Chapter 15 - Uppercarriage Mechanical: Service Manual
Chapter 15 - Uppercarriage Mechanical: Service Manual
Chapter 15 - Uppercarriage Mechanical: Service Manual
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15 Uppercarriage - Mechanical
15.1Coupling
15.1.1Function / operation
15.1.1.1Components location
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15.1.1.2Use
The elastic coupling (torsional vibration damper), which is installed between the Diesel engine and the splitter-
box, compensates for shaft (crankshaft - pump input shaft) misalignments, which could be caused by manu-
facturing 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.
It transfers engine torque to the splitterbox directly and constantly, which means that it cannot be disengaged.
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15.2Splitterbox
15.2.1Technical data
Model R 9250
Splitterbox (type) GFC 320 / 1002
Direction of rotation (as seen when facing the flywheel) counterclockwise
Ratio to pump connections I 1,213
Ratio to pump connection II 0,809
Ratio to pump connection III 0,638
Ratio to pump connection IV 1,128
Weight (without pumps) in kg 1060
Oil quantity in gear in l 70
Oil specification API GL - 5
Oil viscosity SAE 90 or SAE 80W90
For more information about the splitterbox see the BOSCH-REXROTH’s documentation about the splitterbox
GFC 320 1002.
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15.3Swing gear
15.3.1Technical data
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15.3.2Function / operation
The hydraulic excavator rotates at 360°, it although the uppercarriage which is rotating. This operation is pos-
sible 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 lubrica-
tion of the output pinion and the swing ring teeth.
Lubricating the gear partially replaces this reserve.
15.3.2.2Component location
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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.
The gear ratio is combined by both planetary gears. The output torque increases in the same ratio as the output
speed is reduced.
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.
15.3.3Installation / removal
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 speci-
fication 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.
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 docu-
mentation : «Mounting instructions of SAT 450 - 257».
Important :
Check and carefully clean all parts before installation. All the seals should be lightly oiled or
greased before installation.
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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».
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.
Assembly :
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15.3.5Swing brake
15.3.5.1Component location
15.3.5.2Functional description
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 rota-
tion 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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15.4Swing bearing
15.4.1Component location
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15.4.2General data
Machine R 9250
Swing ring type ROD 1304 DJ
Note :
Axial play at delivery is the play a new gear has when installed (measuring the axial).
15.4.2.2Backlash
Backlash is the play between the teeth of the inner ring and the swing gear output pinion.
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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 excavator’s 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 lu-
bricate 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.
– Set the rotary connection into the undercarriage and the tighten screws.
– Connect the air and hydraulic lines on top of the bottom of the rotary connection (check your marks to assure
connect hook up).
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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.
– If necessary, disconnect the lube oil lines.
– Remove mounting screws from the intermediate flange on the rotary connection to the undercarriage and
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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.
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 equip-
ment (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.
Tooth - side A + mm
Tooth - side B + mm
Backlash (α + )mm
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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15.5.1Technical data
20 Buffer
22 Hexagonal head screw M16
25 Cylinder screw M16
27 Buffer
34 Hexagonal head screw M20
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15.5.2Function / operation
The engine, the splitterbox, the main working pumps, the swing pumps and the auxiliary pumps form the power-
pack. 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 hy-
draulic 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 isn’t 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 «Sa-
fety 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
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.
15.5.3.2Installation
15.5.3.3Component location
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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.
Any improper fastening would greatly reduce the expected life of the rubber mounts.
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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.
– Driver’s 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.
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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15.6.1.1Rotating 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 pres-
sure of 1350 bar).
The rotating deck is mounting on the swing ring when the uppercarriage is assembled without the counterwei-
ght. 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.
15.6.1.3Driver’s cab
The driver’s cab is bolted on the four corners of the cab elevation.
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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).
15.6.1.4Powerpacks
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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).
Before mounting, grease must be applied on the head of the thread of the screw and on both sides of the
washer with mobiltac 81’s (ident. 8503279).
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15.6.1.6Fuel tank
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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 81’s (ident. 8503279).
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.
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.).
The bolts must be checked at regular interval, and be retightened if necessary (see Operation and Maintenance
Manual).
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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
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checked at regular interval, and be retightened if necessary (see Operation and Maintenance Manual).
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