Professional Documents
Culture Documents
LFR/en/version: 08 / 2007
Coupling............................................................................................................................................ 15-3
1.1 Function / operation................................................................................................................ 15-3
Splitterbox......................................................................................................................................... 15-5
2.1 Technical data ........................................................................................................................ 15-5
Swing gear........................................................................................................................................ 15-6
3.1 Technical data ........................................................................................................................ 15-6
3.2 Function / operation................................................................................................................ 15-7
3.3 Installation / removal............................................................................................................... 15-10
3.4 Sealing of the swing brake ..................................................................................................... 15-11
3.5 Swing brake............................................................................................................................ 15-13
Swing bearing ................................................................................................................................... 15-14
4.1 Component location................................................................................................................ 15-14
4.2 General data........................................................................................................................... 15-15
4.3 Function / operation................................................................................................................ 15-16
4.4 Installation / removal............................................................................................................... 15-16
4.5 Inspection / wear reporting ..................................................................................................... 15-19
Engine / splitterbox mounting ........................................................................................................... 15-21
5.1 Technical data ........................................................................................................................ 15-21
5.2 Function / operation................................................................................................................ 15-23
5.3 Installation / removal............................................................................................................... 15-23
5.4 Inspection wear reporting ....................................................................................................... 15-27
To Preassembled modules ............................................................................................................... 15-29
6.1 Mounting / Dismounting modules ........................................................................................... 15-30
MJFCIFSS
15 - 1
LFR/en/version: 08 / 2007
Service Manual
15 - 2
MJFCIFSS
Service Manual
Uppercarriage - Mechanical
Coupling
15 Uppercarriage - Mechanical
15.1Coupling
15.1.1Function / operation
LFR/en/version: 08 / 2007
15.1.1.1Components location
MJFCIFSS
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Uppercarriage - Mechanical
Service Manual
Coupling
15.1.1.2Use
The elastic coupling (torsional vibration damper), which is installed between the Diesel engine and the splitterbox, compensates for shaft (crankshaft - pump input shaft) misalignments, which could be caused by manufacturing and dimensional variations. The elastic coupling also absorbs the residual torsional vibration of the
Diesel engine as well as the torque jolts caused by load fluctuations.
LFR/en/version: 08 / 2007
It transfers engine torque to the splitterbox directly and constantly, which means that it cannot be disengaged.
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MJFCIFSS
Service Manual
Uppercarriage - Mechanical
Splitterbox
15.2Splitterbox
15.2.1Technical data
Model
R 9250
Splitterbox (type)
Direction of rotation (as seen when facing the flywheel)
Ratio to pump connections I
Ratio to pump connection II
Ratio to pump connection III
Ratio to pump connection IV
Weight (without pumps) in kg
Oil quantity in gear in l
Oil specification
Oil viscosity
LFR/en/version: 08 / 2007
For more information about the splitterbox see the BOSCH-REXROTHs documentation about the splitterbox
GFC 320 1002.
MJFCIFSS
15 - 5
Uppercarriage - Mechanical
Service Manual
Swing gear
15.3Swing gear
15.3.1Technical data
Gear - type
Unit
min
Nm
-1
Gear ratio
Hydraulic motor
Typ.
FMF250
Weight
Kg
1120
l.
38
Oil quality
API - GL - 5
Oil viscosity
Brake
Nm
47 700
Nm
65 600
bar
26
mm
146,5+0,5
Nm
Nm
Nm
Nm
Nm
Nm
160 - 280
580
210
210
960
1900
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MJFCIFSS
Service Manual
Uppercarriage - Mechanical
Swing gear
15.3.2Function / operation
The hydraulic excavator rotates at 360, it although the uppercarriage which is rotating. This operation is possible thanks to a system, which is called swing system. This system is composed from four swing gears and
the swing bearing. The four swing gears engage the swing ring, and permit the rotation of the uppercarriage.
In this part we first explain the swing gear.
15.3.2.1Function
The swing gear is composed from two stage planetary gears, which are driven by the attached FMF hydraulic
oil motors.
They move the uppercarriage via the output shaft and the internally geared swing ring . The integrated disk
brakes act directly on the gear drive. They are used as a spring applied brake and are vented hydraulically, 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 necessary lubrication reserve for the lubrication of the output pinion and the swing ring teeth.
Lubricating the gear partially replaces this reserve.
LFR/en/version: 08 / 2007
15.3.2.2Component location
MJFCIFSS
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Uppercarriage - Mechanical
Service Manual
LFR/en/version: 08 / 2007
Swing gear
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MJFCIFSS
Service Manual
Uppercarriage - Mechanical
Swing gear
60
Screw
Inner gear
61
Screw
Sun gear
62
Screw
Sun gear
63
Screw
10
Planetary gear
65
Lock washer
11
Planetary gear
66
Lock washer
14
Cover plate
67
Tension pin
15
Planetary carrier
70
Snap ring
16
Planetary carrier
71
Snap ring
17
Output shaft
73
Snap ring
20
Inner gear
76
Headless screw
25
Brake housing
81
O-ring
26
Lubrication cap
82
O-ring
30
Piston
83
O-ring
31
End ring
84
O-ring
35
Ring
85
O-ring
36
Inner disk
86
Breather cover
37
Outer disk
87
Filler neck
40
Disk carrier
88
Groove ring
43
Spring
89
Groove ring
44
Spring
90
Shaft seal
45
Retainer
91
Nilos ring
46
Retainer
100
47
Grooved nut
101
Screw
48
Washer
102
O-ring
57
104
Screw
105
Drain valve
58
15.3.2.3Functional description
The input torque is transferred to the sum gear 5 by the hydraulic oil motor 100.
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 I.
The sun gear 6 drives at the same time via planetary gear 11 and the planetary carrier 16 the output shaft 11
with the reduced speed by planetary gear II.
LFR/en/version: 08 / 2007
The gear ratio is combined by both planetary gears. The output torque increases in the same ratio as the output
speed is reduced.
MJFCIFSS
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Uppercarriage - Mechanical
Service Manual
Swing gear
15.3.3Installation / removal
15.3.3.1Installation of swing gear
1. 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).
2. Lift the gear into the uppercarriage (watch that it is positioned correctly because of oil drain plug).
3. Install screws 104 and torque to prescribed value.
4. Connect the brake, leak oil hydraulic lines to the oil motor and gear.
5. Fill the gear via the quick-change couplings 6 in the service center until the level reaches the middle of the
lower sight glass L. For small quantities. The oil refilling may be done via the filler tubes 3. For oil specification and quantity, refer to the lubrication chart.
6. Check gear, function and pinion mesh into the swing ring.
7. Start a new lubrication cycle for the swing ring gear (push button CYCLE START on the grease control
board) until the housing around the output pinion of the gear is filled with grease.
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MJFCIFSS
LFR/en/version: 08 / 2007
To remove the swing gear, Liebherr recommends to use a special tool (see Tooling).
Service Manual
Uppercarriage - Mechanical
Swing gear
4. Remove the appropriate hydraulic lines and parts, which might be in the way when removing the gear.
5. Remove hydraulic, leak oil and brake lines from the oil motor and the gear.
6. Remove screws 104 and lift the gear with a lifting device from the uppercarriage.
For first installation or reparation, which necessitates the opening of swing gear, see the manufacturer documentation : Mounting instructions of SAT 450 - 257.
LFR/en/version: 08 / 2007
Important :
Check and carefully clean all parts before installation. All the seals should be lightly oiled or
greased before installation.
Drive
Remove all lines, which might be in the way.
The hydraulic and leak oil lines and control lines on the oil motor can possibly stay connected.
Remove screws 101 and lift oil motor 100 from gear.
Replace the O-ring 102 on the oil motor.
Set the oil motor again into the gear. Reinstall the screws 101. For torque values, see page General data.
MJFCIFSS
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Uppercarriage - Mechanical
Service Manual
Swing gear
Disk brake
Note :
Before removing the brake, make sure the attachment is lowered to the ground.
Removal :
Lift the oil motor 100 from the gear.
Remove and plug the brake lines from the gear.
Remove the screws 61 and lift the brake housing 25 from the inner gear 20.
Note :
The ring 31 and piston 30 are spring loaded.
Push down piston 30 with special tool, and two M16 x 120 screws.
Release lock ring 73. Loosen and remove the special tool. Remove the piston 30 with brake housing 25 and
springs 43/44.
Replace O-rings 82, 86 and groove ring 88 with support ring.
Note :
When installing groove rings 88 and 89, make sure they are seated correctly (the groove has
to point to the pressure side and the support ring to the unpressurized side). Lightly grease all
parts.
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MJFCIFSS
LFR/en/version: 08 / 2007
Assembly :
Service Manual
Uppercarriage - Mechanical
Swing gear
15.3.5Swing brake
15.3.5.1Component location
15.3.5.2Functional description
LFR/en/version: 08 / 2007
Pressurised oil is circulated between the piston 30 and the end ring 31, the pressurised oil plates the piston 30
on the brake housing 25. The oil input in the swing brake is a threaded hole (see the arrow A). When the rotation is stopped, the swing break is used. So the alimentation in pressurised oil is stopped, and the springs 43
and 44 are pushing the piston 30 against the disk (see 36 and 37). The planetary gear 10 is stopped, and the
rotation of the excavator too.
MJFCIFSS
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Uppercarriage - Mechanical
Service Manual
Swing bearing
15.4Swing bearing
15.4.1Component location
Upper outer ring
2.
3.
Radial roller
4.
Upper roller
5.
Lower roller
6.
Inner ring
7.
Upper seal
8.
Lower seal
10.
11.
12.
Nut
13.
Counter nut
14.
Undercarriage
15.
Uppercarriage
LFR/en/version: 08 / 2007
1.
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MJFCIFSS
Service Manual
Uppercarriage - Mechanical
Swing bearing
15.4.2General data
Machine
R 9250
ROD 1304 DJ
Swing ring
type
Teeth (Nb)
Nb
114
mm
mm
0,1
0,5
mm
Radial play
Min
Max
mm
mm
0
0,4
Backlash allowable
Min
Max
mm
mm
0,46
0,93
kg
90000
Mounting bolts
Size
Bolt tensioning cylinder
Required pressure (Bar)
Distance between swing ring and the end of bolt
Bolt tension (undercarriage)
Bolt tension (uppercarriage)
Nb
60
M36
5617448
1350
851
570
570
Id
bar
mm
kN
kN
Note :
Axial play at delivery is the play a new gear has when installed (measuring the axial).
15.4.2.2Backlash
LFR/en/version: 08 / 2007
Backlash is the play between the teeth of the inner ring and the swing gear output pinion.
MJFCIFSS
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Uppercarriage - Mechanical
Service Manual
Swing bearing
15.4.3Function / operation
15.4.3.1Functional description
The swing bearing allows the swing ring to turn. This operation permits the rotation between the uppercarriage
and the undercarriage. The inner ring 6 is screwed to the undercarriage 14 thanks to the mounting bolt 11, the
nut 12 and the counter nut 13. The inner of the ring 6 is cogged, and this part meshes with the swing gear. The
upper outer ring 1 and the lower outer ring 2 are forming a guide rail for the inner ring 6. The radial roller 3, the
upper roller 4 and the lower roller 5 permit the rotation between the inner ring and the outer ring (1 and 2). The
outer ring is fixed on the uppercarriage thanks to the mounting bolt 10, the nut 12 and the counter nut 13. So
when the 2 swing gear are running the rotation of the uppercarriage is possible.
When working, the excavators uppercarriage has to absorb stress and strain. These forces are transferred by
the two outer rings 1 and 2, which are mounted on the uppercarriage and the rollers 3, 4 and the inner ring 6,
which is mounted to the undercarriage.
Two seals 7 and 8 prevent dirt and dust from the entering of the swing ring.
The swing ring is lubricated via a central lubrication line on the outer ring of the swing ring. The gear of the inner
ring and pinion are lubricated via a grease packing on the swing gear pinion.
The grease for swing ring and swing gear has to be replaced and checked at certain intervals, see Operation
and Maintenance Manual.
15.4.4Installation / removal
15.4.4.1Installation
To assure proper wear and operation, the mounting surface must be clean and level. Burrs, rust and uneven
spots must be carefully removed.
Set the swing ring onto the undercarriage, make sure it is seated correctly. Tighten the mounting bolts 11
with the tensioning cylinder in a 90 tightening sequence. Check the swing ring for easy movement and lubricate the bearing via the grease fitting.
Pull the undercarriage carefully under the uppercarriage. Lower the uppercarriage slowly and evenly with
the hydraulic jacks onto the swing ring.
Note :
Turn the outer ring of the swing ring into the correct position. The swing gear pinion has to mesh
with the gear and the mounting holes have to be lined up with the threads on the uppercarriage.
Install the bolts 10 and turn them in a 90 sequence with the tensioning cylinder.
Remove the front jacking support and the platform at rear of the excavator.
Reinstall boom cylinder rods to chassis pins.
Connect the air and hydraulic lines on top of the bottom of the rotary connection (check your marks to assure
connect hook up).
Connect the lubrication lines.
Start the Diesel engine, actuate all functions in the undercarriage and check the lines for leaks.
Lubricate the uppercarriage by turning the gear.
Check lubrication.
Check the swing ring for function and clearances.
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MJFCIFSS
LFR/en/version: 08 / 2007
Set the rotary connection into the undercarriage and the tighten screws.
Service Manual
Uppercarriage - Mechanical
Swing bearing
MJFCIFSS
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Uppercarriage - Mechanical
Service Manual
Swing bearing
LFR/en/version: 08 / 2007
Tighten the second nut (it isnt a counternut but rather a thread protection) on the bolt between 500 and
1000 Nm.
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MJFCIFSS
Service Manual
Uppercarriage - Mechanical
Swing bearing
To check the clearance, a gauge with magnetic stand is needed for correct measurement.
Align the uppercarriage with the undercarriage. Attach the gauge to the swing ring. As shown in the previous
figure. Fill the bucket, lift it and extend the attachment as far as possible.
Set the dial on the gauge to zero.
Lift the uppercarriage slightly with the attachment.
The difference between the two measurements is the axial play of the swing ring. Additional measurements
can and should be taken using the same procedure at various swing ring positions.
LFR/en/version: 08 / 2007
To check the clearance, a gauge with magnetic stands is needed for correct measurement.
Align the uppercarriage with the undercarriage. Attach the gauge to the swing ring in front of the excavator as
shown in the previous figure. Apply the travel brake and slowly push the excavator backward with the equipment (the bucket teeth take support in the ground).
Set the dial on the gauge to zero.
Slowly pull the excavator forwards with the attachment.
The difference between the two measurements is the radial play of the swing ring.
MJFCIFSS
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Uppercarriage - Mechanical
Service Manual
Swing bearing
+ mm
Tooth - side B
+ mm
Backlash
( + )mm
LFR/en/version: 08 / 2007
Note :
The backlash must be measures in the middle of the teeth.
Check the tooth clearance, the swing ring and the swing gear teeth with a lead strip.
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MJFCIFSS
Service Manual
Uppercarriage - Mechanical
Engine / splitterbox mounting
LFR/en/version: 08 / 2007
MJFCIFSS
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Uppercarriage - Mechanical
Service Manual
Buffer
22
25
27
Buffer
34
LFR/en/version: 08 / 2007
20
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MJFCIFSS
Service Manual
Uppercarriage - Mechanical
Engine / splitterbox mounting
15.5.2Function / operation
The engine, the splitterbox, the main working pumps, the swing pumps and the auxiliary pumps form the powerpack. The powerpack is one of the most important part of the hydraulic excavator. It assures mechanically the
displacement of nearly every part of the excavator.
The splitterbox is a spur gear, installed between the engine and the hydraulic pumps.
It is driven via the elastic coupling by the flywheel on the diesel engine and transfers engine output to the hydraulic pumps. Due to the different ratios between the different output shafts, the splitterbox allows for the
exactly desired RPM for each pump (main working pumps, swing pumps and auxiliary pumps).
When the engine is running, the powerpack is subject to vibrations. To protect the hydraulic excavator from
vibrations and the shocks of the powerpack, buzzers have been installed under the powerpacks. They are used
as dampers, the coupling is used as a damper too.
15.5.3Installation / removal
When the engine or the splitterbox isnt in order to work, if you have a replacement powerpack, the best solution
is to change the powerpack and repair the faulty powerpack after the installation of the replacement powerpack.
For more safety, before the removal or the installation of a part of the hydraulic excavator, see the chapter Safety Work Procedures / Risk Assessment. Attachment must be in a rested position. Turn off isolators S9.1 for
the batteries. This isolation is located on the left catwalk above the door that leads to powerpack.
15.5.3.1Removal
Removal of the powerpack
Drain coolant from radiator.
Drain the oil from the following components : engine, coupling, splitterbox, main working pumps, swing
pumps and auxiliary pumps.
Disconnect all the hoses, which are connected to the powerpack, and immediately close off opened lines
to prevent contamination.
Disconnect all electrical wiring from the powerpack.
Strip the powerpack covering.
Remove inlet and exhaust systems.
Strip the catwalk box right and left.
Start undoing the powerpack bolts necessary for the removal of the powerpack.
Left out the powerpack with the jacking equipment.
Put the powerpack on the ground.
LFR/en/version: 08 / 2007
MJFCIFSS
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Uppercarriage - Mechanical
Service Manual
15.5.3.2Installation
Installation of the powerpack
Lift the powerpack on the hydraulic excavator with the jacking equipment at its position.
Screw the powerpack bolts necessary for the installation.
Install the catwalk box right and left on the powerpack.
Open the lines, and immediately connect all the hoses on the powerpack.
Connect all electrical wiring from the powerpack.
Install inlet and exhaust systems.
Fix the powerpack covering.
Fill up the engine, the coupling, the splitterbox, the main working pumps, the swing pumps and the auxiliary
pumps with oil.
Fill up the radiator.
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MJFCIFSS
Service Manual
Uppercarriage - Mechanical
Engine / splitterbox mounting
LFR/en/version: 08 / 2007
MJFCIFSS
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Uppercarriage - Mechanical
Service Manual
LFR/en/version: 08 / 2007
15.5.3.3Component location
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MJFCIFSS
Service Manual
Uppercarriage - Mechanical
Engine / splitterbox mounting
LFR/en/version: 08 / 2007
Check the mounting screws 34 on the engine bracket and the engine or gear mounts (pos. 22 and pos. 25)
regularly for tightness, retighten, if necessary.
Tightening torque for screws M16, item 22 : 280 Nm (207 ft.lbs.).
Tightening torque for screws M16, item 25 : 280 Nm (207 ft.lbs.).
Tightening torque for screws M20, item 34 : 560 Nm (413 ft.lbs.).
Caution!
The screws 22 and 25 or the rubber mounts must never be tightened as long as the engine
and the splitterbox are not firmly fixed together, or if the mounts are pretensioned by any force
but the weight of the engine and the splitterbox.
MJFCIFSS
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Uppercarriage - Mechanical
Service Manual
LFR/en/version: 08 / 2007
Any improper fastening would greatly reduce the expected life of the rubber mounts.
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MJFCIFSS
Service Manual
Uppercarriage - Mechanical
Engine / splitterbox mounting
LFR/en/version: 08 / 2007
MJFCIFSS
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Uppercarriage - Mechanical
Service Manual
To Preassembled modules
LFR/en/version: 08 / 2007
Due to their size, most of the mounting bolts require, to be tensioned to the prescribed torque, the use of a
special, hydraulic or electric actuated tensioning device.
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MJFCIFSS
Service Manual
Uppercarriage - Mechanical
To Preassembled modules
The rotating deck is in rotation with the undercarriage thanks to the swing ring.
The stud bolts M36 (pos. 4) for the mounting of the swing ring 10 to the uppercarriage 11 (rotating deck) must
be tensioned to 570 kN. The stud bolts M36 (pos. 3) for the mounting of the swing ring 10 to the rotating deck
12 must be tensioned to 570 kN. Tighten the protection nuts 5 on the bolts and between 500 and 1000 Nm.
The use of special tensioning procedure and tool is necessary to obtain the correct bolt tension (LIEBHERR
recommends the use of the special bolt tensioning cylinder ident. nb. 5617448, at the required hydraulic pressure of 1350 bar).
LFR/en/version: 08 / 2007
The rotating deck is mounting on the swing ring when the uppercarriage is assembled without the counterweight. For more information on the mounting or the dismounting of the rotating deck see the part installation /
removal of Swing bearing.
MJFCIFSS
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Uppercarriage - Mechanical
Service Manual
To Preassembled modules
15.6.1.2Counterweight
The counterweight is fixed at the end of the rotating deck. It is fixed in two points with 4 mounting bolts M42 at
a point, the bolts must be tightened to 5400 Nm (3982 ft.lbs.). The counterweight is mounted on the hydraulic
excavator at the end, only when the rest of the uppercarriage has been installed.
The drivers cab is bolted on the four corners of the cab elevation.
The silent-block is bolted on the cab elevation with three screws. The cab is bolted on the silent-block with three
screws.
These screws are of size M16 and must be tightened to 280 Nm (206 ft.lbs.).
The bolts must be checked at regular interval, and be retightened if necessary (see Operation and Maintenance
Manual).
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MJFCIFSS
LFR/en/version: 08 / 2007
15.6.1.3Drivers cab
Service Manual
Uppercarriage - Mechanical
To Preassembled modules
LFR/en/version: 08 / 2007
15.6.1.4Powerpacks
MJFCIFSS
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Uppercarriage - Mechanical
Service Manual
To Preassembled modules
15.6.1.5Hydraulic tank
The hydraulic tank is bolted on the left side of the rotating deck with 4 screws.
The mounting bolts M30 of the hydraulic tank must be tightened to 1900 Nm (1400 ft.lbs.).
The bolts must be checked at regular interval, and be retightened if necessary (see Operation and Maintenance
Manual).
LFR/en/version: 08 / 2007
Before mounting, grease must be applied on the head of the thread of the screw and on both sides of the
washer with mobiltac 81s (ident. 8503279).
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MJFCIFSS
Service Manual
Uppercarriage - Mechanical
To Preassembled modules
LFR/en/version: 08 / 2007
15.6.1.6Fuel tank
The hydraulic tank is bolted on the right side of the rotating deck with 6 screws.
The mounting bolts M30 of the fuel tank must be tightened to 2100 Nm (1550 ft.lbs.).
The bolts must be checked at regular interval, and be retightened if necessary (see Operation and Maintenance
Manual).
Before mounting, grease must be applied on the head of the thread of the screw and on both sides of the
washer with mobiltac 81s (ident. 8503279).
MJFCIFSS
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Uppercarriage - Mechanical
Service Manual
To Preassembled modules
LFR/en/version: 08 / 2007
15.6.1.7Cab elevation
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MJFCIFSS
Service Manual
Uppercarriage - Mechanical
LFR/en/version: 08 / 2007
To Preassembled modules
The cab elevation is bolted on the left side of the rotating deck side with 6 screws.
MJFCIFSS
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Uppercarriage - Mechanical
Service Manual
To Preassembled modules
The mounting bolts M30 of the cab elevation must be tightened to 2100 Nm (1550 ft.lbs.).
The bolts must be checked at regular interval, and be retightened if necessary (see Operation and Maintenance
Manual).
The left catwalk box is bolted on the power pach with 8 screws. The mounting bolts M20 of the left catwalk box
must be tightened to 560 Nm (413 ft.lbs.).
LFR/en/version: 08 / 2007
The bolts must be checked at regular interval, and be retightened if necessary (see Operation and Maintenance
Manual).
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MJFCIFSS
Service Manual
To Preassembled modules
LFR/en/version: 08 / 2007
The right catwalk box is bolted on the power pack with 9 screws.
The four mounting bolts 2 (M24) of the right catwalk box must be tightened to 960 Nm (710 ft.lbs.). The five
mounting bolts 11 (M20) of the right catwalk box must be tightened to 560 Nm (413 ft.lbs.). The bolts must be
checked at regular interval, and be retightened if necessary (see Operation and Maintenance Manual).
MJFCIFSS
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Service Manual
LFR/en/version: 08 / 2007
To Preassembled modules
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MJFCIFSS