9002

Section
9002

UPPERSTRUCTURE, TURNTABLE
AND COUNTERWEIGHT

Copyright © 2007 CNH America LLC.

All rights reserved.
CNH Lep SM160B9002-0NA Printed in USA.
May 2007
9002-2
TABLE OF CONTENTS
SPECIAL TORQUE SETTINGS...................................................................................................................................... 2
SPECIFICATIONS .......................................................................................................................................................... 2
UPPERSTRUCTURE...................................................................................................................................................... 3
Inspection.................................................................................................................................................................... 3
Removal ...................................................................................................................................................................... 4
Installation ................................................................................................................................................................... 6
COUNTERWEIGHT ...................................................................................................................................................... 10
Removal .................................................................................................................................................................... 10

WARNING: This symbol is used in the manual to indicate important safety messages. Whenever you see this
! symbol, carefully read the message that follows. It concerns your safety.

SPECIAL TORQUE SETTINGS

See Section 1002

SPECIFICATIONS
Weight ................................................................................................................................................... See Section 1002
Quantity of grease to be applied
to the turntable ........................... 18 Kg (39.68 lb) (CX160B); 14 Kg (30.86 lb) (CX210B); 14,5 Kg (31.96 lb) (CX240B)

Lep SM160B9002-0NA Issued 05-07

 9002-3
UPPERSTRUCTURE
Inspection
STEP 1
Inspecting the turntable
If the upperstructure no longer swings regularly or
makes a creaking noise, this shows that the turntable is
worn or damaged. If there is a time lapse before the
upperstructure starts to swing, this shows that the ring
gear of the turntable is damaged. When an operator 1
works with a machine, he must pay attention to any
unusual noises which could indicate turntable wear. If
the operator hears unusual noises and if the
upperstructure has a time lapse before it starts
swinging, he must carry out the following inspection. 2
STEP 2
Park the machine on hard, level ground. Lower the
attachment to the ground.
STEP 3 3
Reduce engine speed to idle for 30 seconds, then shut CI00F509B
down the engine. Remove the two screws (1) and which fasten the
access panel (2) to the machine. Remove the access
STEP 4 panel (2). Remove and scrap the access panel seal (3).
STEP 5

WARNING: If you put your hand in the ring gear

access orifice when the upperstructure is
swinging, you could be serious injured. Before
! applying grease by hand to the ring gear, always
make sure that the bucket or the tool is on the
ground and that the engine is shut down.

Request help from an assistant to operate the swing

gear. Check for scratches, a missing tooth, scaling,
cracks or other damage to the ring gear, using a pocket
torch. In the event of damage, refer to "Removing the
Remove the screws (1) which fasten the lower housing
upperstructure" and change the upperstructure
(2) to the machine and remove the lower housing (2).
turntable.
STEP 6
Install a new seal on the access panel and install the
access panel on the machine using screws and lock
washers.

Lep SM160B9002-0NA Issued 05-07

9002-4
STEP 7 STEP 4
Install the lower housing on the machine using screws
and flat washers. 1
Removal
STEP 1

2
JS001631
Park the machine on hard, level ground. Lower the
attachment to the ground.
STEP 2
Release pressure in hydraulic system in the hydraulic
reservoir (see Section 8000).
STEP 3

1 FUEL TANK LOWER ACCESS PANEL

2 HYDRAULIC RESERVOIR LOWER ACCESS PANEL

Disassemble the retaining screws (1), and then remove
the negative terminal (2) of the battery.
When removing the terminal and harness, secure them
so that they do not interfere with the frame. Also, be
sure to protect them with a rubber cap or other
protective device, to prevent sparks.
Remove the lower access panel (2) from the fuel tank
(1) located at the front and to the right. Place a
receptacle under the fuel tank drain valve. Open the
drain valve and drain the fuel.
NOTE: See Section 1002 for the fuel tank capacity.
STEP 5
Remove the lower access panel (1) from the hydraulic
reservoir (2). Place a receptacle under the hydraulic
reservoir drain valve. Open the drain valve and drain
the hydraulic fluid into the receptacle.
NOTE: See Section 1002 for the capacity of the
hydraulic reservoir and of the total system.
STEP 6
Refer to Section 8006 and remove the hydraulic swivel.
STEP 7
Refer to Section 9003 and remove the bucket, the
dipper and the boom.
STEP 8
Refer to the page 10 in this section and remove the
counterweight.

Lep SM160B9002-0NA Issued 05-07


STEP 9
Install lifting rings at the rear of the upperstructure.
Connect a suitable lifting device to these lifting rings
and to the lifting rings located at the front of the
upperstructure, above the boom brackets. Take up any
slack in the lifting equipment, to ensure the
upperstructure is fully supported before lifting starts.
NOTE: Refer to specifications on page 2 for the weight
of the upperstructure. Make sure that the lifting device
has sufficient lifting and support capacity for the
upperstructure.
STEP 10
1 4
CT06K091
Using paint or another marking product, make marks
on the upperstructure, turntable (4) and the
undercarriage, to facilitate re-assembly of the
upperstructure and the turntable.
NOTE: The numbers in brackets in the following steps
refer to the schematic on page 6.
Lep SM160B9002-0NA
9002-5
STEP 11
Remove the screws (1) which fasten the upperstructure
to the turntable (4).
STEP 12
Carefully lift the upperstructure while disengaging it
from the undercarriage. Place the upperstructure on
suitable stands to protect the swing pinion against any
damage.
STEP 13
Install lifting rings on the turntable (4). Connect a
suitable lifting device to the lifting rings. Take up any
slack in the lifting equipment, to ensure that the
turntable is fully supported before lifting starts.
NOTE: Refer to specifications on page 2 for the weight
of the turntable.
STEP 14
Remove the screws (2) and the flat washers (3) which
fasten the turntable to the undercarriage. Carefully lift
the turntable while disengaging it from the
undercarriage. Place the turntable on suitable stands to
protect the surfaces of the turntable against any
damage. Remove the lifting equipment from the lifting
rings and disassemble the lifting rings from the
turntable.
Issued 05-07
9002-6
Installation
Turntable

4 1

3
2

CI00F510
1 SCREW
2 SCREW
3 FLAT WASHER
4 TURNTABLE

STEP 1 STEP 3
Clean the mating surfaces of the undercarriage and the Position the turntable (4) on the undercarriage. Align
turntable. the marks on the turntable (4) and on the
undercarriage. Remove the lifting equipment and
NOTE: The numbers in brackets in the following steps
disassemble the lifting rings from the turntable.
refer to the turntable schematic.
STEP 2
Install lifting rings on the turntable (4) and connect a
suitable lifting device to these rings. Take up any slack
in the lifting equipment, to ensure that the turntable is
fully supported before lifting starts.
NOTE: Refer to specifications on page 2 for the weight
of the turntable.

Lep SM160B9002-0NA Issued 05-07

 9002-7
STEP 4 STEP 7
Coat the screw threads (1) with Loctite 262. Install the
screws (1) in the turntable and the upperstructure to
fasten the upperstructure en position. Tighten the
screws (1) to the torques specified on page 2.
STEP 8
Remove the lifting equipment, then disassemble the
lifting rings.
STEP 9
Refer to Section 8006 and reassemble the hydraulic
swivel.
4 STEP 10
CD00G043 Refer to Section 9003 and reassemble the boom, the
Coat the screw threads (2) with Loctite 262. Install the dipper and the bucket on the machine.
screws (2) and flat washers (3) to fasten the turntable
(4) to the undercarriage. Tighten the screws (2) to the STEP 11
torques shown on page 2. Make sure that the hydraulic reservoir drain valve is
closed. To fill the reservoir, refer to the Section "Filling
STEP 5 the Reservoir" in the Operator’s Manual.
Connect a suitable lifting device to the lifting rings
located at the front of the upperstructure, above the NOTE: See Section 1002 for the capacity of the
boom brackets, and to the rings mounted on the frame hydraulic reservoir and the capacity of the total system.
at the rear of the upperstructure.
NOTE: Refer to specifications on page 2 for the weight
of the upperstructure. Make sure that the lifting
equipment has sufficient lifting and support capacity for
the upperstructure.
NOTE: When the upperstructure is lowered and
touches the turntable and the ring gear, make sure that
the swing reduction gear pinion engages perfectly with
the teeth on the upperstructure ring gear.
STEP 6
Carefully install the upperstructure in position on the
turntable. Align the marks on the upperstructure and on
the turntable. Check that the mounting orifices of the
upperstructure are aligned with those of the turntable.
NOTE: The numbers in brackets in the following steps
refer to the schematic on page 6.

Lep SM160B9002-0NA Issued 05-07

9002-8
STEP 12 STEP 14
Refer to page 10, "Installing the counterweight" and
1 install the counterweight.

WARNING: If you put your hand in the ring gear

access orifice when the upperstructure is
swinging, you can be seriously injured. Before
! applying grease by hand to the ring gear, always
check that the bucket or tool is on the ground
and that the engine is shut down.

1 FUEL TANK LOWER ACCESS PANEL

2 HYDRAULIC RESERVOIR LOWER ACCESS PANEL

Install the access panels (1) and (2).

STEP 13
Make sure that the fuel tank drain valve is closed, fill
the tank (see the Operator’s Manual).
NOTE: See Section 1002 for the fuel tank capacity.
STEP 14

Open the left-hand side door. Install the batteries in the

machine. Reconnect the battery cables (2), with the
positive cable always first. Tighten using the screws
(1). Close the left-hand side door.

Lep SM160B9002-0NA Issued 05-07

 9002-9
STEP 15 STEP 20

2
CT06K090
Apply grease to the grease fittings on the turntable.
Install a new seal.
3 STEP 21
Install the access panel with its seal, on the machine.
CI00F509B
Remove the two screws (1) and which fasten the Fasten it in position with the three screws and the
access panel (2) to the upperstructure. Remove the locking washers.
access panel (2). Scrap the seal (3). STEP 22
STEP 16
Apply grease by hand to the ring gear.
STEP 17
Start the engine and swing the upperstructure an eighth
of a turn. Stop the engine.
STEP 18
Apply grease by hand to the ring gear again.
STEP 19
Repeat the operation until all the teeth of the ring gear
are perfectly greased.
NOTE: Refer to specifications on page 2 for the
quantity of grease to be applied.

Install the lower housing (2) under the machine, using

screws (1) and washers.

Lep SM160B9002-0NA Issued 05-07

9002-10
COUNTERWEIGHT
Removal
STEP 1 STEP 3

Remove the 2 caps (2) from the top of the Connect the shackle (1) to the eyebolts, and then use
counterweight (1). the wire ropes and crane to secure the counterweight
so that it does not fall during removal and installation
STEP 2 operations.
STEP 4

Install the 36-mm 2 eyebolts (1) in place of the Disassemble the retaining screws (1) from the
removed caps. counterweight.

NOTE: Spray lubricating oil on the eyebolts.

NOTE: Fully tighten the eyebolts, and then loosen
them by a half turn.

Lep SM160B9002-0NA Issued 05-07

 9002-11
STEP 5 STEP 6

Use the wire ropes and crane to lift and remove the
counterweight.
NOTE: Move the counterweight about 50 cm (19.68 in)
to the rear while lifting it so that it does not interfere with
the pipes.

Thoroughly check that the location is safe before

lowering the counterweight on a crosstie.
NOTE: Thoroughly secure the counterweight with the
wire ropes and crane so that it does not fall down.

Lep SM160B9002-0NA Issued 05-07

9002-12
NOTES
...........................................................................................................................................................................................
...........................................................................................................................................................................................
...........................................................................................................................................................................................
...........................................................................................................................................................................................
...........................................................................................................................................................................................
...........................................................................................................................................................................................
...........................................................................................................................................................................................
...........................................................................................................................................................................................
...........................................................................................................................................................................................
...........................................................................................................................................................................................
...........................................................................................................................................................................................
...........................................................................................................................................................................................
...........................................................................................................................................................................................
...........................................................................................................................................................................................
...........................................................................................................................................................................................
...........................................................................................................................................................................................
...........................................................................................................................................................................................
...........................................................................................................................................................................................
...........................................................................................................................................................................................
...........................................................................................................................................................................................
...........................................................................................................................................................................................
...........................................................................................................................................................................................
...........................................................................................................................................................................................
...........................................................................................................................................................................................
...........................................................................................................................................................................................
...........................................................................................................................................................................................
...........................................................................................................................................................................................
...........................................................................................................................................................................................
...........................................................................................................................................................................................
...........................................................................................................................................................................................
...........................................................................................................................................................................................
...........................................................................................................................................................................................
...........................................................................................................................................................................................
...........................................................................................................................................................................................
...........................................................................................................................................................................................
...........................................................................................................................................................................................
...........................................................................................................................................................................................
...........................................................................................................................................................................................

Lep SM160B9002-0NA Issued 05-07