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Service Manual

Chapter 15 - Uppercarriage mechanical


Uppercarriage - Mechanical ............................................................................................................................. 15-3
1
2
3

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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

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Service Manual

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Uppercarriage - Mechanical
Coupling

15 Uppercarriage - Mechanical
15.1Coupling
15.1.1Function / operation

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15.1.1.1Components location

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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.

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It transfers engine torque to the splitterbox directly and constantly, which means that it cannot be disengaged.

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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

GFC 320 / 1002


counterclockwise
1,213
0,809
0,638
1,128
1060
70
API GL - 5
SAE 90 or SAE 80W90

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For more information about the splitterbox see the BOSCH-REXROTHs documentation about the splitterbox
GFC 320 1002.

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Service Manual

Swing gear

15.3Swing gear
15.3.1Technical data
Gear - type

Unit

Max. output speed

min

Nominal output torque

Nm

-1

SAT 450 / 257


40
50000
28,25

Gear ratio
Hydraulic motor

Typ.

FMF250

Weight

Kg

1120

Oil quantity on gear

l.

38

Oil quality

API - GL - 5

Oil viscosity

From -30C to 10C : SAE 80


From -15C to 30C : SAE 80 W 90 or SAE 90
From 0C to 50C : SAE 85 W 140

Brake

Disk brake / spring applied, pressure released

Brake torque dynamic

Nm

47 700

Brake torque static

Nm

65 600

Oil pressure min. to release brake

bar

26

mm

146,5+0,5

Nm
Nm
Nm
Nm
Nm
Nm

160 - 280
580
210
210
960
1900

Axial play torques :

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A) Axial play of sun gear 5 (test distance


between top of sun gear 5 and mounting
face of oil motor
B) Friction of tapered roller bearing 57 / 58
C) Torque - screw 60
D) Torque - screw 61
E) Torque - screw 63
F) Torque - screw 101
H) Torque - screw 104

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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.

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15.3.2.2Component location

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Swing gear

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Uppercarriage - Mechanical
Swing gear

Output shaft housing

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

Oil motor FMF

47

Grooved nut

101

Screw

48

Washer

102

O-ring

57

Tapered roller bearing

104

Screw

Tapered roller bearing

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.

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The gear ratio is combined by both planetary gears. The output torque increases in the same ratio as the output
speed is reduced.

15.3.2.4Function 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.

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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.

15.3.3.2Removal of swing gear


1. Lower attachment to the ground.
2. Remove the caps 4 of the expansion reservoirs 7.
3. Drain the oil of the gear at operating temperature :
Unscrew the cover of the drain valve 1.
Screw the drain hose provided 6 to the drain valve and let the oil flow out into a suitable container.
Remove the hose 6.
Screw the cover of the drain valve 1 back on.
Put the sealing cap 4 on the expansion reservoir 7.

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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.

15.3.4Sealing of the swing brake


15.3.4.1To seal the gear

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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.

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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.

Insert ring 31 with new groove ring 89 on piston 30.


Insert spring 43/44 and piston 30 onto brake housing 25.
With tool, push the piston 30 down and insert snap ring 73, make sure it is seated correctly. Remove tool.
Insert brake housing 25 with new seal into the inner gear. Install screws 61 with washer 66. Make sure screws
61 are tightened correctly, see torque page General data - Swing gear.

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Assembly :

Service Manual

Uppercarriage - Mechanical
Swing gear

Mount the oil motor 100.


To install gear, see installation of the gear.

15.3.5Swing brake
15.3.5.1Component location

15.3.5.2Functional description

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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.

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Swing bearing

15.4Swing bearing
15.4.1Component location
Upper outer ring

2.

Lower outer ring

3.

Radial roller

4.

Upper roller

5.

Lower roller

6.

Inner ring

7.

Upper seal

8.

Lower seal

10.

Mounting bolt to uppercarriage

11.

Mounting bolt to undercarriage

12.

Nut

13.

Counter nut

14.

Undercarriage

15.

Uppercarriage

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1.

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Uppercarriage - Mechanical
Swing bearing

15.4.2General data
Machine

R 9250
ROD 1304 DJ

Swing ring

type

Teeth (Nb)

Nb

114

Axial play at delivery


Min
Max

mm
mm

0,1
0,5

Max. axial play

mm

Radial play
Min
Max

mm
mm

0
0,4

Backlash allowable
Min
Max

mm
mm

0,46
0,93

Weight of uppercarriage (without attachment)

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).

15.4.2.1Max. axial play


The maximum permissible play in the bearing indicates the maximum allowable play (wear). The swing ring
can be used safety until the maximum play is reached. The swing ring does not have to be replaced if it still
turns smoothly and without binding. The bearing does have to be replaced if its binds or is hard to turn, even
before the maximum clearance is reached.
However, it is necessary to continuously check the swing ring for smooth operation and binding.

15.4.2.2Backlash

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Backlash is the play between the teeth of the inner ring and the swing gear output pinion.

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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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Set the rotary connection into the undercarriage and the tighten screws.

Service Manual

Uppercarriage - Mechanical
Swing bearing

The S marks (hardening backlash = the beginning and the end


of the track hardening) on the upper ring to rotating deck and on the
lower ring to undercarriage should
be in a 90 angle to the travel and
the main working direction.

15.4.4.2Removing the swing ring


To replace the swing ring, the uppercarriage has to be lifted off of the undercarriage with a lift or a crane.
Lifting and shoring material, such as chains, cables, slings, shackles and wood should be properly selected
(see weight of uppercarriage on the page Swing bearing - General data).
Before lifting the uppercarriage with a crane, remove the attachment.
When lifting the uppercarriage with a lift cylinder or jacks, as described in the following paragraph, the attachment is not removed from the machine.
Check the boom cylinder for the leaks.
Caution!
It is not permitted or necessary for any person to be under the jacked up uppercarriage when
the following procedure is followed!
Park the machine with the uppercarriage turned by 90 on flat, solid ground. Fully extend the attachment
and lower it (the bucket must rest on roller pads).
Mark and then plug and remove the lower air and hydraulic lines. Catch the hydraulic oil in an appropriate
container.
Mark and then plug and remove the upper hydraulic lines.
LFR/en/version: 08 / 2007

If necessary, disconnect the lube oil lines.


Remove mounting screws from the intermediate flange on the rotary connection to the undercarriage and
lift the rotary connection from the undercarriage.
Remove boom cylinder rod to chassis pins. Retract and chain cylinders.
Install the front jacking support with the pins (at the place of the cylinders).
Install the platform at the rear of the excavator.
Position the hydraulic jacks under the counterweight and under the front jacking support.
Remove all of the outer swing gear bolts 10 from the swing ring to the uppercarriage with the tensioning
cylinder.
With hydraulic jacks, lift the uppercarriage evenly until the undercarriage is free. To prevent the uppercar-

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Swing bearing

riage from sinking, additional shim must be inserted.


Carefully pull the undercarriage out and remove the bolts 11 with the tensioning cylinder from the undercarriage to the swing ring.
Lift off the swing ring and set it down on a prepared surface.

15.4.4.3Mounting the bolts of the swing ring


For operating instructions of the tensioning cylinder, see chapter 5.
The special tool may only be operated by qualified personnel, especially trained for the use of this high pressure tensioning device and aware of the operating instructions as well of the recommendations for accident
and damage prevention concerning this tool.
Use appropriate working platforms and lifting devices to install and hold in position the special tool while tensioning the bolts.

15.4.4.4Swing ring bolts tensioning procedure


Coat the bolts with grease.
Screw the bolt in the swing ring thread. The distance between the swing ring and the end of bolt must be
as stated in the technical data chart. Install the washer and screw the nut onto the bolt by hand down to the
support surface. Check that there is no play between the swing ring and the uppercarriage and the undercarriage. If necessary, use hexagonal screw for preassembly.
Screw the bolt tensioning cylinder onto the bolt with an allen wrench (approximately 30 - 50 Nm) down to
the support surface. If necessary, use the inspection hole in the change bushing to ensure that the unit is
screwed on far enough.
Connect the pressure hose to the bolt tensioning cylinder and the high pressure pump unit.
Generate the required pressure (see technical data chart) with the high pressure unit.
When the joint is under pressure, use a ratchet to screw the nut onto the bolt (approximately 60 - 100 Nm).
Open the stop valve on the high pressure pump unit to release pressure on bolt tensioning cylinder.
Do not re-close the stop valve until the piston have returned to their lower end position.
Remove unit from joint in the opposite order of succession described above.
When all the bolts have been tightened, the first bolt should be re-tensioned. This is necessary because in
the process of tensioning the load on the first (or next) bolt is slightly reduced.

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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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Uppercarriage - Mechanical
Swing bearing

15.4.5Inspection / wear reporting


15.4.5.1Measuring the clearances
Max. clearance

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.

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15.4.5.2Measuring the radial play

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.

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Swing bearing

Measuring the backlash


To measure the backlash, a strip of lead approximately 10 mm wide, 120 mm long and 2 mm thick can be used.
Park the machine on flat, level ground, release the swing lock and swing brake. Extend the attachments and
lift it about 1 m off the ground.
Place lead strip or wire horizontally in the center on both sides of one swing ring tooth. Slowly rotate the uppercarriage by pushing against the extended attachment. Remove the lead strip and measure as shown now :
Tooth - side A

+ mm

Tooth - side B

+ mm

Backlash

( + )mm

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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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Uppercarriage - Mechanical
Engine / splitterbox mounting

15.5Engine / splitterbox mounting


15.5.1Technical data

The engine and the splitterbox are fixed to each other.


The engine is fixed on the powerpack via a bracket mounted on rubber cushions.

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The splitterbox is fixed on the powerpack via buffers.

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Engine / splitterbox mounting

Buffer

22

Hexagonal head screw M16

25

Cylinder screw M16

27

Buffer

34

Hexagonal head screw M20

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20

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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.

Removal of the engine


Drain coolant from the radiator.

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Drain the oil from the engine and the coupling.


Disconnect all the hoses, which are connected to the powerpack and immediately close off open lines to
prevent contamination.
Disconnect all electrical wiring from the engine.
Prepare splitterbox for engine removal. Splitterbox is heavy and may fall back. Block under the back of the
splitterbox to prevent it falling back.
Strip the engine from the splitterbox.
Remove inlet exhaust systems.
Start undoing the engine bolts necessary for the removal.
Remove the engine covering.

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Engine / splitterbox mounting

Lift out the engine with jacking equipment.


Put the engine on the ground.

Removal of the splitterbox


Drain the oil from the splitterbox, the main working pumps, the swing pumps and the auxiliary pumps.
Disconnect all the hoses, which are connected to the powerpack, and immediately close off open lines to
prevent the contamination.
Disconnect all electrical wiring from the powerpack.
Prepare engine for splitterbox removal. The engine is heavy and may fall back. Block under the back of the
engine to prevent it falling back.
Strip the engine, the coupling, the main working pumps, the swing pumps and the auxiliary pumps from the
splitterbox.
Remove exhaust systems.
Start undoing the engine bolts necessary for the removal.
Remove the splitterbox covering.
Lift out the splitterbox with jacking equipment.
Put the splitterbox on the ground.

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.

Installation of the engine


Lift the engine on the hydraulic excavator with the jacking equipment at its position.
Screw the engine and the coupling with the splitterbox and screw the engine bolts necessary for the installation.
Open the lines, and immediately connect all the hoses, which allow the working of the engine on it.
Connect all electrical wiring from the engine.
Install inlet and exhaust systems.
Fix the engine covering.
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Fill up the engine and the coupling with oil.


Fill up the radiator.

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Engine / splitterbox mounting

Installation of the splitterbox


Lift the splitterbox on the hydraulic excavator with the jacking equipment at its position.
Screw the splitterbox with the engine and the coupling and screw the splitterbox bolts necessary for the installation.
Install the main working pumps, the swing pumps and the auxiliary pumps on the splitterbox.
Open the lines, and immediately connect all the hoses, which allow the working of the engine on it.
Connect all electrical wiring from the engine.
Install inlet and exhaust systems.
Fix the splitterbox covering.

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Fill up the splitterbox with oil.

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Engine / splitterbox mounting

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15.5.3.3Component location

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15.5.4Inspection wear reporting

15.5.4.1Engine and splitterbox mounting screws

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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.

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Engine / splitterbox mounting

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Any improper fastening would greatly reduce the expected life of the rubber mounts.

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15.5.4.2Splitterbox mounting screws


Check the tightness of mounting screws 3 from splitterbox to the diesel engine SAE housing regularly. Retighten if necessary.
NmTightening torque for screws M12, item 3 : 117 Nm (87 ft.lbs).

15.5.4.3Elastic bedding of the engine and splitterbox - replacement of the rubber


buffers
The rubber cushions 20 at front face of engine and the buffers 27 at the splitterbox side must be checked and
replaced at regular intervals.

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See maintenance schedule in Operation and Maintenance Manual.

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15.6To Preassembled modules


To make easier the mounting and the dismounting of the hydraulic excavator, and especially the uppercarriage,
the excavator has been divided in different modules. These different modules are mounted apart. Then they
are assembled together to form the hydraulic excavator.
The modules, which form the uppercarriage, are the following :
Powerpack.
Counterweight.
Catwalk box left.
Catwalk box right.
Drivers cab.
Fuel tank.
Hydraulic tank.
Rotating deck.
To mount or dismount modules, use a jacking equipment. There is a special equipment for the uppercarriage
(Ident. Nb. 9805218). To lift the uppercarriage, fix the rotating deck with the jacking equipment at the begin and
at the end of the uppercarriage.
The mounting bolts necessary for the assemblage of the different modules must regularly be checked and be
retightened if necessary. See maintenance chart for check intervals.

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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15.6.1Mounting / Dismounting modules


15.6.1.1Rotating deck

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).

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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.

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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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15.6.1.3Drivers cab

Service Manual

Uppercarriage - Mechanical
To Preassembled modules

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15.6.1.4Powerpacks

The powerpack is bolted on rotating deck with 16 screws.


The mounting bolts M20 of the powerpack must be tightened to 560 Nm (413 ft.lbs.).
The bolts must be checked at regular interval, and retightened if necessary (see Operation and Maintenance
Manual).

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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).

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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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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).

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15.6.1.7Cab elevation

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The cab elevation is bolted on the left side of the rotating deck side with 6 screws.

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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).

15.6.1.8Left catwalk box

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.).

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The bolts must be checked at regular interval, and be retightened if necessary (see Operation and Maintenance
Manual).

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15.6.1.9Right catwalk box

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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).

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