grease cap 26, mounted on the housing 2, covers the pinion of the drive shaft 17 to the connection on the swing ring. The cap is filled with grease via a lubrication line. It releases grease to the pinion and swing gears every time the uppercarriage turns. Gear maintenance The gear has to be checked regularly - in intervals given in maintenance guide lines in section 3 - for leaks and oil level as well as mounting tightness of gear and oil motor. ‘The gear oil also has to be changed in certain intervals. Maintenance of lubrication system The grease in the grease cap has to be replaced or added to in certain intervals, see also maintenance guidelines in section 3. LIEBHERR Issue : 12/2001Service Manual Hydraulic Excavator Swing Gear "SAT" 4, REMOVAL AND INSTALLATION OF SWING GEAR 4.1. Removal of swing gear Lower attachment to the ground. Remove cap on drain valve 105, attach oil drain hose (in the excavator's too! kit) and drain the gear oil in an appropriate container. Remove oil drain hose and attach cap on drain valve 105. Remove the appropriate hydraulic lines and parts, which might be in the way when removing the gear. Remove hydraulic, leak oil and brake lines from the oil motor and gear e Remove screws 104 and lift the gear with a lifting device from the upper carriage. 4.2 INSTALLATION OF SWING GEAR Coat the lower part of the gear in the area of centering in the lower uppercarriage sheet with anticorrosive grease (preferably use “Optimol White T", ident no. 8500307). Lift the gear into the upper carriage (watch that it is positioned correctly because of the oil drain plug) / Install screws 104 and torque to prescribed value, see ‘Technical Data”. Connect the brake, leak oil and hydraulic lines to the e@ oil motor and gear Remove the cover 97 and add gear cil see lubrication chart in section 1. via the filler tube until the level reaches the upper mark on the dipstick 13, Reinstall the cover 97 Check gear and function and pinion mesh into the swing ring, Replace the grease for the swing ring teeth lubrication on grease fitting 106 and check the swing ring lubrication, SAAT AJ RODDR -A/R924 6001-> LIEBHERR 09.10.05 AJ R934-R 9445001 Issue: 12/2001Service Manual Hydraulic Excavator 61 ‘Swing Gear "SAT" 5. TO SEAL THE GEAR DP Note: ‘The work described in paragraph 5.1 and 5.2 can be completed when the gear is installed. Important: Check and carefully clean all parts before installation. All seals should be lightly oiled or greased before installation 54 52. Sealing in the area of the swing motor Remove all lines which might be in the way. ‘The hydraulic and leak oil lines and control lines on the il motor can possibly stay connected, e Remove screws 101 and lift oil motor 190 from the gear, Replace the o-ring 102 on the oil motor. Set the oil motor 190 again into the gear. Reinstall the screws 101. For torque values, see "Technical Data” Sealing in the area of the multi-disks brake Note: Before removing the brake, make sure the attachment is lowered to the ground. Description : The sealing operation is described in the § “Repair on the brake in the subgroup “Swing Brake”, 09.10.06 LIEBHERR 12/2001Service Manual Hydraulic Excavator Swing Gear "SAT" SAAT A/ROQ00R -A/ R924 6001» LIEBHERR 09.10.07 A/R934-R 944 5001—> = Issue : 12 / 2001Service Manual 6 10 1" 2 15 16 7 20 25 26 30 31 35 36 37 40 4a Hydraulic Excavator Exploded view, parts list, sectional view Output shaft housing 43 Sun gear 44 Sun gear 45 Planetary gear 46 Planetary gear 47 Dipstick 49 Planetary carrier 37 Planetary carrier 58 Output shaft 60 Inner gear 6 Brake housing 62 Lubrication cap 63 Piston 65 End ring 66 Ring 70 Inner disk n Outer disk 3B Disk carrier 7 Spring {not mounted on 900 B) 7 Spring Spring Retainer Retainer Grooved nut Support ring Tapered roller bearing Tapered roller bearing Screw Screw Plug (only 900 B) Screw Lock washer Lock washer Snap ring Snap ring Snap ring Support ring 82 33 84 88 89 90 1 94 7 101 102 104 105 190 900 910 960 Swing Gear "SAT" O-ring O-ring O-ring Groove ring Groove ring Shaft seal Nilos ring Plug (only 900 8) Filler tube Screw O-ring Screw Drain valve Oil Motor HMF or FMF Repair kit / brakes Gasket set / gear Repair kit / brake disks Notice the adjustment values and torques See “Technical Dat A,B,C, D,E, F, H $2. 09.10.08 LIEBHERR 12/2001Service Manual Hydraulic Excavator Swing Gear "SAT" 190 102 S166 84 82 31 35 @ 36/37 70. {_ 77 10: 1 104-@).-— i \ 20: H nN i 83 f "1 a 16 Bi 47 105: -————— @ > B 57 90 17 ; B— 58 \ 1 63/66 |S 49 26 Ss e SAAT ‘A/R9008 -A/ R904 6001» LIEBHERR 09.10.09 R934-R9445001> Issue : 12 / 2001Service Manual 6. Exploded view, parts list, es sectional view 10 uN B 5 16 7 20 25 26 30 31 35 36 37 40 SSA Hydraulic Excavator Output shaft housing 42. Spring B Sun gear (not mounted on 9008) 7 Sun gear 43 Spring 82 Planetary gear 44 Spring 83 Planetary gear 45 Retainer 84 Dipstick 46 Retainer 88 Planetary carrier 47 Grooved nut 89 Planetary carrier 49 Support ring 90 Output shaft 57 Tapered roller bearing 1 Inner gear 58 Tapered roller bearing 94 Brake housing 60 Screw 97 Lubrication cap 61 Screw 101 Piston 62 Plug (only 9008) 102 End ring 63 Screw 104 Ring 65 Lock washer 105 Inner disk 66 Lock washer 190 Outer disk 70 Snap ring 900 Disk carrier 71 Snap ring 910 960 Swing Gear "SAT" Snap ring Support ring Oring O-ring O-ring Groove ring Groove ring Shaft seal Nilos ring Plug (only 900 8) Filler tube Screw O-ring Screw Drain valve Oil Motor HMF or FMF Repair kit / brakes Gasket set / gear Repair kit / brake disks Notice the adjustment values and torques A,B,C, D,E, F,H See "Technical Data”, § 2. 09.10.10 LIEBHERR 12/2001Service Manual Hydraulic Excavator Swing Gear "SAT" 190. 97 25 42/03/44 88 30 89 L 73 e 4 : 5 49 26 SAAT A/ R914 A/ R924 6001—~ LIEBHERR 09.10.11 Issue | 12/2001Service Manual Hydraulic Excavator Swing Brake A. Construction of the swing brake circuit 1. Disk brake, see fig. 1 The brake is integrated into the swing brake and acts on the gear drive. It is a hydraulically vented, wet disk bake. The brake disks 36/37 are pressed together mechanically by the preload force of springs 42/43/44 and released by actuating ‘the piston 30 with servo pressure (on the opposite side of the spring). @ 2 scenciavave v7, 00.2 Solenoid valve Y7 is integrated in the control and regulating oil unit 50. In neutral position, the solenoid valve connects chamber "K" with the tank (brake is applied). In working position, it connects chamber “K" with servo pressure (brake is released) e 3. Circuit board A1001, see fig. 3 This circuit board controls the solenoid valve "Y7" via its output stage "V4". If the circuit board receives the signal “brake released” from the switching unit via the CAN-BUS 2, the output stage makes alive the power output to solenoid valve Y7. Refer to the sub-group “Components of the electric system" for the arrangement of the circuit board A1001. SAAT ‘A/RANDR -A/ R924 6001» AR 09.20.01 A/R934-R 944 5001—> aoeService Manual Hydraulic Excavator Swing Brake B. Control and function of the swing brake circuit e 1. Elements for swing brake control - Push button $17- on the switching unit = Rocker switch $57* - in the handle of the right joystick - Impulse transmitter B53* - mounted to the connector plate of the swing motor * B53 and S57 are mounted only on machines having semi- automatic brake control, see next §. 2. The operation of the brake Depending on the machine type, the control of the swing brake is different (direct or semi-automatic) - On machines with direct brake control (A / R900 8 up to A R924) the brake is alternately applied and released by depressing the push botton $17, Yin rest position FL | “orate socice “Brake applied" iba . ay oy Se = Rees - 7 (Or | Yrisalive 09.20.02 LIEBHERR 12/2001Service Manual Hydraulic Excavator Swing Brake = On machines with semi-automatic brake control (R 934 and R 944) the push button $17 select the brake operating mode (brake applied or semi-automatic) = In one position the brake remains always applied. In this case the red control light in the button S17 lights up. - Inthe other position, the brake isin semi-automatic mode and is controlled via the rocker switch $57 mounted to the right joystick lever: = with the rocker switch $57 tilted down, the brake is appled, respectively it applies as soon as the uppercarriage speed gets lower than a limit value, - with the rocker switch $57 tilted up, the brake remains released. TZ Brake applied »O s7 Crmaaroe — PE Tarpon RPM < brake applied Y7 B53 Y7 YT is alive : ee 4p SAAT AJ R900B -A/ R924 6001—> LIEBHERR 09.20.03 A) R934-R944 5001 Issue: 12/2001Service Manual Hydraulic Excavator Swing Brake 3. Principle Schematic reac: L ee X6.1 Liaison | hte asses eve see] wsann| EI 30 50 190 195 196 =e 5300, wan)? Hydraulic pump / Servo-control Control and regulating oil unit Swing motor ‘Swing brake Swing gear 09.20.04 A1100(4) 1010 (n) A/R900B-A/R924 ‘A001 A007-H7 A100. At001-H9 Atoor.vs A010 Ast00 A1010-F8 Ator0+H8 A1100-F8 1100448 si7 yr Printplate- Control ESPO1 LED green / Input signal e@ LED red / Default LED green / Output signal Amplifier Swing brake Pirintplate/ Fuses (R-machines) Plrintplate contol £502 (A-machines) Fuse LED / Output Fs Fuse LED / Output Fs Switch ‘swing brake Solenoid valve /swing brake LIEBHERR 12/2001Service Manual Hydraulic Excavator Swing Brake © > Prince scremavi 195 196 30 Hydraulic pump / Servo-control 50 Control and regulating oil unit 190 Swing motor 195 Swing brake 196 Swing gear A/R934-R944 ‘A101 ‘A1001-H7 A1001-H8 1001-49 AN001-V8 Anor0 A1010-F8 A110 53 si7 ss7 v7 Printplate- Control ESPO1 LED green /Inputsignal LED red Default LED green / Output signal Amplifier Swing brake Plrintplate / Fuses Fuse LED / Output FB Impuls transmitter saving motor * switeh swing brake Switch swing brake * Solenoid valve / swing brake * only on machines with semi automatic brake control SAAT A/R900B -A/ R924 6001 LIEBHERR AJ R934-R 9445001 09.20.05 Issue: 12/2001Service Manual Hydraulic Excavator Swing Brake SAN NHHHHHHI HHH NSH HN HHH NNNAAAS AIHA SSAA SSSA SSSA SSSNNASISNASSSSSNNNNNS . Repair on the brake (sealing the brake and replacing the brake disks) If a lot of noise can be heard in the brakes, the brake pads are worn. The outer disks should be replaced immediately. The brake also has to be replaced if the braking action decreases, DEP Important! Before repairing the brakes, make 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 the complete gear section views in the subgroup "Swing gear SAT". 1. Removal of swing motor 190 and brake housing 25 Remove the necessary hydraulic lines to reach the gear. Remove screws 101 and pull the oil motor 190 with connected hydraulic lines from the gear. Remove the brake lines from the gear. 102 Remove the screws 61 and brake housing 25 from inner gear 20. f 42/43/44) 2. Disassembly of brake housing 25 DEF> Important : Push down piston 30 with special tool no. 20 - 23 -see subgroup 2.07- and two screws M16 120 or M16 140, The ring 31 and piston 30 are spring loaded. Release snap ring 73, loosen the tool and remove it. Remove piston 30, springs 42/43/44 and o-rings 82 / 86 and grooved ring 88 from brake housing 25. 09.20.06 LIEBHERR 12/2001Service Manual Hydraulic Excavator Swing Brake Push end ring 31 from piston 30 and pull off grooved ring 89. Remove front ring 35, brake disks 36/37 and rear ring 35 from the inner gear 20. 3. Assembly of the brake housing 25 Important: Carefully clean and check all parts for wear before installation. Set the rear ring 35 into the inner gear 20 and insert the outer and inner disks 37/36 in order: Outer disk- inner disk - outer disk etc. Set the front ring 35 onto the last outer disk, Insert the grooved ring 89 into the end ring 31 and grooved ring 88 and o-rings into the brake housing 25. Note: Mount the support rings to the side opposite the pressure Lightly lubricate the grooved rings before installation. Pull o-ring 82 onto the brake housing 25, lightly lubricate it before installation. Push end ring 31 into the piston 30. Insert springs 42/43/44 and push piston 30 onto the brake housing 25. With tool no. 20, push the piston 30 down. Insert snap ring 73 (watch that it is seated correctly), remove the tool. 4. To reinstall brake housing 25 and swing motor 190 Replace o-rings 102 on the oil motor and 84 on the brake housing; lubricate them lightly before installation Push the brake housing 25 into the inner gear 20 and mount screws 61 with washer 66. For torque values, see "Technical Data” in subgroup "Swing Gear” Push oil motor 190 into the sun gear 5 and brake housing 25 and mount with screws 101. For torque values, see “Technical Data” in subgroup “Swing Gear" Connect brake lines to the gear. Check the brake for function, see description of function. 73, 82. 31 20. 89 30 86 Design of gear housing 25 turned by 90° 88 42/43/4425 SAAT A/R900R -A/R924 6001> LIEBHERR A/R934-R9445001—> 09.20.07 Issue: 12/2001