15 Uppercarriage Mechanical1

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Chapter 15 - Uppercarriage mechanicalUppercarriage - Mechanical ............................................................................................................................. 15-3

1 Coupling............................................................................................................................................ 15-31.1 Function / operation................................................................................................................ 15-3

2 Splitterbox......................................................................................................................................... 15-52.1 Technical data ........................................................................................................................ 15-5

3 Swing gear........................................................................................................................................ 15-63.1 Technical data ........................................................................................................................ 15-63.2 Function / operation................................................................................................................ 15-73.3 Installation / removal............................................................................................................... 15-103.4 Sealing of the swing brake ..................................................................................................... 15-113.5 Swing brake............................................................................................................................ 15-13

4 Swing bearing ................................................................................................................................... 15-144.1 Component location................................................................................................................ 15-144.2 General data........................................................................................................................... 15-154.3 Function / operation................................................................................................................ 15-164.4 Installation / removal............................................................................................................... 15-164.5 Inspection / wear reporting ..................................................................................................... 15-19

5 Engine / splitterbox mounting ........................................................................................................... 15-215.1 Technical data ........................................................................................................................ 15-215.2 Function / operation................................................................................................................ 15-235.3 Installation / removal............................................................................................................... 15-235.4 Inspection wear reporting ....................................................................................................... 15-27

6 To Preassembled modules ............................................................................................................... 15-296.1 Mounting / Dismounting modules ........................................................................................... 15-30

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15 Uppercarriage - Mechanical

15.1Coupling

15.1.1Function / operation

15.1.1.1Components location

Uppercarriage - Mechanical

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15.1.1.2UseThe 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 theDiesel 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

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

Model R 9250Splitterbox (type)Direction of rotation (as seen when facing the flywheel)Ratio to pump connections IRatio to pump connection IIRatio to pump connection IIIRatio to pump connection IVWeight (without pumps) in kgOil quantity in gear in lOil specificationOil viscosity

GFC 320 / 1002counterclockwise

1,2130,8090,6381,1281060

70API GL - 5

SAE 90 or SAE 80W90


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15.3Swing gear


Gear - type Unit SAT 450 / 257Max. output speedNominal output torqueGear ratioHydraulic motorWeightOil quantity on gearOil qualityOil viscosity

BrakeBrake torque dynamicBrake torque staticOil pressure min. to release brakeAxial play torques :A) Axial play of sun gear 5 (test distance

between top of sun gear 5 and mountingface of oil motor

B) Friction of tapered roller bearing 57 / 58C) Torque - screw 60D) Torque - screw 61E) Torque - screw 63F) Torque - screw 101H) Torque - screw 104

min-1

Nm

Typ.Kgl.

NmNmbar

mm

NmNmNmNmNmNm

405000028,25FMF250112038API - GL - 5From -30C to 10C : SAE 80From -15C to 30C : SAE 80 W 90 or SAE 90From 0C to 50C : SAE 85 W 140Disk brake / spring applied, pressure released47 70065 60026

146,5+0,5

160 - 2805802102109601900

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15.3.2Function / operationThe 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 andthe 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.

15.3.2.1FunctionThe swing gear is composed from two stage planetary gears, which are driven by the attached FMF hydraulicoil motors.

They move the uppercarriage via the output shaft and the internally geared swing ring . The integrated diskbrakes act directly on the gear drive. They are used as a spring applied brake and are vented hydraulically, ifthere 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 descriptionThe 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 reducedspeed 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 11with 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 outputspeed is reduced.

15.3.2.4Function of lubrication systemThe grease cap 26, mounted on the housing 2, covers the pinion of the drive shaft 17 to the connection on theswing ring. The cap is filled with grease via a lubrication line. It releases grease to the pinion and swing gearsevery time the uppercarriage turns.

23561011141516172025263031353637404344454647485758

Output shaft housingInner gearSun gearSun gearPlanetary gearPlanetary gearCover platePlanetary carrierPlanetary carrierOutput shaftInner gearBrake housingLubrication capPistonEnd ringRingInner diskOuter diskDisk carrierSpringSpringRetainerRetainerGrooved nutWasherTapered roller bearingTapered roller bearing

60616263656667707173768182838485868788899091100101102104105

ScrewScrewScrewScrewLock washerLock washerTension pinSnap ringSnap ringSnap ringHeadless screwO-ringO-ringO-ringO-ringO-ringBreather coverFiller neckGroove ringGroove ringShaft sealNilos ringOil motor FMFScrewO-ringScrewDrain valve


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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 anticorrosivegrease (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 thelower 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 controlboard) until the housing around the output pinion of the gear is filled with grease.

15.3.3.2Removal of swing gearTo remove the swing gear, Liebherr recommends to use a special tool (see Tooling).

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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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.

15.3.4Sealing of the swing brake

15.3.4.1To seal the gear

DriveRemove 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.

Important :Check and carefully clean all parts before installation. All the seals should be lightly oiled orgreased before installation.


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Disk brake

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.

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 andsprings 43/44.

Replace O-rings 82, 86 and groove ring 88 with support ring.

Assembly :

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 screws61 are tightened correctly, see torque page General data - Swing gear.

Note :Before removing the brake, make sure the attachment is lowered to the ground.

Note :The ring 31 and piston 30 are spring loaded.

Note :When installing groove rings 88 and 89, make sure they are seated correctly (the groove hasto point to the pressure side and the support ring to the unpressurized side). Lightly grease allparts.

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Mount the oil motor 100.

To install gear, see installation of the gear.

15.3.5Swing brake


15.3.5.2Functional descriptionPressurised oil is circulated between the piston 30 and the end ring 31, the pressurised oil plates the piston 30on 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 43and 44 are pushing the piston 30 against the disk (see 36 and 37). The planetary gear 10 is stopped, and therotation of the excavator too.


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15.4Swing bearing

15.4.1Component location

1.

2.

3.

4.

5.

6.

7.

8.

10.

11.

12.

13.

14.

15.

Upper outer ring

Lower outer ring

Radial roller

Upper roller

Lower roller

Inner ring

Upper seal

Lower seal

Mounting bolt to uppercarriage

Mounting bolt to undercarriage

Nut

Counter nut

Undercarriage

Uppercarriage

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15.4.2General data

15.4.2.1Max. axial playThe maximum permissible play in the bearing indicates the maximum allowable play (wear). The swing ringcan be used safety until the maximum play is reached. The swing ring does not have to be replaced if it stillturns smoothly and without binding. The bearing does have to be replaced if its binds or is hard to turn, evenbefore the maximum clearance is reached.

However, it is necessary to continuously check the swing ring for smooth operation and binding.

15.4.2.2BacklashBacklash is the play between the teeth of the inner ring and the swing gear output pinion.

Machine R 9250

Swing ring

Teeth (Nb)

Axial play at deliveryMinMax

Max. axial play

Radial playMinMax

Backlash allowableMinMax

Weight of uppercarriage (without attachment)

Mounting boltsSizeBolt tensioning cylinderRequired pressure (Bar)Distance between swing ring and the end of boltBolt tension (undercarriage)Bolt tension (uppercarriage)

type

Nb

mmmm

mm

mmmm

mmmm

kg

Nb

IdbarmmkNkN

ROD 1304 DJ

114

0,10,5

2

00,4

0,460,93

90000

60M36

56174481350851570570

Note :Axial play at delivery is the play a new gear has when installed (measuring the axial).


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15.4.3Function / operation

15.4.3.1Functional descriptionThe swing bearing allows the swing ring to turn. This operation permits the rotation between the uppercarriageand the undercarriage. The inner ring 6 is screwed to the undercarriage 14 thanks to the mounting bolt 11, thenut 12 and the counter nut 13. The inner of the ring 6 is cogged, and this part meshes with the swing gear. Theupper outer ring 1 and the lower outer ring 2 are forming a guide rail for the inner ring 6. The radial roller 3, theupper roller 4 and the lower roller 5 permit the rotation between the inner ring and the outer ring (1 and 2). Theouter ring is fixed on the uppercarriage thanks to the mounting bolt 10, the nut 12 and the counter nut 13. Sowhen 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 bythe 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 innerring 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 Operationand Maintenance Manual.

15.4.4Installation / removal

15.4.4.1InstallationTo assure proper wear and operation, the mounting surface must be clean and level. Burrs, rust and unevenspots must be carefully removed.

Set the swing ring onto the undercarriage, make sure it is seated correctly. Tighten the mounting bolts 11with 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 withthe hydraulic jacks onto the swing ring.

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). 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.

Note :Turn the outer ring of the swing ring into the correct position. The swing gear pinion has to meshwith the gear and the mounting holes have to be lined up with the threads on the uppercarriage.

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15.4.4.2Removing the swing ringTo 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 attach-ment is not removed from the machine.

Check the boom cylinder for the leaks.

Park the machine with the uppercarriage turned by 90 on flat, solid ground. Fully extend the attachmentand 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 appropriatecontainer.

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

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-

The S marks (hardening bac-klash = the beginning and the endof the track hardening) on the up-per ring to rotating deck and on thelower ring to undercarriage shouldbe in a 90 angle to the travel andthe main working direction.

Caution!It is not permitted or necessary for any person to be under the jacked up uppercarriage whenthe following procedure is followed!


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riage from sinking, additional shim must be inserted. Carefully pull the undercarriage out and remove the bolts 11 with the tensioning cylinder from the undercar-

riage 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 ringFor 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 pres-sure tensioning device and aware of the operating instructions as well of the recommendations for accidentand damage prevention concerning this tool.

Use appropriate working platforms and lifting devices to install and hold in position the special tool while ten-sioning 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 thesupport surface. Check that there is no play between the swing ring and the uppercarriage and the under-carriage. If necessary, use hexagonal screw for preassembly.

Screw the bolt tensioning cylinder onto the bolt with an allen wrench (approximately 30 - 50 Nm) down tothe support surface. If necessary, use the inspection hole in the change bushing to ensure that the unit isscrewed 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. 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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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 previousfigure. 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 measurementscan and should be taken using the same procedure at various swing ring positions.

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 asshown 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.


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Measuring the backlashTo 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 andlift 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 upper-carriage by pushing against the extended attachment. Remove the lead strip and measure as shown now :

Tooth - side A

Tooth - side B

+ mm

+ mmBacklash ( + )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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15.5Engine / splitterbox mounting


The engine and the splitterbox are fixed to each other.

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

The splitterbox is fixed on the powerpack via buffers.


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20

22

25

27

34

Buffer

Hexagonal head screw M16

Cylinder screw M16

Buffer

Hexagonal head screw M20

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15.5.2Function / operationThe 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 thedisplacement 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 theexactly 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 fromvibrations and the shocks of the powerpack, buzzers have been installed under the powerpacks. They are usedas dampers, the coupling is used as a damper too.

15.5.3Installation / removalWhen 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 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

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. 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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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 instal-

lation. 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. Fill up the engine and the coupling with oil. Fill up the radiator.

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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 ins-

tallation. 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. Fill up the splitterbox with oil.


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15.5.4Inspection wear reporting

15.5.4.1Engine and splitterbox mounting screwsCheck 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.).



Caution!The screws 22 and 25 or the rubber mounts must never be tightened as long as the engineand the splitterbox are not firmly fixed together, or if the mounts are pretensioned by any forcebut the weight of the engine and the splitterbox.


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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 screwsCheck the tightness of mounting screws 3 from splitterbox to the diesel engine SAE housing regularly. Retigh-ten 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 rubberbuffers

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

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 theyare 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 andat the end of the uppercarriage.

The mounting bolts necessary for the assemblage of the different modules must regularly be checked and beretightened 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 aspecial, 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) mustbe tensioned to 570 kN. The stud bolts M36 (pos. 3) for the mounting of the swing ring 10 to the rotating deck12 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 (LIEBHERRrecommends 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 ata point, the bolts must be tightened to 5400 Nm (3982 ft.lbs.). The counterweight is mounted on the hydraulicexcavator at the end, only when the rest of the uppercarriage has been installed.

15.6.1.3Drivers cab

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 threescrews.

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 MaintenanceManual).

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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 MaintenanceManual).


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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.).


Before mounting, grease must be applied on the head of the thread of the screw and on both sides of thewasher 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.).


Before mounting, grease must be applied on the head of the thread of the screw and on both sides of thewasher 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.).


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 boxmust be tightened to 560 Nm (413 ft.lbs.).


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15.6.1.9Right catwalk box

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 fivemounting bolts 11 (M20) of the right catwalk box must be tightened to 560 Nm (413 ft.lbs.). The bolts must bechecked at regular interval, and be retightened if necessary (see Operation and Maintenance Manual).

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Index

15 Uppercarriage Mechanical1

Documents

Transcript of 15 Uppercarriage Mechanical1