MJFCIFSS!GSBODF!

TBT Assembly Manual

ASSEMBLY MANUAL

R 9350

Table of Contents
General safety
Tightening torques
Hytorc instruction
SWP 4.01.002 “ R9350 Assembly Procedure”
Assembly schedule
Site Layout
Lifting instruction

pared by : Factory : Equipment :

4.01.002
B.Bedo Mgs! R9350
Inspected by : Title : Date of issue : Validated by the safety site officer :
F. Gresser TABLE OF CONTENTS 20/09/2006 Page 1 of 1
Service Manual General

1 Safety
Working with an excavator can be dangerous, it could result in injury or death if proper precautions are
not taken! WE URGE YOU TO READ THIS MANUAL CAREFULLY! This safety information is
provided to operators and maintenance mechanics to ensure the safe operation and maintenance of
the excavator. It is essential that you read and familiarise yourself with this information, which explains
safety requirements, precautions and specific hazards of which you should be aware. This also
applies to any personnel, who might be working on the machine only occasionally, such as during set
up or maintenance. It is essential that you read and familiarise yourself with this information, which
explains safety requirements and precautions and specific hazards of which you should be aware.
Careful adherence to these safety guidelines will permit safe operation and maintenance and
potentially prevent personal injury to yourself and others, and possible damage to the excavator.
Important safety notes such as DANGER, CAUTION or NOTE are used throughout this manual to
emphasise important or critical instructions.
In this manual, DANGER, CAUTION or NOTE are defined as follows :

DANGER
Denotes an extreme intrinsic hazard, which could result in a high probability of death or serious injury
if proper precautions are not taken.

CAUTION
Denotes a reminder of safety practices or directs attention to unsafe practices if proper precautions
are not taken.

K NOTE
NOTE describes operation and maintenance procedures, which should be followed to keep your
excavator in operation and to insure long machine life and / or to facilitate certain procedures.
In addition to these instructions you must follow the safety regulations applicable to your work
environment and job site and any federal, state and local safety requirements (a model
excavators must also follow local and federal highway regulations).
For EC countries, guidelines 89 / 655 / EWG contain the minimum safety guidelines for users.

1.1 Destined use

The excavator with the standard backhoe, grapple or bucket attachment may only be used to loosen,
pick up, move, load and dump soil, gravel, rock, or other material and to load trucks, barges, conveyor
belts, or rock crushing systems.
Special guidelines are applicable for machines used for lifting applications and special safety devices
must be installed.
Any other use above and beyond the applications described above, such as breaking out rock or
demolishing buildings, pounding in posts etc. requires special attachments and safety devices.
If the machine is exposed to the risk of falling down objects during operation, the cab machine must be
fitted with a safety device according to the FOPS prescriptions
Transporting personnel or loads etc. is not considered destined use and is therefore prohibited. The
manufacturer / dealer is not responsible for any resulting damage. Any risk must be carried by the
user himself.
Destined use is considered part of observing and adhering to all regulations and inspection and
maintenance guidelines given in this Operation and Maintenance Manual.

R 994B Litronic LIEBHERR 1.01-3

From Date: 04 / 2003
Service Manual General

When climbing on or off the excavator, use

1.2 General safety information both hands for support and face the
machine.
• Study the Operation and Maintenance
• If needed, use the front window as an
Manual before operating or working on the
escape hatch.
excavator.
Make sure that you have additional • If no other guidelines are given, perform
information for special attachments of your maintenance and repairs utilising the
machine, read it and understand it! following precautions :
• Allow only authorised personnel to - Park excavator on firm and level ground.
operate, service or repair the excavator. Rest the attachment on the ground.
Make sure to observe any minimum
- Place all control in neutral position and
applicable age requirement.
raise the safety lever.
• Allow only properly trained personnel to
- Turn the engine off and remove the ignition
operate or work on the excavator; make
key.
sure to clearly specify the person who is
responsible for set up, maintenance and • Before working on the hydraulic circuit,
repairs. move all joysticks and pedals with the
ignition key in contact position to relieve
• Make sure the operator knows his
the servo pressure and the remaining
responsibility regarding the observance of
pressures in the different main circuits. In
traffic regulations and permit him to refuse
addition, relieve the pressure in the
any unsafe instructions given my a third
hydraulic tank as described in the
person.
Operation and Maintenance Manual.
• Any persons still in training should only
• Secure all loose parts on the excavator.
operate or work on the machine under the
supervision and guidance of an • Never operate the excavator without a
experienced person. complete walk around inspection. Check if
all warning decals are on the machine and
• Check and observe any person working or
if they are all legible.
operating the excavator periodically and
regularly, if they observe safety • Observe all danger and safety guidelines.
instructions and guidelines given in the
Operation and Maintenance Manual. • For certain special applications, the
excavator must be equipped with specific
• Wear proper work clothing when operating safety equipment. Use the excavator only,
or working on the excavator. Rings, if they are installed and functioning
watches, bracelets and loose clothing such properly.
as ties, scarves, unbuttoned or unzipped
shirts and jackets are dangerous and could • Never perform any changes, additions or
cause injury! modifications on the machine, which could
Wear proper safety equipment, such as influence the safety, without obtaining the
safety glasses, safety shoes, hard hats, permission from the manufacturer. This
work gloves, reflector vests and ear also applies to the installation and
protection. adjustment of safety devices and safety
valves as well as to any welding on the
• Consult our employer or supervisor for carrying parts.
specific safety equipment requirements
and safety regulations on the job site. • Do not install any equipment or
attachments made by other manufacturers
• Always tilt up the safety lever before or any which are not specially authorised
leaving the operator’s seat. by LIEBHERR for installation without first
obtaining the written permission from
• Do not carry tools, replacement parts or
LIEBHERR.
other supplies while climbing on or off the
LIEBHERR will issue any required
excavator. Never use the steering column,
technical documentation for approved
control levers or joysticks as handholds.
installations.
• Never jump off the excavator, climb on and
• Should the electrical circuit be modified or
off the excavator using only the steps, rails
additional components be installed, so the
and handles provided.
modification must be performed according

R 994B Litronic LIEBHERR 1.01-4

From Date: 04 / 2003
Service Manual General

to the national standards and safety 1.4 Fire and explosion prevention
regulations (such as OSHA per the USA).
• Always turn off the engine while refuelling
• The installation must be certified by an
the excavator.
approved organisation and a copy of the
certification has to be sent to the • Never smoke or allow an open flame in
LIEBHERR company. refuelling areas or where batteries are
being charged, or where batteries or
flammable materials are stored.
1.3 Crushing and burn prevention • Always start the engine as described in the
Operation and Maintenance Manual.
• Never work underneath the excavator
unless it is safely resting on the ground • Check the electrical system regularly and
and / or is properly blocked and supported. frequently.
All defects, such as loose connections,
• Never use damaged or insufficient wire burnt out fuses and bulbs, burnt or
ropes, slings or chains. damaged cables must be repaired
Always wear gloves when handling wire immediately by an electrician or especially
ropes. trained personnel.
• Never reach into bores during attachment • Never store flammable fluids on the
installation or removal. Never align bores machine except in the storage tanks
with your fingers or hands. Use proper intended for the excavator’s operation.
alignment tools when installing, changing
or servicing attachments. • Inspect all components, lines, tubes and
hoses for oil and fuel leaks and / or
• Keep objects away from the radiator fan. damage.
Rotating fans will swirl and throw out Replace or repair any damaged
objects, which can become very components immediately.
dangerous and cause severe injury to you Any oil, which escapes from leaks, can
and others. easily cause fire.
• Avoid contact with any components • Be certain that all clamps, guards and heat
containing coolant. At or near operating shields are installed. These components
temperature, the engine coolant is hot and prevent vibration, rubbing, chafing and
under pressure and could cause severe heat build-up. Install tie wraps to fasten
burns. hoses and wires, as required.
• Check the coolant level only after the • Cold start ether is extremely flammable.
radiator cap is cool enough to touch. Use ether only in ventilated areas and as
Remove the radiator cap slowly to relieve directed. Never use it near heat sources or
pressure. open flames; do not permit anybody to
smoke.
• Do not allow your skin to come into contact
with hot oil or components containing hot • Know the location of the excavator’s fire
oil. At or near operating temperature, extinguisher and be familiar with its
engine and hydraulic oil is hot and can be operation. Make sure you know your local
under pressure. fire regulations and fire reporting
procedures.
• Always wear safety glasses and protective
gloves when handling batteries. Keep • A fire extinguisher can be attached inside
sparks or open flames away! the operator’s cab, using the four threaded
holes provided in the rear left support of
• Never permit anyone to hand guide the the cab.
bucket or grapple into position.
• When working in the engine area, make
sure the top covers and side doors are
properly secured or closed with the
appropriate supports.
• Never work underneath or on the
excavator unless it is properly blocked and
supported.

R 994B Litronic LIEBHERR 1.01-5

From Date: 04 / 2003
Service Manual General

• Tilt the safety lever down and check all

1.5 Machine start up safety indicators, gauges, warning devices and
controls for their proper indication.
• Before excavator start up, perform a
• Start and operate the engine only in a well
thorough walk around inspection.
ventilated area. If necessary, open doors
• Visually inspect the excavator; look for and windows.
loose bolts, cracks, wear, any leaks and Warn up the engine and hydraulic system
any evidence of vandalism. to operating temperatures. Low engine and
hydraulic oil temperatures can cause the
• Never start or operate an unsafe excavator to be unresponsive.
excavator.
• Check that all attachment functions are
• Report all defects to your foreman or operating properly.
supervisor and make sure they are
corrected immediately. • Move the excavator slowly into an open
area and check all travel functions for their
• Make sure all the covers and doors are proper operation, check travel and swing
closed and looked and all warning decals brakes, the steering function as well as the
are on the machine. turn signals and lights.
• Make sure all windows, as well as inside
and outside mirrors are clean, and secure
all doors and windows to prevent any
unintentional movement.
1.7 Machine operating safety
• Be certain that the area surrounding the • Familiarise yourself with job site rules. Be
excavator is free of other personnel, and informed about traffic and hand signals
that no one is working on or under the and safety signs. Ask who is responsible
excavator before starting the engine. for signalling.
Check your surrounding for any obstacles
• After entering the cab, adjust the in the working and movement range, check
operator’s seat and controls, the inside the load carrying capacity of the terrain,
and outside mirror, the armrests and and secure the job site to shield it from any
fasten and adjust the seat belt. Be certain public highway traffic.
that all controls can be reached
comfortably. • Always keep a safe distance from
overhangs, walls, drop offs, and unstable
• All noise protection devices on the ground.
machine must be functional during
operation. • Be alert of changing weather conditions,
bad or insufficient visibility and changing
ground conditions.

1.6 Engine start up and operating • Be alert for utility lines, check the location
of underground cables, gas and water
safety lines, and work especially careful in that
• Before start up, check if all indicator lights vicinity. If necessary and / or if required,
and instruments are functioning properly, call local authorities to mark the location.
place all controls in neutral position and tilt • Keep sufficient distance to electrical lines.
the safety lever up. When working in the vicinity of high
• Before starting the engine, alert any voltage electrical lines, keep proper
nearby personnel that the excavator is distance to assure that the attachment
being started by sounding the horn. does not come close to the lines.
DANGER! You must inform yourself about
• Start the machine only when seated in the safe distances.
operator’s seat, and with the seat belt
fastened (if installed). • Preferably have the electrical lines de-
energised (and lockout / tagged out
• If you have no other instructions, start the according to the regulations applicable on
engine as outlined in the Operation and the job-site) each time it is possible, and in
Maintenance Manual. any case if the closeness of the working
area make it necessary.

R 994B Litronic LIEBHERR 1.01-6

From Date: 04 / 2003
Service Manual General

• In case you do touch a high voltage line by to the ground and turn the excavator facing
accident, proceed as follows : downhill.
If possible, always operate the excavator
- Do not leave the machine, with the attachment positioned uphill or
- Move the machine, if possible, from the downhill, never sideways.
danger zone until you obtain sufficient
• Always travel slowly on rough or slippery
distance,
ground and on slopes.
- Warn any personnel in the vicinity not to
• Always travel downhill at permissible
come close to the excavator and not to
speed, so you don’t loose control over the
touch it,
machine. The engine must run at nominal
- Instruct or initiate that someone turns off speed, use only the foot pedals to brake
the voltage. and slow down the machine.
Never shift during down hill travel, always
- Do not leave the machine until you are
shift to a lower gear before travelling
absolutely sure that voltage in the line,
downhill.
which had been touched or damaged,
has been turned off! • Never load over an occupied truck.
Request that the driver leave the cab, even
• Before moving the machine, make sure
if a rock protection is installed.
that the attachments and equipment is
secured properly to avoid accidents. • For demolition work, clearing, crane
operation, etc. always use the appropriate
• When travelling on the public roads or
protection device designed for this specific
highways, make sure to observe traffic
application.
regulations, and make sure that the
machine meets federal and local public • If operating in visually obstructed terrain or
highway standards. whenever necessary, have another person
guide you. Always have only one person
• Always turn on the lights if visibility is bad
signalling you.
or if you are still working during dusk.
• Allow only experienced persons to attach
• Never allow other personnel on the
loads or to guide operators. The guide
excavator.
must be visible by the operator and / or
• Operate the excavator only while seated must be in voice contact with him.
and with the seat belt fastened, if installed.
• Depending on the attachment combination,
• Report any problems or needed repairs to it is possible for the bucket teeth to hit the
your foreman or supervisor and make sure cab, the cab protection or the boom
they are corrected immediately. cylinders. Be very careful when the bucket
teeth get in this range to prevent any
• Do not move the excavator until you are damage.
certain that no one is endangered by
moving the excavator. • In case of a thunderstorm :
• On machines without negative brakes • Lower the attachment to the ground and if
check the brake system before starting to possible anchor the digging tool into the
work, as outlined in the Operation and soil.
Maintenance Manual.
• Leave the cab and move away from the
• Never leave the operator’s seat while the machine before the storm breaks out.
machine is still moving. Otherwise, you must stop the excavator,
turn off the radio and keep inside the
• Never leave the machine unattended closed cab until the end of the storm.
(within view of machine), with the engine
running.
• When moving the excavator, keep the
uppercarriage in lengthwise direction and
keep the load as close as possible to the
ground.
• Prevent any working movements, which
could tip the machine over. If the excavator
begins to tip or slip on a grade,
immediately lower the attachment and load

R 994B Litronic LIEBHERR 1.01-7

From Date: 04 / 2003
Service Manual General

carefully drive up the ramp and onto the

1.8 Machine parking safety flat bed trailer.
• When the excavator is on the trailer,
• Park the excavator only on firm and level
release the uppercarriage lock pin, turn the
ground.
uppercarriage back and lower the
• If it becomes necessary to park the attachment.
machine on a grade, properly block and If the backhoe attachment is attached, tilt
secure it with wedges. the stick and bucket in and relock the
uppercarriage.
• Lock the uppercarriage with the lock pin.
• Carefully secure the uppercarriage and
• Lower the attachments to the ground and other parts with chains, wedges and blocks
anchor the bucket lightly in the ground. to prevent slipping.
• Bring all operating levers in neutral • Release the hydraulic pressure, remove
position and engage the travel and swing the ignition key, raise the safety lever,
brakes. close and lock the cab, lock and secure all
• Turn the engine off as outlined in the others doors and leave the machine.
Operation and Maintenance Manual and • Carefully check out the transport route.
raise the safety lever before you leave the Make sure that the width, height and
operator’s seat. weight allowances are within the permitted
• Lock the machine, remove all keys and limits.
secure the excavator against vandalism • Check that there is enough clearance
and unauthorised use. underneath all bridges, underpasses, utility
lines, and in tunnels.
• During the unloading procedure, proceed
1.9 Machine transporting safety with the same care and caution as during
the loading procedure. Remove all chains
• Use only suitable transporting and lifting and wedges. Start the engine as outlined
devices with sufficient capacity. in the Operation and Maintenance Manual.
• Park the machine on firm and level ground Carefully drive off the loading platform.
and block the chains or wheels. Keep the attachment as close as possible
to the ground level. Have another person
• If necessary, remove part of the guide and signal you.
attachments during transport.
• When loading the machine on a flatbed
trailer or railroad car; be sure that the 1.10 Machine towing safety
loading ramp incline is less than 30° and
covered with wooden planks to prevent • Observe the correct procedure : check the
skidding. index in your Operation and Maintenance
• Remove all mud, snow or ice from track Manual, and refer to the appropriate
components before moving up the ramp. section : “Towing the Excavator”.

• Before loading, secure the uppercarriage • Only tow the excavator if absolutely
with the undercarriage with the lock pin. necessary, for example to remove it for
repairs from dangerous job site.
• Align the machine with the loading ramp.
• Be sure all towing and pulling devices such
• Attach the manual control levers to the foot as cables, hooks, and couplers are safe
pedals for sensitive control. and adequate.
• Have another person guide and signal the • Make sure that the cable or the towing rod
operator. are strong enough and are routed around
the center of the undercarriage or to the
• Have blocks or wedges ready to block the towing hook on the undercarriage, which is
machine, if necessary, to prevent the designated for this purpose.
machine from rolling backwards. Be aware that any damage to the machine
• Retract the attachment as far as possible caused by towing is never covered by the
and lower the attachment as close as manufacturer’s warranty.
possible to the loading surface and

R 994B Litronic LIEBHERR 1.01-8

From Date: 04 / 2003
Service Manual General

• Never allow anyone to stand near the sure the excavator is parked on firm a level
cable when pulling or towing the ground and the engine is turned off.
excavator.
• During maintenance and service work,
• Keep the cable tight and free of kinks. make sure you always retighten any
loosened screw connections!
• Engage travel slowly, and do not jerk. With
a slack cable, the sudden impact of the • If it is necessary to disconnect or remove
load being towed could snap and break. any safety devices during set up,
maintenance or repair, make sure that
• During the towing procedure, keep within after completion of repairs, the safety
the required transport position, permissible devices are reinstalled and checked for
speed and distance. proper function.
• After the towing procedure is completed, • Before any maintenance work and
return the machine to its previous state. especially when working under the
• Proceed as outlined in the Operation and machine, make sure a “Do not operate” tag
Maintenance Manual when putting the is attached to the starter switch. Remove
excavator back in service. the ignition key.
• After end of the maintenance works or
repair, restart the machine according to the
1.11 Machine maintenance safety instructions “Machine start up”, in this
manual.
• The machine may not be made unsafe • Before any repairs or maintenance work,
when performing maintenance work. Never clean any oil, fuel and / or cleaning
attempt maintenance procedures or substances from any fittings and
repairs you do not understand. connections.
• Check the Operator’s and Maintenance • Don’t use any harsh cleaners and use only
Manual for service and maintenance lint free cloths.
intervals. Make sure you use only
appropriate tools for all maintenance work. • Use only non-flammable cleaning fluids to
clean the machine.
• Refer to your Operator’s and
Maintenance Manual to see, who is • Any welding, torch or grinding work on the
authorised to perform certain repairs. The machine must be explicitly authorised.
operator should only perform the daily / Before any using a welder, torch or
weekly maintenance procedures. grinder, clean off any dust and dirt and
The remaining work may only be remove any flammable materials from the
performed by especially trained personnel. surrounding area. Make sure the area is
sufficiently ventilated.
• Use only replacement parts corresponding Danger of fire and explosion!
to the technical requirements specified by
manufacturer. This is assured by using • Before cleaning the machine with the
only original Liebherr replacement parts. water or steam (high pressure cleaning) or
other cleaning fluids, make sure that all
• Always wear proper work clothing when openings, which, for safety and / or
maintaining the excavator. Certain work functioning reasons should not be exposed
may only be performed with a hard hat, to water / steam / cleaners; are covered
safety shoes, safety glasses and gloves. and / or masked off. Especially sensitive
• During maintenance, do not allow are electrical motors, control boxes and
unauthorised personnel to enter the plug connectors.
maintenance area. Make sure that the temperature sensors of
the fire alarm and extinguishers system do
• Secure the maintenance area, as not come in contact with the hot cleaning
necessary. fluids, which could trigger the fire
• Inform the operator before any special or extinguishing system.
maintenance work. Make sure he knows Remove all coverings and masking
the person, who is in change of the work. material after completing the cleaning
procedure.
• If not otherwise noted in the Operation Then check all fuel lines, engine oil lines
and Maintenance Manual, always make and hydraulic oil lines leaks, loose

R 994B Litronic LIEBHERR 1.01-9

From Date: 04 / 2003
Service Manual General

connections, chafing and / or damage. Fix operator. The guide must be within the
any problems immediately. visibility range of the operator and / or
must be in direct voice contact with the
• If you use a high pressure cleaner with operator.
steam or hot water to clean the machine,
observe following recommendations : • When working overhead, use appropriate
and safe ladders, scaffolding or other
• The distance between the nozzle and the working platforms designated for that
surface to be cleaned must be no lower purpose.
than 20 inches. Never step on parts or components on the
• The water temperature should not exceed machine when maintaining or repairing
60°C (140°F). items overhead.
When working high above ground, make
• Limit the water pressure to 80 bar sure you are fitted with ropes and
maximum (11500 PSI). appropriate safety devices, which will
• If you employ cleaning fluid, only use prevent a possible fall.
neutral cleaning agents such as customary Always keep handles, steps, railings,
car shampoos diluted to 2 or 3 percent platforms and ladders free of dirt, snow
maximum. and ice!

• Never employ aggressive cleaning agent • When working on the attachments, for
or high pressure cleaning apparatus (water example when replacing the bucket teeth,
or steam) during the two first months makes sure the attachment is supported
following machine delivery or repainting. properly. Never use metal on metal
support!
• Observe all product safety guidelines when
handling oils, grease, and other chemical • Never work underneath the machine if it is
substances. raised or propped up with the attachment.
The undercarriage must be supported with
• Make sure service fluids and replacement wooden blocks and supports.
parts are disposed of properly and in an
environmentally sound manner. • Always support the raised machine in such
a way that any shifting to the weight
• When using hot service fluids, be very change will not influence the stability. Do
careful (they can cause severe burns and not support the machine with metal on
injury!). metal support.
• Operate combustion motors and fuel • Only qualified, especially trained personnel
operated heaters only in well ventilated may work on travel gear, brake and
areas. Before operating these units, check steering systems.
ventilation.
In addition, always follow applicable local • If it becomes necessary that the machine
regulations. must be repaired on a grade, block the
chains with wedges and secure the
• Never try to lift heavy parts. Use uppercarriage with the lock pin.
appropriate lifting devices with sufficient
load carrying capacity. When replacing or • Only qualified, especially trained personnel
repairing parts or components, make sure may work on the hydraulic system.
they are mounted very carefully on lifting • Never check for leaks with bare hands,
devices, to prevent any possible danger. always wear gloves. Fluid escaping from a
Use only suitable and technically sound small hole can have enough force to
lifting devices, make sure that the lifting penetrate the skin.
tackle, wire cables, etc. has adequate load
carrying capacity. • Never loosen or remove lines or fittings
Never position yourself, walk or work before the attachment has been lowered to
underneath suspended loads. the ground and the engine has been
turned off. Then turn the ignition key to
• Never use damaged lifting devices, or contact position, move all servo controls
devices which are not sufficient to carry (joysticks and foot pedals) in both
the load. directions to release pressures. Then
Always wear gloves when handling wire release the tank pressure as outlined in
cables. this Operation Maintenance Manual.
• Ask only experienced personnel to attach
loads and guide and signal the crane

R 994B Litronic LIEBHERR 1.01-10

From Date: 04 / 2003
Service Manual General

• Always disconnect the battery cable before • Even if hoses and lines are stored and
working on the electrical system or before used properly, they undergo a natural
any arc welding on the machine. Always aging process. For that reason, their
disconnect the negative (-) cable first and service lift is limited.
reconnect it last. Improper storage, mechanical damage and
improper use are the most frequent causes
• Check the electrical system regularly. of hose failures.
Make sure that any problems, such as The service life of a hose may not exceed
loose connections, burnt out fuses and six years, including a storage period of not
bulbs, scorched or chafed cables are fixed more than two years (always check the
immediately by an electrician or qualified manufacturer’s date on the hoses).
personnel. Using hoses and lines close to the limit
• Use only original fuses with the specified ranges of permitted use can shorten the
amperage. Never use a different size or service life (for example at high
stronger fuse than the original fuse. temperatures, frequent working cycles,
extremely high impulse frequencies, multi
• On machines with electrical medium or shift or around the clock operations).
high voltage systems :
• Hoses and lines must be replaced if any of
- If there is any problem with the electrical the following points are found during an
energy supply, turn the machine off inspection :
immediately.
- Damage on the external layer into the
- Follow established lockout / tagout inner layer (such as chaffings, cut and
procedures where applicable. rips);
- Any work on the electrical system may - Brittleness of the outer layer (crack
only be performed by a qualified formation of the hose material);
electrician or qualified personnel under
the guidance and supervision of an - Changes in shape, which differ from the
electrician, according to electro-technical natural shape of the hose or line, when
regulations. under pressure or when not under
pressure, or in bends or curves, such as
• If any work is required on any parts which separation of layers, blister or bubble
carry current, use a second person to turn formation;
off the main battery switch, if necessary.
Rope the work area off with a red and - Leaks;
white safety rope or chain, and set up - Non observance of installation
warning signs. Use only insulated tools. requirements;
• When working on medium and high - Damage or deformation of hose fittings,
voltage components, shut off the voltage which might reduce the strength of the
and connect the supply cable to the fitting or the connection between hose
ground and ground the components, such and fitting;
as the condensor, with a grounding rod.
- Any movement of hose away from the
• Check all disconnect parts if they are truly fitting;
free of current, ground them and close
them off quickly. Insulate any close-by, - Corrosion on fittings, which might reduce
current carrying parts. the function or the strength of the fitting;
- Storage or service life has been exceeded.
When replacing hoses or lines, always use
1.12 Hydraulic lines and hoses original replacement parts.

• Hydraulic lines and hoses may never be • Route or install the hoses and lines
repaired! properly. Do not mix up the connections!

• All hoses, lines and fittings must be • Always take care to avoid torsional strain
checked regularly, but at least one time when installing a new hose. On high
per year for leaks and any externally pressure hydraulic hoses, the mounting
visible damage! Any damaged sections screws must be first mounted on the both
must be replaced immediately! Excaping ends (full flange or half clamp) and
oil can cause injuries and fires! tightening only thereafter.

R 994B Litronic LIEBHERR 1.01-11

From Date: 04 / 2003
Service Manual General

• On high pressure hoses having one curved two hands and one foot or with one hand
end, always tighten first the screws on the and two feet.
curved hose end and only then the screws
• As soon as you can reach the handle of
on the straight hose end.
the door with your free hand unlock and
• Install and tighten the hose clips that may open the door before climbing up any
be mounted on the hose middle only when more.
the both hose ends are already tightened.
• Keep and guide the door all the way with
• Always install hoses so to avoid any your hand lock it in its opened position,
friction with other hoses and parts. making sure it is securely fixed in this
position, so it can not be slammed by the
• We recommend to keep a distance wind.
between hose and other parts of at least
one half of the hose outer diameter. Keep • Take care to keep yourself apart from the
a minimum gap of 1/2 inch in any case. slewing range of the door during the whole
of its opening motion.
• After mounting a hose connecting two
parts that are movable to each other, • Some external influences, and especially
check during the return to service that the the wind, may make the opening of the
hose is not rubbing in the whole moving door uneasy.
range.
• Go on climbing up, always holding yourself
by three points, enter the cab and seat
down to the seat.
1.13 Additional safety guidelines for • If applying fasten the seat belt. Unlock the
excavators fitted with a cab door using the unlocking lever and close
elevation the door holding it by the handle designed
for this purpose.
• When operating an excavator with a cab
elevation, observe the following safety • Only the reafter lower the safety lever and
instructions, which complete the general start the machine.
safety information provided in the • It is essential to have your seat belt
operation and maintenance manual for the fastened if you want to operate the
machine. machine with the cab door opened.
• Keep ladders, footsteps, handles and • Should the belt be missing on your
handrail in clean condition and always free machine, so you must compulsorily get
them from mud, oil, grease, ice, snow or one installed before you start working with
any other obstacles. opened cab door.
• To guarantee an easy opening of the cab • Before climbing down the cab, you must
door in all weather conditions, coat the make sure the machine is parked on a flat,
rubber seals around the door with silicon firm and level ground and the ladders and
oil or talcum every two months and more steps are aligned on upper and
often if necessary. Regularly grease the undercarriage.
hinges and lock of the cab door as well the
fixing device of the door in opened • Then open the cab door and lock it in
position. opened position and make sure it is
securely fixed in this position.
• During maintenance works, always wear
safety glasses and proper protective • Be aware of difficult weather conditions
clothes. and anticipate their possible
consequences. The wind for example
• To climb up or down the cab, the could slam the cab door.
excavator must be parked on firm, flat and
level ground and the uppercarriage must • If necessary unfasten the seat belt.
be swung so to align ladders and steps on • Carefully begin climbing down, facing the
upper and undercarriage. machine and always holding the contact at
• Face the excavator when climbing up and three points, until you reach the height
always hold on to the machine at three where you can close the cab door in the
points, i.e. keep the contact with the best conditions, keeping yourself apart
access components at the same time with from its slewing range and guiding it with
the hand until closed.

R 994B Litronic LIEBHERR 1.01-12

From Date: 04 / 2003
Service Manual General

• If you want so lock the door and take away • Slowly and carefully go down to the floor.
the key.

R 994B Litronic LIEBHERR 1.01-13

From Date: 04 / 2003
Service Manual General

2 Tightening

2.1 Tightening torques

2.1.1 Factory standarts WN 4037 – Tightening forces and torques of metric screws

This chart provides the standard torque values for nuts and bolts. This torque chart should be used
unless a specific torque is given in the manual.
Surface condition:
· Black tempered or bonderized
· Galvanized / electroplated
· DACROMET 500
· Screw and nut lubricated, medium friction factor µG=0,12

Standard metric thread Fine metric thread

Tightening Tightening Tightening Tightening
Bolt size Grade force torque Bolt size Grade force torque
FM in N MA in Nm FM in N MA in Nm
8.8 4050 2,8
M4 10.9 6000 4,1
12.9 7000 4,8
8.8 6600 5,5
M5 10.9 9700 8,1
12.9 11400 9,5
8.8 9400 9,5
M6 10.9 13700 14,0
12.9 16100 16,5
8.8 13700 15,5
M7 10.9 20100 23,0
12.9 23500 27
8.8 17200 23 8.8 18800 24,5
M8 10.9 25000 34 M8x1 10.9 27500 36
12.9 29500 40 12.9 32500 43
8.8 24800 36
M9x1 10.9 36500 53
12.9 42500 62
8.8 27500 46 8.8 31500 52
M10 10.9 40000 68 M10x1 10.9 46500 76
12.9 47000 79 12.9 54000 89
8.8 29500 49
M10x1,25 10.9 43000 72
12.9 51000 84
8.8 40000 79 8.8 45000 87
M12 10.9 59000 117 M12x1,25 10.9 66000 125
12.9 69000 135 12.9 77000 150
8.8 42500 83
M12x1,5 10.9 62000 122
12.9 73000 145
8.8 55000 125 8.8 61000 135
M14 10.9 80000 185 M14x1,5 10.9 89000 200
12.9 94000 215 12.9 104000 235
8.8 75000 195 8.8 82000 205
M16 10.9 111000 280 M16x1,5 10.9 121000 300
12.9 130000 330 12.9 141000 360

R 994B Litronic LIEBHERR 1.01-15

From Date: 02 / 2002
Service Manual General

Standard metric thread Fine metric thread

Tightening Tightening Tightening Tightening
Bolt size Grade force torque Bolt size Grade force torque
FM in N MA in Nm FM in N MA in Nm
8.8 94000 280 8.8 110000 310
M18 10.9 135000 390 M18x1,5 10.9 157000 440
12.9 157000 460 12.9 184000 520
8.8 102000 290
M18x2 10.9 146000 420
12.9 170000 490
8.8 121000 390 8.8 139000 430
M20 10.9 173000 560 M20x1,5 10.9 199000 620
12.9 202000 650 12.9 232000 720
8.8 152000 530 8.8 171000 580
M22 10.9 216000 750 M22x1,5 10.9 245000 820
12.9 250000 880 12.9 285000 960
8.8 175000 670 8.8 207000 760
M24 10.9 249000 960 M24x1,5 10.9 295000 1090
12.9 290000 1120 12.9 346000 1270
8.8 196000 730
M24x2 10.9 280000 1040
12.9 325000 1220
8.8 230000 1000 8.8 267000 1110
M27 10.9 330000 1400 M27x1,5 10.9 381000 1580
12.9 385000 1650 12.9 445000 1850
8.8 255000 1070
M27x2 10.9 365000 1500
12.9 425000 1800
8.8 280000 1350 8.8 335000 1540
M30 10.9 400000 1900 M30x1,5 10.9 477000 2190
12.9 465000 2250 12.9 558000 2560
8.8 321000 1490
M30x2 10.9 457000 2120
12.9 534000 2480
8.8 350000 1850 8.8 410000 2050
M33 10.9 495000 2600 M33x1,5 10.9 584000 2920
12.9 580000 3000 12.9 683000 3420
8.8 395000 2000
M33x2 10.9 560000 2800
12.9 660000 3300
8.8 410000 2350 8.8 492000 2680
M36 10.9 580000 3300 M36x1,5 10.9 701000 3820
12.9 680000 3900 12.9 820000 4470
8.8 440000 2500
M36x3 10.9 630000 3500
12.9 740000 4100
8.8 490000 3000 8.8 582000 3430
M39 10.9 700000 4300 M39x1,5 10.9 830000 4890
12.9 820000 5100 12.9 971000 5720
8.8 530000 3200
M39x3 10.9 750000 4600
12.9 880000 5300

R 994B Litronic LIEBHERR 1.01-16

From Date: 02 / 2002
Service Manual General

2.1.2 Torque values for the mounting screws on the SAE fittings

This chart provides the standard torques values for the mounting screws on the SAE fittings. This
torque chart should be used unless a specific torque is given in the manual.

2.1.2.1 High pressure fittings

Torque value in Nm (ft.lbs) – Quality 10.9
Flange size Screw size
Split half flange Flange without rim Flange with rim
1/2” M8 31 (23) / /
3/4” M10 62 (45) 45 (33) 65 (48)
1” M12 108 (80) 70 (51) 110 (81)
1”1/4 M14 172 (127) 120 (88) 180 (133)
1”1/2 M16 264 (195) 170 (125) 250 (184)
2” M20 350 (258) 250 (184) 450 (332)

2.1.2.2 Low pressure half flanges

Torque value in Nm (ft.lbs)
Flange size Screw size
Quality 8.8 Quality 10.9
1/2” M8 22 (16) 31 (23)
3/4” M10 44 (32) 62 (45)
1” M10 44 (32) 62 (45)
1”1/4 M10 44 (32) 62 (45)
1”1/2 M12 76 (56) 108 (80)
2” M12 76 (56) 108 (80)
2”1/2 M12 76 (56) 108 (80)
3” M14 122 (90) 172 (127)
3”1/2 M16 187 (138) 264 (195)
4” M16 187 (138) 264 (195)
5” M16 187 (138) 264 (195)

R 994B Litronic LIEBHERR 1.01-17

From Date: 04 / 2003
Service Manual General

SAE grade
1 or 2 5 6 or 7 8
number
Minimum Medium
Quality of material indeterminate Best commercial
commercial commercial
2
To : To : To : 1026 N/mm
2 2 2
Minimum tensile in 1/2” – 472 N/mm 3/4” – 821 N/mm 5/8” – 958 N/mm
2
N / mm 3/4” – 438 N/mm
2
1” – 787 N/mm
2
3/4” – 910 N/mm
2

2
1” – 376 N/mm
Capscrew head
marking
6

2.1.3 Hexagon-socket-head cap screw

Body size Wrench size Approx. Torque values (Nm)
Thread Number
(Inches) mm Inch. Body size Grade 1,2 Grade 5 Grade 6,7 Grade 8
1/4 11 ---- UNC 20 6,4 7 11 14 16
UNF 28 8 14 19
5/16 14 9/16 UNC 18 7,9 15 23 26 33
UNF 24 18 26 37
3/8 17 11/16 UNC 16 9,5 24 42 46 60
UNF 24 27 47 66
7/16 19 3/4 UNC 14 11,1 38 66 75 95
UNF 20 41 75 106
1/2 22 7/8 UNC 13 12,7 53 102 115 142
UNF 20 56 115 163
5/8 27 1-1/16 UNC 11 15,9 113 203 226 285
UNF 18 129 231 325
3/4 32 1-9/92 UNC 10 19,1 142 366 380 508
UNF 16 156 400 569
7/8 36 1-7/16 UNC 9 22,2 217 536 597 820
UNF 14 237 590 915
1 41 1-5/8 UNC 8 25,4 319 800 895 1234
UNF 14 339 895 1342

2.1.4 Notes :

Always use the torque values listed above when specific torque values are not available.
The above is based on the use of clean, dry threads.
Reduce torque by 10% when engine oil is used as a lubricant.
Reduce torque by 20% if new plated capscrews are used.
Capscrews threaded into aluminium may require reductions in torque 30% or more of Grade 5
capscrews torque and must attain two capscrew diameters of thread engagement.

R 994B Litronic LIEBHERR 1.01-18

From Date: 04 / 2003
Service Manual General

2.1.5 Wrench size for metric screw

Wrench size for hexagonal screw Wrench size for allen head screw
Bolt size
mm Inches mm Inches
M3 5.5 7/32 2.5 ----
M4 7 9/32 3 ----
M5 8 ---- 4 5/32
M6 10 ---- 5 ----
M8 13 1/2 6 ----
M10 17 11/16 8 ----
M12 19 3/4 10 ----
M14 22 7/8 12 ----
M16 24 61/64 14 9/16
M18 27 1-1/16 14 9/16
M20 30 1-3/16 17 43/64
M22 32 1-9/32 17 43/64
M24 36 1-7/16 19 3/4
M27 41 1-5/8 19 3/4
M30 46 1-13/16 22 7/8
M33 50 2 24 61/64
M36 55 2-3/16 27 1-1/16
M39 60 2-3/8 27 1-1/16
M42 65 2-9/16 32 1-9/32
M45 70 2-3/4 32 1-27/64
M48 75 3 36 1-27/64
M52 80 3-5/32 ---- ----
M56 85 3-3/8 ---- ----
M60 90 3-9/16 ---- ----
M64 95 3-3/4 ---- ----

R 994B Litronic LIEBHERR 1.01-19

From Date: 04 / 2003
Service Manual General

2.2 Hytorc

2.2.1 Safety

First install Hy-torc for physical damage. Damaged hoses may rupture at high pressure, tool could fly
apart causing injury. Check hoses and fittings for damage. Check tooling for physical damage.
Inspect electric pump.
Inspect sockets for wear or physical damage.
Fit tooling to the bolt head and adjust the reaction arm to the correct position. Make sure that the
tooling is in serviceable condition and that the reaction arm is at the best position to give the tool
maximum support. If necessary a support should be used to hold the tool in position.
Set required pressure on pump. Check pressure on chart against bolt dimension and grade to obtain
correct torque.
Commence tensioning. Check that the hoses are not jammed or twisted and that the tool is supported.
Tensioning completed. Release all hydraulic pressure. If necessary gain assistance in the removal of
the tooling.

R 994B Litronic LIEBHERR 1.01-20

From Date: 04 / 2003
HYTORC Agence centre-est, 22 bis avenue de Collongue , 69130 ECULLY , France
Tel : 04.78.33.39.19 Fax : 04.78.33.50.35 e-mail:[email protected]
Web site: www.hytorc-ce.com

HYTORC
The Torque Machine
Operational and spare parts manual

Section2 Instructions before use

READ CAREFULLY: Most malfunctions in new equipment are the result of improper
operation and/or set-up assembly.

PREPARATION: Remove HYTORC Torque Machine from shipping container.

INSPECTION: Visually inspect all components for shipping damage. If any damage is
found, notify carrier immediately.

2-1
Working Pressure
The tool's maximum working pressure is 10,000 PSI (700kg/crn2).

Make sure that all hydraulic equipment used with this tool is rated for 10,000 PSI Operating Pressure.

2-2
Hydraulic Connections
With older style pumps (SST-10, SST-20), the retract side of the system may remain pressurized after the
pump has been switched "off'. This trapped pressure makes it impossible to loosen the retract-side fittings by hand.

To release the pressure, find the 5/16" manual override holes in the end of the black solenoids on the pump. With a
welding rod, alien key or similar device, push in on the ends of both solenoids, each in turn, and the residual pressure will
be released. All fittings will then be hand tight again.

Newer style pumps (HYTORC 115, HYTORC 230, HYTORC AIR) are equipped with an auto-pressure relief.

Never disconnect or connect any hydraulic hoses or fittings without first unloading the wrench and the pump. If the
system includes a gauge, double cheek the gauge to assure pressure has been released.

When making connections with quick disconnect couplings, make sure the couplings are fully engaged. Threaded
connections such as fittings, gauges etc. must be clean and securely tightened and leak free.

CAUTION: Loose or improper threaded fittings can be potentially dangerous if pressurized, yet, severe over
tightening can cause premature thread failure. Fittings need to be only tightened secure & leak free. Never grab,
touch or in any way come in contact with a hydraulic pressure leak. Escaping oil can penetrate the skin and cause
injury.
HYTORC Agence centre-est, 22 bis avenue de Collongue , 69130 ECULLY , France
Tel : 04.78.33.39.19 Fax : 04.78.33.50.35 e-mail:[email protected]
Web site: www.hytorc-ce.com

2-3
Electrical Connections
Ensure proper power availability to prevent motor failure or dangerous electrical overloading.

Compare the motor nameplate for required amperage.

Do not use electric pump if the 3-prong electrical plug is not whole.

Minimize the length of extension cords and be sure they are of adequate wire size, with ground. connections.

Extension cord should be #10 AWG gauge.

WARNING: Electric motors may spark. Do not operate in an explosive atmosphere or in the

presence of conductive liquids. Use an air motor pump instead.

2-4
Air Connections
Ensure that you have sufficient air flow (in cfm) to operate your pneumatic pump. If in doubt, compare the pump
manufacturer's recommended air flow rating prior to pressurizing pump. Improper air flow may damage the pump
motor. For best results use air hoses larger than 3/4" diameter.

Use of a filter regulator lubricator (FRL) is highly recommended. (Pictured below.)

1. ADJUST OIL FLOW TO 1-2 DROPS PER MINUTE

2. FILL HALF WAY WITH GRADE 46 HYDRAULIC OIL SUPPLIED
HYTORC Agence centre-est, 22 bis avenue de Collongue , 69130 ECULLY , France
Tel : 04.78.33.39.19 Fax : 04.78.33.50.35 e-mail:[email protected]
Web site: www.hytorc-ce.com

Section3 Operation
3-1
General
All HYTORC Torque Machines are supplied completely assembled, ready for use. A HYTORC Hydraulic
Power Pack, for use with your HYTORC machine, is recommended to provide the speed, pressure and
portability that makes your HYTORC System efficient and accurate.

The System accuracy of your MXT Series tool is +/- 3% based upon manufacturer's specifications. This accuracy
may be certified through calibration by HYTORC or any other qualified calibration facility whose program is
traceable to the National Institute of Standards and Technology (N.I.S.T).

Using a calibrated gauge enhances the accuracy of your HYTORC System.

3-2
Connecting the System
The wrench head and power pack are connected by a 10,000 PSI operating pressure, (40,000 PSI burst) twinline hose
assembly. Each end of the hose will have one male and one female connector to assure proper interconnection between
pump and wrenchheads.

IMPORTANT

To avoid tool malfunction, do not reverse connectors.

DO NOT tamper with the set screw on the uniswivel assembly. It is factory set for safety purposes, and
adjustments should only be made by trained personnel.

Connect the twinline hose to the uniswivel as shown below:

Insure the connectors are fully engaged and screwed snugly and completely together.
HYTORC Agence centre-est, 22 bis avenue de Collongue , 69130 ECULLY , France
Tel : 04.78.33.39.19 Fax : 04.78.33.50.35 e-mail:[email protected]
Web site: www.hytorc-ce.com

3-3
Drive Direction Change
To remove the square drive, disengage the drive retainer assembly by depressing the center round button and gently
pulling on the square end of the square drive. The square drive will slide easily out.

To insert the drive in the tool, place the drive in the desired direction, engage drive and bushing splines, then twist drive
and bushing until ratchet spline can be engaged. Push drive through ratchet. Depress drive retainer button, engage
retainer with drive and release button to lock.

The above diagram illustrastes the direction the square drive should face for loosening and tightening of a standard right
hand fastener.

3-4
Reaction Arm
All HYTORC Torque machines are equipped with a universal reaction arm. These reaction arms are employed to absorb
and counteract forces created as the unit operates. The reaction arm should extend in the same direction of the square
d14ve; however, slight adjustments may be made to suit your particular application.

NOTE: The standard MXT reaction arm cannot be welded on and should not be modified.

The reaction arm for all MXT Series tools are splined to slide over the rear (cylinder) portion of the tool. In operation, the
reaction arm must be fully engaged and secured by inserting the spring loaded reaction arm clamp at the base of the
housing into the groove of the reaction arm.
HYTORC Agence centre-est, 22 bis avenue de Collongue , 69130 ECULLY , France
Tel : 04.78.33.39.19 Fax : 04.78.33.50.35 e-mail:[email protected]
Web site: www.hytorc-ce.com

3-5
Setting Torque
Once the system is fully connected and the proper power supply available, it is time to adjust the pump
pressure to the level needed on your job.

When tightening, use the manufacturer's specifications to determine the torque value which you will
ultimately require.

Appendix 1 - which is presented as a guideline for comparison only - gives typical torque values specified
for the most commonly encountered fasteners.

Torque sequence may vary from plant to plant and even within individual plants, depending upon the
gasket material, etc. Always abide by local procedures.

Next, find the pressure-torque conversion table applicable to the tool which you intend to use. A complete
copy of that chart appears in Appendix II.

An example of finding the desired torque required is as follows:

Assume you are going to use a HY-3MXT to torque a 1-1/4" bolt to 1,265 ft Ibs.

Start by going to the Torque/pressure conversion chart and read left-to-right across the top line (Starts
out PSI HY-MXT HY-MXT etc) To the column HY-MXT.

Read straight down to the number closest to 1,265 ft Ibs, which in this case is 1,280 - about 1.5% over the
targeted torque value.

Now, using 1,280, read back to the left on that same line and read the pump pressure, under the PSI
column, 4,000 PSI.

To be technically correct, you should diminish that 4,000 PSI by 1.5% (to 3940), but 1,280 is well
within the tool's +/- 3 % accuracy range, so proceed to set 4,000 PSI on your pump's regulator valve.
HYTORC Agence centre-est, 22 bis avenue de Collongue , 69130 ECULLY , France
Tel : 04.78.33.39.19 Fax : 04.78.33.50.35 e-mail:[email protected]
Web site: www.hytorc-ce.com

3-6
Setting the Pressure on the Pump
To set the pressure on the pump, follow this procedure:

1. Loosen the knurled locking ring below the "T" handle on the pump's external pressure regulator. Then
turn the "T" handle (shown in figure 6) counter clockwise (CCW) until it turns freely and easily.

2. Turn the pump "on". Using the pump's remote control pendant, push down the advance switch (or button
on air pumps) and hold it.

3. While holding the pump in the advance mode, slowly turn the "T" handle clockwise and observe the pump
pressure gauge rise.

NOTE: Always adjust the regulator pressure up - never down.

4. When your gauge reaches 4,000 PSI, stop turning the "T" handle and let the gauge settle out.

5. If the pressure continues to rise (above 4,000), release the advance button and back off your pressure slightly
- by turning CCW on the "T" handle. Then re-depress the advance switch on your remote and slowly bring
pressure up to 4,000 again.

6. When the pressure is correct, turn the pump "off" and tighten the knurled lock nut provided under the "T handle.
This sets pump pressure, which determines torque tool output.

7. Once your target pressure is set and locked, cycle the pump once more to ensure that your pressure setting did not
change as you turned down the knurled knob.

Example of a Pressure Regulator Valve

3-7
Applying the Torque Machine - the Tightening Process
1.Having set your target pressure, cycle the tool three or four times to full pressure. Cycling the tool ensures
that the system is operating properly and removes trapped air, if any.

2. Place the proper size impact socket on the square di4ve and secure properly with a locking ring and pin.

3. Place the tool and the socket on the nut, making sure that the socket has fully engaged the nut. Further ensure that
the drive retainer is engaged.

4. Make sure the reaction arm is firmly abutted against a stationary object (i.e. an adjacent nut, flange, equipment
housing etc.)
HYTORC Agence centre-est, 22 bis avenue de Collongue , 69130 ECULLY , France
Tel : 04.78.33.39.19 Fax : 04.78.33.50.35 e-mail:[email protected]
Web site: www.hytorc-ce.com

5. When positioning the wrench, make sure that the hose connections are well clear of any obstructions, and that, all
body parts are safely out of harm 's way.

6. THEN, AND ONLY THEN, apply momentary pressure to the system to ensure proper tool placement. If it
doesn't look or act right, stop and re-adjust the reaction arm
3-8
Operating the Torque Machine
1.By pushing down on the remote control button in the advance position, the rear of the tool will be
pushed back until its reaction arm will contact its reaction point.

2.Continue to hold down the button as the socket turns until you hear an audible "click" which will
signify the hydraulic cylinder inside the tool is fully extended and will not turn the socket further.

3.Continuing to hold down the remote control button will result in a rapid buildup of pressure to the
point of where the gauge reads what was preset prior to applying the wrench.

IMPORTANT. The reading of full preset pressure after the cylinder is extended DOES NOT
INDICATE that this pressure (torque) is applied to the bolt. It only indicates that the cylinder is
fully extended and cannot turn the socket further until the tool automatically resets itself.

Releasing the remote control button will retract the cylinder. The tool will automatically reset itself and the
operator will hear an audible "click" indicating he can again push the remote control button and the socket
will turn. Each time the cylinder is extended and retracted, it is called a cycle. Successive cycles are made
until the tool "stalls" at the pre-set Torque/PSI with an accuracy of +/- 3%. Repeatability is +/- 1%.

IMPORTANT. ALWAYS ATTEMPT ONE FINAL CYCLE TO INSURE THE "STALL" POINT
HAS BEEN REACHED.

Should the tool "lock-on" after the final cycle, push down on the remote control button once more (to
build pressure) and, while maintaining this pressure, pull back on the accuracy assurance pawl lever.
Releasing the remote control while continuing to hold back the on the accuracy assurance pawl lever will
allow the tool to be removed easily.

3-9
Loosening Procedures
First, set the pump to 10,000 PSI. Change the drive and the reaction arm to the loosening mode, assuring the
reaction arm abuts squarely off a solid reaction point. Press and hold the remote control button down. Pressure
will decrease as the socket begins to turn. As the cylinder extends fully, you will hear an audible "click".
Release the remote control button, and the cylinder automatically retracts, at which time you again hear the
audible "click". Repeat this process until the fastener can be removed by hand.

NOTE: IF THE BOLT DOES NOT LOOSEN WITH THE ABOVE PROCEDURE, IT IS AN
INDICATION THAT YOU REQUIRE THE NEXT LARGER SIZE TOOL TO LOOSEN THE BOLT.
HYTORC Agence centre-est, 22 bis avenue de Collongue , 69130 ECULLY , France
Tel : 04.78.33.39.19 Fax : 04.78.33.50.35 e-mail:[email protected]
Web site: www.hytorc-ce.com

Section 5 HYTORC POWER PACKS

4-1
General Information
All HYTORC Power Packs operate at a pressure range from 500 to 10,000 PSI and are fully adjustable.
They have been en engineered and designed for portability and high flow for increased speed. Before using your
HYTORC power pack, check the following points:

· is the reservoir filled with oil?

· Where is the closest electrical outlet at the job site?

· Is there enough air pressure (1 00 PSI) and flow at the job site? (Air units only)

· Is the gauge mounted and rated for 10,000 PSI?

. Is the oil filler plug securely in place?

4-2
Working Pressure
The Pump's maximum working pressure is 10,000 PSI(700 kg/e ). Make sure all hydraulic equipment and
accessories are rated for 10,000 PSI operating pressure.

4-3
Hydraulic Connections
Never disconnect or connect hydraulic hoses or fittings without first unloading the wrench. Unplug the electrical cord of
the pump, and open all hydraulic controls several times to assure that the system has been depressurized. If the system
includes a gauge, double cheek the gauge to assure pressure has been released.

When making a connection with quick disconnect couplings, make sure the couplings are fully engaged.
Threaded connections such as fittings, gauges etc. must be clean and securely tightened and leak free.

CAUTION: Loose or improperly threaded couplers can be potentially dangerous if pressurized, however, severe
over tightening can cause premature thread failure. Fittings need to be only tightened secure and leak free. Never
grab, touch or in any way come in contact with a hydraulic pressure leak. Escaping oil can penetrate the skin and
cause injury.

Do not subject the hose to potential hazard such as sharp surfaces, extreme heat or heavy
impact. Do not allow the hose to kink and twist. Inspect the hose for wear before it is used.
HYTORC Agence centre-est, 22 bis avenue de Collongue , 69130 ECULLY , France
Tel : 04.78.33.39.19 Fax : 04.78.33.50.35 e-mail:[email protected]
Web site: www.hytorc-ce.com

4-4
Electrical Power
1. CHECK FOR PROPER ELECTRICAL SUPPLY BEFORE CONNECTING.

2. THIS MOTOR MAY SPARK. DO NOT OPERATE IN AN EXPLOSIVE ATMOSPHERE OR IN

PRESENCE OF CONDUCTIVE LIQUIDS.
a. Do not use a power or extension cord that is damaged or has exposed wiring.

b. All single phase motors come equipped with a three prong grounding type plug to fit the proper
grounded type electrical outlet. Do not use a two prong ungrounded extension cord as the pump's motor must
be grounded.

3. Compare motor nameplate against power availability to prevent motor burnout or dangerous electrical
overloading.

4-5
Prior to Use
Check hydraulic oil level to prevent possible pump burnout. Open the filler plug located on the reservoir plate. Look at
oil fill level on the oil sight gauge. The oil level should be approximately 2" from the top of the reservoir plate- with
motor off. Add HYTORC oil as necessary. Do not mix different grades of oil.

Make sure all desired gauge, valve, hose and quick coupler connections are tight and secure before operating.

The use of a pressure gauge is required for normal pump operation. Mounted on the manifold, the gauge permits the
operator to monitor the load on the wrench. 1/40/o calibrated gauges are available for most applications.

4-6
Operation
Before starting your Electric Pump (HYTORC 115/230), connect your hydraulic hoses to both the pump and torque
wrench.

Place the toggle switch in the ON position and the rocker switch on the hand control pendant in the OFF position. To start
the pump, depress and release the yellow safety button.

NOTE: The safety button is an added feature designed to prevent premature starting and should only he depressed
by the tool operator.

Push the rocker switch to advance and release. This will start your pump and place it in the retract position.

NOTE: Read the section labeled HYTORC OPERATIONS and SETTING TORQUE prior to installing the torque
wrench onto the application.

Your HYTORC 115/230 hydraulic pump has been designed with an auto shut off system. The pump will shut off after
approximately 30 seconds of non-cycling. This will prevent overheating and unnecessary wear which will prolong the life
of your pump. To restart the pump, the yellow safety button must again be depressed prior to use.
HYTORC Agence centre-est, 22 bis avenue de Collongue , 69130 ECULLY , France
Tel : 04.78.33.39.19 Fax : 04.78.33.50.35 e-mail:[email protected]
Web site: www.hytorc-ce.com

Section 5 - PREVENTIVE MAINTENANCE

5-1
Preventive Maintenance -
Torque Machines
Tool failure, although rare, does occur. Such failure is most often in the hydraulic couplers or hoses. These items are
repairable or replaceable immediately, since they are available universally. Failure of structural members of the tool are
quite rare, but replacement parts are available from stock. All repairs to HYTORC tools may be made by reasonably
experienced individuals according to the aforementioned instructions.

·Lubrication

All moving parts should periodically be coated with a good quality NLGI #2 molybdenum disulfide grease. Under harsh
environmental conditions, cleaning and lubricating should be performed more frequently.

·Hydraulic Hoses

Hoses should be checked for cracks and leaks after each job. Hydraulic fittings can become plugged
with dirt and should be flushed periodically.

·Quick-Connects

Fittings should be kept clean and not allowed to be dragged along the ground or floor, as even small particles of dirt can
cause the internal valves to malfunction.

·Springs

Springs are used for the drive pawl assembly and for the accuracy assurance pawl. These springs can be replaced if
necessary.

·Cylinder Seals

If the cylinder requires disassembly, it is recommended that the cylinder seals be replaced at the same time. Seal kits are
readily available.

·Structural Members

All structural parts on the tool should be inspected once a year to determine if there are any cracks, chips or deformities.
If so, immediate replacement is required.
HYTORC Agence centre-est, 22 bis avenue de Collongue , 69130 ECULLY , France
Tel : 04.78.33.39.19 Fax : 04.78.33.50.35 e-mail:[email protected]
Web site: www.hytorc-ce.com

5-2
Preventive Maintenance -
Hydraulic Power Packs
HYTORC Hydraulic Power Packs are precision-built units and, as such, do require a certain amount of care and
maintenance.

· Hydraulic Oil

Oil should be completely changed after every 40 hours of operation, or at least twice a year. Always make sure the
reservoir is filled with fluid. If additional oil is required, use only high-grade hydraulic oil.

· Quick-Disconnects

Fittings should be checked periodically for leaks. Dirt or foreign materials should be kept away from fittings. Clean
before use.

· Hydraulic Gauge

Some gauges are liquid filled. Should this liquid level drop, it indicates external leakage, and replacement is necessary.
Should the gauge fill with hydraulic oil, it indicates internal failure and it should be discarded.

· Filter on Pump

The filter should be replaced twice a year in normal use and more often if the pump is used daily or in a dirty, harsh
environment.

· Remote Control

(Air Unit) The air line to the remote control unit should be checked for obstructions or kinks in the line periodically. If
there is a bend or break in the line, it must be replaced. The spi4ng-loaded buttons on the remote handle should be
checked in the event of operating difficulties. (Electric Unit) The rocker switch should be checked periodically if any
indication of problems exist.

· Air Valve

This valve should be checked twice a year.

· Brushes and Brush Holders

(Electric Unit) Check and replace, if worn.

· Armature

(Electric Unit) Check yearly.

HYTORC Agence centre-est, 22 bis avenue de Collongue , 69130 ECULLY , France
Tel : 04.78.33.39.19 Fax : 04.78.33.50.35 e-mail:[email protected]
Web site: www.hytorc-ce.com

Section 6 Troubleshooting
Symptom Probable cause Required action
Gauge shows pressure build-up b 1/Couplings loose or inoperative 1/Tighten and/or replace couplings. Use test#1 listed below to
the tool will not cycle. 2/ Solenoid inoperative isolate problem.
2/ Check using test #2 below. If solenoid is bad, replace.
Cylinder will not retract 1/ See above 1/ See above
2/Voltage to electric pump is too low t 2/Get shorter extension cord or upgrade to 12 AWG, 25 amp
line drop or inadequate amperage is rating or better. If shop power is adequate , draw power from
available welding machine or cal rod transformer.
3/ Linkage between piston rod and driv3/ Replace parts as necessary.
arms are broken.
Cylinder pressure will not build. 1/ Oil blow by in tool (piston seal leak 1/ Replace defective parts . Shop job
blown O-ring, cracked piston) 2/ Check to see if subplate is worn by;
2/ Pump problem a/ Remove screws from pump motor to reservoir, slide pump
motor to the side, turn pump on and while holding down on the
button, put your finger in the dump tube (round tube under the
directional control valve) – if you feel pressure, then replace the
subplate and shear seals.
2a/Check to see if you have leaks from the external relief valve
the 2 oil line connections (bottom of relief valve and connection
pump body – other end of oil line. If leaking, retighten with
9/16” open end wrench . shop job
2b/If pumps sounds like a lot of pebbles in a tin can, the
problem may be a worn motor coupling – if worn replace .
shop job
2c/AIR PUMPS- Faulty air valve due to excessive moisture and
dirt in air supply. Disassemble air valve and wipe any residue fr
air valve piston- spray brake cleaner into air valve body, dry
thoroughly . Disassemble all small air lines and blow out with
compressed air. Lubricate both air valve piston and body with
hydraulic oil (sparingly) and reassemble. Shop job
2d/ Air pumps- faulty remote control valve cartridge. replace
Cylinder/ tool leaks 1/Safety relief valve on swivel has 1a/ tighten all hose and couplers. If leaks continues, adjust
lifted safety settings –Test #4
1b/ Check to see if the system is properly plumbed by running
test #5 (high pressure on retract side will lift the safety relief
valve)
2/Blown O-ring in cylinder 2/ Replace O-ring with proper high pressure O-ring. Shop job
3/ Defective gland seal 3/ Replace gland seal. Shop job

Tool operates backwards 1/ Couplings reverse 1/ Run test #5. Replumb system as necessary
2/ Multiple hoses in even numbers 2/ As plumbed, HYTORC hoses may only be joined together in
numbers. ONLY if it is necessary to use 2,4,6 hoses- make an
adapter from spare high pressure couplings and nipples
Ratchet return with retract stroke 1/ Broken or otherwise inoperable 1/Replace reaction pawl and/or spring. Shop –job.
reaction pawl
Ratchet will not take successive 1/Broken or otherwise inoperative 1/Replace drive pawl and/or spring – shop job
strokes drive pawl or spring
2/Cylinder not retracting completely 2/Remove tool from nut and cycle freely for several strokes
If problem persists, check pawls
2a/Operator not allowing adequate time for cylinder to retract
fully
3/Linkage between piston rod and 3/Replace parts as necessary . shop job
drive pawl is broken

Gauge records no pressure 1/ Gauge connection is loose 1/ Tighten coupling

2/ Bad gauge 2/ Replace gauge
3/ Pump will not build pressure 3/ See cylinder will not build pressure above
4/Tool seals are blown 4/ Replace defective seals. Shop Job
HYTORC Agence centre-est, 22 bis avenue de Collongue , 69130 ECULLY , France
Tel : 04.78.33.39.19 Fax : 04.78.33.50.35 e-mail:[email protected]
Web site: www.hytorc-ce.com

Symptom Probable cause Required action

Tool locks onto nut 1/Reaction pawl is loaded when the 1/Press advance button on remote and build pressure- continue
tool is max'd out in torque to press down on remote
while pulling back on one of the accuracy assurance levers-
release remote while
continuing to hold back on levers.
2/ Tool is operating backwards 2/Push advance button down-tool should immediately fall free-
run test #5
3/ Tool is wedged under a fixed object 3/Remove shroud from around ratchet. Using any tool available
the drive pawl out of the ratchet and at the same time pull back
on the accuracy assurance levers.
Tool should swing free or burn away the socket or obstruction.
Pump will not build pressure 1/ Air or electric supply is low 1/ Check air pressure or voltage
2/Defective relief or regular valve 2/ Replace valve . Shop job
3/ Low oil or clogged filter 3/Fill reservoir and clean filter
4/ internal leak in oil line from 4/ Open reservoir ,inspect oil line while trying to build pressure
external relief valve to pump body. leaking tighten fittings or replace
Motor sluggish or inefficient 1/ Air or electric supply is low 1/ See #1 in preceding block
"Sound sick" slow to build pressu 2/ Clogged filter 2/ Clean or replace filter
Pump heats up 1/ Improper use 1/Operator is continuing to hold down on the
advance stroke after the cylinder has reached
end of stroke; this causes a lot of oil to go
through a very small hole in relief- valve-
causing heat build- up. Have operator release advance stroke
after accuracy assurance levers spring forward.
2/ Remote control is left in "on" 2/Turn pump off whenever not actually being used. Do not
position when pump is not actively leave pump running when tool is not in use.
in use.
Hose or tool fitting is damaged or 1/ Broken or melted plastic outer 1/If underlying Kevlar or steel is still intact continue operation
leaks covering .Inspect frequently.
2/Frayed Kevlar or steel strands 2/Cut hose in half and discard. Replace hose
3/Oil leaks through fibers 3/ Cut hose in half and discard. Replace hose
4/Broken fittings 4/ Remove old fitting and replace with steel high pressure
fittings only. After changing fittings, always run test #5 to
insure proper plumbing.

Electric pump will not run 1/ Loose electric connections in contro 1/Open control box and visually inspect for loose threaded or
box push-on connectors. Reconnect loose wires. If in doubt check
wiring diagram.
DANGER: Box contains high voltage- always unplug prior to
touching in control box.
2/Bad brushes 2/Change brushes. Shop job
3/ Motor burned up 3/ Replace motor or components whichever is necessary.
HYTORC Agence centre-est, 22 bis avenue de Collongue , 69130 ECULLY , France
Tel : 04.78.33.39.19 Fax : 04.78.33.50.35 e-mail:[email protected]
Web site: www.hytorc-ce.com

TEST #1
Attach hoses to pump and tool in the normal manner. Press the advance button and hold it down. If the
pump pressure, builds and the hoses "flex" but the tool still refuses to cycle, the problem is most likely a
loose or defective coupling connection. To find out where the bad coupling is, remove the tool from the
hoses and many the loose ends together and cycle the pump. If the gauge pressure reads no more than
500 PSI, then the bad fitting is on the tool. A significantly greater. pressure indicates that the Problem
is in either the pump or a hose fitting.

TEST #2
Place a welding rod or thin screwdi4ver in the opening of either side of the solenoid. Press and then
release the advance button. Repeat this process on the opposite side of the solenoid. You should feel
the solenoids moving back and forth. If either side is "dead " the solenoid is bad and needs to be
replaced. Note: if in an urgent situation, the tool may be cycled "manually by pushing the solenoids
back and forth through these access holes.

TEST #3
Remove tool from hoses. Cycle pump. If pump fails to build pressure, the problem is with the pump.
If it does build pressure, the problem is with hydraulic blow-by in the tool.

TEST #4
Connect tool, pump and hoses together normally and turn pump "on". As oil leaks from the small
port. under the uniswivel, use a proper size Allen wrench and slowly tighten (clockwise) the set
screw positioned between the couplings on the uni-swivel. Continue to tighten until the flow stops
plus a quarter rum.

TEST #5
THIS TEST SHOULD BE RUN PRIOR TO EVERY USE OF A HYTORC TOOL
Connect the tool, pump and hoses together as normal. Cycle the pump several times. Cycle the system once
more and observe the sequence of operation. As you depress the advance button, the tool drive shroud urn
about 24 degrees and you should hear an audible "click". on square drive tools, you will also notice that the
accuracy assurance levers will move to the rear of the tool and spring forward. At this point, release the
advance button .You should see no further movement and after a moment you will hear another audible "
click". This is how the tools are designed to operate. If you observe any other sequence of operation, the
system is out of order and cannot deliver more than 100/o of its designed capacity. Take immediate corrective
action. For reference, tools and pumps are designed from the factory plumbed as follows. This ensures that the
tool, pump and ONE hose cannot possible be connected up incorrectly.

Tool : Advance Side – Male / Retract Side Female

Hose: Advance Side - Female to Female / Retract, Side- Male to Male

Pump : Advance Side – Male / Retract Side - Female

Note that connecting two (or any EVEN number) of hoses together creates "one" hose which is plumbed
backwards! Male to Female and Female to Male. This will cause the system to operate backwards per Test #5 above, If
you hose isn't long enough, connect 3 hoses together, move your pump or call HYTORC for a longer hose assembly.
HYTORC Agence centre-est, 22 bis avenue de Collongue , 69130 ECULLY , France
Tel : 04.78.33.39.19 Fax : 04.78.33.50.35 e-mail:[email protected]
Web site: www.hytorc-ce.com

Section 7 DISASSEMBLY
1. Make sure the tool is fully retracted.

2. Remove the reaction arm.

3. Remove shroud (#31) by removing the two buttonhead cap screws at the base of the housing.
Unhook the spring. Or, if equipped with four screws, remove the remaining two screws.

4. Remove square drive (#5) by pressing center button of drive retainer (#11) while pulling square drive
out of tool. NOTE: If you have an "A' series tool (square drive is square the entire length of drive),
you must first remove the retaining rings on the outside edge of both drive sleeves (#8) and tap the
square drive through the tool.

5. Remove the 2 square drive sleeves (#8). To remove drive sleeve, line up a round punch with
groove in sleeve from the opposite side and tap punch with hammer, or if equipped, remove
retaining rings on outside of edge of drive sleeve and slide drive sleeves out.

6. Carefully remove serial plates (NOTE: save serial plates as they must be glued back when tool is
assembled) to uncover housing access holes.

7.Line up rod pin (#19) with access holes in housing and punch rod pin through housing (NOTE: Some
models may have a set screw at the end of the connector rod (#17'). This must be removed prior to
removing the rod pin. This set screw is no longer required and may be discarded.)

8. Remove ratchet (#6), 2 drive plates (#4), and drive pawl assembly (#63)

9.Remove screw from each lever (#15), and pull levers out of housing.

10. Remove the accuracy assurance pawl (#10) along with the accuracy assurance
pawl spring (#18).

11.Remove the end cap using the proper size of hex stock (#26-E) ; Or remove the 8 end
cap bolts (#34) and tighten both jacking screws to remove the end cap (#26)

12.Remove the piston rod assembly which consists of parts (17,24,25,29) by tapping
connector rod (#17) with a punch and a hammer through the cylinder.

13. To change the seals, refer to the diagram below.

Note: For assembly, follow the instructions in reverse. Be sure to properly lubricate all components
prior to use.
HYTORC Agence centre-est, 22 bis avenue de Collongue , 69130 ECULLY , France
Tel : 04.78.33.39.19 Fax : 04.78.33.50.35 e-mail:[email protected]
Web site: www.hytorc-ce.com
HYTORC Agence centre-est, 22 bis avenue de Collongue , 69130 ECULLY , France
Tel : 04.78.33.39.19 Fax : 04.78.33.50.35 e-mail:[email protected]
Web site: www.hytorc-ce.com

APPENDIX
XLT TOOL SCHEMATIC
HYTORC Agence centre-est, 22 bis avenue de Collongue , 69130 ECULLY , France
Tel : 04.78.33.39.19 Fax : 04.78.33.50.35 e-mail:[email protected]
Web site: www.hytorc-ce.com

APPENDIX XLT TOOL PARTS LIST

# DESCRIPTION HY 10 XLT
1* Housing complete XLT-10-01
3 Reaction arm XLT-10-03
4 Drive plate universal XLT-10-04
5 Square drive square through XLT-10-05-A
5 Square drive spline XLT-10-05-1
6 Ratchet square XLT-10-06-A
6 Ratchet spline XLT-10-06-1
7 Drive bushing for steel sleeve XLT-10-07-0
7 Drive bushing for B/A sleeve XLT-10-07-1
8 Drive sleeve rond steel XLT-10-08-0
8 Drive sleeve square BR/alu XLT-10-08-A
8 Drive steel spline BR/ALU XLT-10-08-1
10 Reaction pawl XLT-10-10
11 Drive retainer XLT-10-11
13 Drive plate roll pin XLT-10-12
15 Lever XLT-10-15
17 Piston connector rod XLT-10-17
18 Reaction pawl spring XLT-10-18
19 Rod pin XLT-10-19
20 Drive sleeve O-ring XLT-10-20
24 Piston sleeve XLT-10-24
25 Piston with sleeve XLT-10-25
26 End cap with screws XLT-10-26
26 End cap used with E style housing only None
27 Spring drive pawl (2) XLT-10-27
28 Reaction arm clamp XLT-10-28
29 Piston rod XLT-10-29
30 Retaining ring XLT-10-30
31-0 Shroud ,4 screws type XLT-10-31-0
31-1 Shroud, spring type XLT-10-31-1
32 Screw, shroud XLT-10-32
33 Spring secondary drive pawl XLT-10-33
34 Screws ,End cap XLT-10-34
37 Screws, RA clamp XLT-10-37
38 Spring, RA clamp XLT-10-38
39 Lever screws XLT-10-39
40 Roll pin ,primary DP / reaction pawl XLT-10-42
41 Roll pin secondary DP XLT-10-41
42 Roll pin , reaction pawl XLT-10-42
43 Reaction arm boots with screws XLT-10-43
44 Boot screws XLT-10-43
45 Screws, End cap jacking XLT-10-45
58 Screws, shroud spring XLT-10-58
59 Shroud spring XLT-10-59
** Piston rod assembly XLT-10-61
** Seal kit universal XLT-10-62
#,++63 Drive pawl assembly kit XLT-10-63
#,64 Roll pin Kit (all roll pins) XLT-10-64
65 Reaction arm crane None
#00 Uniswivel assembly XLT-003
#00 Uniswivel seal Kit XLT-001-00

*E series housing includes 01-E, 07-1, 26-E and 31-1 ++ Drive pawl assembly kit includes 10, 17 and 19
# Available only as an assembly ** Piston rod assembly includes 24 ,25 and 29
HYTORC Agence centre-est, 22 bis avenue de Collongue , 69130 ECULLY , France
Tel : 04.78.33.39.19 Fax : 04.78.33.50.35 e-mail:[email protected]
Web site: www.hytorc-ce.com

APPENDIX Dimensional data

HYTORC HY 10 XLT
Min. Nm 1449
Max. Nm 14498
Accuracy +/- 3 %
Housing TITAL 399
Uni-swivel Standard
Reaction arm TITAL 399, vertical,360 Degree, torsion absorbing
Weight 11 Kgs

HYTORC L1 L2 H1 H2 H3 H4 R1 R2 SQ
HY 10 XLT 223,5 352,81 100,08 142,49 182,88 228,60 49,53 195,33 1”1/2

Dimensions in Millimeters.
HYTORC Agence centre-est, 22 bis avenue de Collongue , 69130 ECULLY , France
Tel : 04.78.33.39.19 Fax : 04.78.33.50.35 e-mail:[email protected]
Web site: www.hytorc-ce.com

APPENDIX MXT TOOL PARTS LIST

# DESCRIPTION HY-10 MXT

1 Housing Assembly MXT-10-01

3 Reaction Arm Assembly MXT-10-03
4 Drive Plate Universal XLT-10-04
5 Square Drive Spline XLT-10-05-1
6 Ratchet Spline XLT-10-06-1
7 Drive Bushing XLT-10-07-1
8 Drive Sleeve Spline XLT-10-08-1
10 Reaction Paw XLT-10-10
11 Drive Retainer Assembly XLT-10-11
13 Drive Plate Roll Pin XLT-10-13
15 Left & Right Button Assembly MXT-10-15
15L Button Lever Assembly MXT-10-15L
15R Button Lever Assembly MXT-10-15R
18 Reaction Pawl Spring MXT-10-18
19 Rod End Pin XLT-10-19
26 End Cap MXT-10-26
27 Drive Pawl Spring XLT-10-27
28 Reaction Arm Lever MXT-10-28
30 Drive Sleeve Retainer Ring XLT-10-30
31 Shroud MXT-10-31
32 Shroud Screw XLT-10-32
33 Drive Pawl Spring Secondary XLT-10-33
34 Reaction Arm Thrust Plate MXT-10-367
37 Thrust Plate Screws MXT-10-503
38 Reaction Arm Lever Spring MXT-10-508
40 Roll Pin Drive Pawl Primary XLT-10-40
41 Roll Pin Drive Pawl Secondary XLT-10-41
42 Roll Pin Reaction Pawl XLT-10-42
43 Reaction Arm Boot XLT-10-43
44 Boot Screws XLT-10-44
45 Pin Reaction Arm Lever MXT-10-509
46L MXT Serial Plate Left MXT-10-46L
46R MXT Serial Plate Right MXT-10-46R
48 Access Plug MXT-10-02
58 Screw, Shroud Spring XLT-10-58
59 Shroud Spring XLT-10-59
61 Piston Rod Assembly XLT-10-61
62 Seal Kit MXT-10-62
63 Drive Pawl Assembly ffit XLT-10-63
00 Uniswivel Assembly MXT-0010
00 Uniswivel Seal Kit MXT-0010-00
HYTORC Agence centre-est, 22 bis avenue de Collongue , 69130 ECULLY , France
Tel : 04.78.33.39.19 Fax : 04.78.33.50.35 e-mail:[email protected]
Web site: www.hytorc-ce.com

APPENDIX MXT Dimensional data

HYTORC HY 10 MXT
Min. Nm 1560
Max. Nm 15 620
Accuracy +/- 3 %
Housing TITAL 399
Uni-swivel Standard
Reaction arm TITAL 399, vertical,360 Degree, torsion absorbing
Weight 13,4 Kgs

HYTORC L1 L2 L3 L4 H1 H2 H3 R1 R2 Square
HY 10 MXT 239 355,6 55 215 100 148,8 199 49,5 195 1”1/2

Dimensions in millimeters
HYTORC Agence centre-est, 22 bis avenue de Collongue , 69130 ECULLY , France
Tel : 04.78.33.39.19 Fax : 04.78.33.50.35 e-mail:[email protected]
Web site: www.hytorc-ce.com

APPENDIX XLCT Dimensional data

Dimensions in millimeters

Radius for the 95 mm ratchet link is 75,69 mm.

HYTORC Agence centre-est, 22 bis avenue de Collongue , 69130 ECULLY , France
Tel : 04.78.33.39.19 Fax : 04.78.33.50.35 e-mail:[email protected]
Web site: www.hytorc-ce.com

APPENDIX HY 30 XLCT tool parts list

# DESCRIPTION HY 30 XLCT
1 Housing XLCT-30-01
1 Housing “C” series None
2 Cylinder end cap XLCT-30-02
3 Piston XLCT-30-03
4 Piston rod XLCT-30-04
5 Rod end XLCT-30-05
3,4,5 Piston rod assembly XLCT-30-06
6,7,8 Seal Kit XLCT-30-13
9 Cylinder end cap screws (8) XLCT-30-07
10 Fixed pin upper XLCT-30-08
11 Fixed pin set screws (2) XLCT-30-09
12 Link pin short XLCT-30-10
12 Link pin long XLCT-30-11
13 Link pin retainer screws XLCT-30-12
14 Uniswivel assembly XLT-003
15 Uniswivel mount screws XLT-00-004
16 Uniswivel seal kit (not shown) XLT-001-00
17 Hex link reaction pad (not shown) XLCT-30-14
HYTORC Agence centre-est, 22 bis avenue de Collongue , 69130 ECULLY , France
Tel : 04.78.33.39.19 Fax : 04.78.33.50.35 e-mail:[email protected]
Web site: www.hytorc-ce.com

# DESCRIPTION HY 30 XLCT
1 Reaction block spacer XLCT-30-45
1 Reaction block spacer extended None
2 Top spacer XLCT-30-46
3 Reaction pawl spring spacer XLCT-30-47
4 Reaction pawl spring XLCT-30-37
5 Side plate roll pin XLCT-30-48
6 Side plate screw bottom XLCT-30-50
7 Side plate screw top XLCT-30-51
8 Side plate (left or right) XLCT-30-52#
9 Drive plate XLCT-30-35#
10 Reaction pawl XLCT-30-36#
11 shroud XLCT-30-43#
12 Shroud screws XLCT-30-44
13 Drive pawl spring XLCT-30-27
14 Drive pawl primary XLCT-30-22
15 Drive pawl secondary XLCT-30-23
16 Hex ratchet XLCT-30-28-HX
17 Drive pin XLCT-30-33
18 Drive pin spring XLCT-30-34
19 Drive spring roll pin XLCT-30-32
20 Link pin short (no pad) XLCT-30-10
20 Link pin long (with pad) XLCT-30-11
24 Spring seat XLCT-30-49

# designate blank size or ratchet size

HYTORC Agence centre-est, 22 bis avenue de Collongue , 69130 ECULLY , France
Tel : 04.78.33.39.19 Fax : 04.78.33.50.35 e-mail:[email protected]
Web site: www.hytorc-ce.com

TABLE DE CONVERSION PRESSION-COUPLE

CLE HYDRAULIQUE HYTORC-HY 10 MXT ou XLT
PRESSION : COUPLE

PSI : BAR : NM

1000........70...................1560
1200 84 1866
1400 98 2172
1600 110 2727
1800 124 2822
2000.......138...................3118
2200 152 3424
2400 165 3731
2600 179 4037
2800 193 4343
3000.......207...................4650
3200 220 4956
3400 234 5262
3600 248 5569
3800 262 5875
4000.......276...................6182
4200 290 6496
4400 303 6811
4600 317 7125
4800 331 7440
5000.......345...................7754
5200 358 8063
5400 372 8372
5600 386 8681
5800 400 8990
6000.......414...................9299
6200 427 9617
6400 441 9934
6600 455 10251
6800 468 10568
7000.......482..................10885
7200 496 11203
7400 510 11520
7600 524 11837
7800 538 12154
8000.......552..................12472
8200 565 12786
8400 579 13101
8600 593 13415
8800 607 13730
9000.......620..................14044
9200 634 14359
9400 648 14673
9600 662 14988
9800 676 15302
10000…………..690…………………………………………..15617

The torque unit is Newton Meter.

HYTORC Agence centre-est, 22 bis avenue de Collongue , 69130 ECULLY , France
Tel : 04.78.33.39.19 Fax : 04.78.33.50.35 e-mail:[email protected]
Web site: www.hytorc-ce.com

TABLE DE CONVERSION PRESSION-COUPLE

CLE HYDRAULIQUE HYTORC-HY 30 XLCT
Utilisation avec cartouche à oeil

PRESSION : COUPLE

PSI : Bar : NM

1000........70...................4311
1200 84 5173
1400 98 5604
1600 110 6897
1800 124 7759
2000.......138...................8622
2200 152 9484
2400 165 10346
2600 179 11208
2800 193 12070
3000.......207..................12932
3200 220 13795
3400 234 14657
3600 248 15519
3800 262 16381
4000.......276..................17243
4200 290 18105
4400 303 18968
4600 317 19830
4800 331 20692
5000.......345..................21554
5200 358 22416
5400 372 23278
5600 386 24140
5800 400 25003
6000.......414..................25865
6200 427 26727
6400 441 27589
6600 455 28451
6800 468 29313
7000.......482..................30176
7200 496 31038
7400 510 31900
7600 524 32762
7800 538 33624
8000.......552..................34486
8200 565 35349
8400 579 36211
8600 593 37073
8800 607 37935
9000.......620..................38797
9200 634 39659
9400 648 40522
9600 662 41384
9800 676 42246
10000......690..................43108

The torque unit is Newton Meter.

Service Manual Safe Work procedure

SAFE WORK PROCEDURE – N°4.03.001

R9350 Assembly procedure

(Standard)

HAZARD PRECAUTIONS
STEP WORK PROCEDURE ILLUSTRATIONS TOOLS CHECK
IDENTIFIED TO BE TAKEN
OFF
1 Follow SWP 0.01

2 Prepared suitable Area too small, Minimum 60x50 Grader

assembly area inaccessible or soft meters.
Area must be level
and compacted well
enough to support
300 tons.
Must be accessible
for semi-trailers and
large crane

Prepared by : Factory : Equipment : SWP Number :

B.Bedo Mgs! R9350 Face Shovel 4.03.001
Inspected by : Title : Date of issue : Validated by the safety site officer :
F. Gresser ASSEMBLY PROCEDURE (Standard) 18/09/2006 Page 1 of 8
Service Manual Safe Work procedure

SAFE WORK PROCEDURE – N°4.03.001

HAZARD PRECAUTIONS
STEP WORK PROCEDURE ILLUSTRATIONS TOOLS CHECK
IDENTIFIED TO BE TAKEN
OFF
3 Locate suitable Personal injury & Must be away from
infrastructure congestion assembly area, but
adjacent.
4 Mobilize equipment Wrong tooling 2 Light vehicle for assembly staff
1 truck crane (lift 1 T at 8 m)
2 crane 60 T
1 man lift with telescopic arm
1 Forklift 6 T
1 hytorc kit & associated tooling
1 large air compressor with 3 outlets
1 stud stretcher
1 ½” & 1 “ impact guns with hoses
electric grinders, sanders, drills, lights,
leads, & misc
1 generator set 240 Volts
5 Manpower 6 persons : 1 supervisor 4 fitter
4 mechanics tool box.
1 electrician 1 electric
+ cranes operator set
Unload component on site Heavy lifts, Coordinate lifts & Cranes
6 according to the Layout moving trucks, traffic. Ensure that Slings
See weight & lifting personal injury correct lifting slings Stands
instruction in the and practices are
“Assembly Manual” used

Prepared by : Factory : Equipment : SWP Number :

B.Bedo Mgs! R9350 Face Shovel 4.03.001
Inspected by : Title : Date of issue : Validated by the safety site officer :
F. Gresser ASSEMBLY PROCEDURE (Standard) 18/09/2006 Page 2 of 8
Service Manual Safe Work procedure

SAFE WORK PROCEDURE – N°4.03.001

HAZARD PRECAUTIONS
STEP WORK PROCEDURE ILLUSTRATIONS TOOLS CHECK
IDENTIFIED TO BE TAKEN
OFF
Undercarriage Rigger to coordinate 4x35 t
7 Position track frames and Heavy lifts, lifts. Use correct shackles
install girder. crushing, working lifting gear & required
(Track frames need to be area congested procedures at all
measured to ensure times. Do not walk
squareness, so the center under suspended
girder will fit) loads.

Undercarriage Cranes
Connect undercarriage Height Rigger to coordinate Slings
hydraulic hoses Weight lifts. Use correct Tools to
Tension track frame bolts Crushing lifting gear & locate
8
procedures at all bolt holes
times. Do not walk
under suspended
loads.
Attachment Pinched fingers, or Make sure end of
9 Position boom on stand crushing cylinder is secure.
Fit boom cylinder Height Keep fingers clear.
Weight Wear safety glass at
Hydraulic pressure all times

Prepared by : Factory : Equipment : SWP Number :

B.Bedo Mgs! R9350 Face Shovel 4.03.001
Inspected by : Title : Date of issue : Validated by the safety site officer :
F. Gresser ASSEMBLY PROCEDURE (Standard) 18/09/2006 Page 3 of 8
Service Manual Safe Work procedure

SAFE WORK PROCEDURE – N°4.03.001

HAZARD PRECAUTIONS
STEP WORK PROCEDURE ILLUSTRATIONS TOOLS CHECK
IDENTIFIED TO BE TAKEN
OFF
Upper carriage Heavy lifts Stand clear Tools to
Lift upper deck and fit on Crushing Use correct lifting align
undercarriage (check the Pinched fingers gear & lifting holes
“S” marks according of Hydraulic pressure techniques Crane s
10 Service Manual instruction Use suitable tools to Lifting
chapter 15) align holes tools N°
Fit stud & tension on slew 1000 -
ring 0910

Tension studs Hydraulic pressure Use correct tools 5617448

11 Weight Tensioning cylinder 5617336
5617448, hydraulic
pump station
5617336

Attachment Pinched fingers, or Make sure end of harness

12 Install boom cylinder crushing cylinder is secure.
pipe work & arch hoses Height Keep fingers clear.
Weight Wear safety glass at
Hydraulic pressure all times

Prepared by : Factory : Equipment : SWP Number :

B.Bedo Mgs! R9350 Face Shovel 4.03.001
Inspected by : Title : Date of issue : Validated by the safety site officer :
F. Gresser ASSEMBLY PROCEDURE (Standard) 18/09/2006 Page 4 of 8
Service Manual Safe Work procedure

SAFE WORK PROCEDURE – N°4.03.001

HAZARD PRECAUTIONS
STEP WORK PROCEDURE ILLUSTRATIONS TOOLS CHECK
IDENTIFIED TO BE TAKEN
OFF
Upper carriage Height Rigger to coordinate photo Rigger
Position Power Pack Weight lifts. Harness
Position fuel tank Heavy lifts Use correct lifting
Fit the boom on the upper gear & procedures at
carriage. (34 t boom with all times.
13 cylinders) Wear harness
Make sure all
Position hydraulic tank attached components
including cylinders
are properly located
& secure
Tension all module Hydraulic pressure Follow hytorc
14 assembly bolts on the hytorc procedure Hytorc
Crushing fingers

Fit cabin side walkway Height Use scaffold Scaffold

15 and handrail on the Cab Weight 2 mechanics are
elevation required

Prepared by : Factory : Equipment : SWP Number :

B.Bedo Mgs! R9350 Face Shovel 4.03.001
Inspected by : Title : Date of issue : Validated by the safety site officer :
F. Gresser ASSEMBLY PROCEDURE (Standard) 18/09/2006 Page 5 of 8
Service Manual Safe Work procedure

SAFE WORK PROCEDURE – N°4.03.001

HAZARD PRECAUTIONS
STEP WORK PROCEDURE ILLUSTRATIONS TOOLS CHECK
IDENTIFIED TO BE TAKEN
OFF
Upper carriage Height Use correct lifting
16 Install cab elevation Weight gear & procedures
Fit cab Crushing Stand clear when
Fit catwalk boxes right moving the load
Fit catwalk boxes left Keep fingers clear
Connect electrics
Connect hydraulics hoses

Basic machine assembly Heavy component Keep personnel Harness

17 Connect rotary connection Pinched fingers clear
hoses Height Keep fingers clear.
Install counterweight & Wear safety glass at
tension bolts all times
Fill hydraulic with oil

Prepared by : Factory : Equipment : SWP Number :

B.Bedo Mgs! R9350 Face Shovel 4.03.001
Inspected by : Title : Date of issue : Validated by the safety site officer :
F. Gresser ASSEMBLY PROCEDURE (Standard) 18/09/2006 Page 6 of 8
Service Manual Safe Work procedure

SAFE WORK PROCEDURE – N°4.03.001

HAZARD PRECAUTIONS
STEP WORK PROCEDURE ILLUSTRATIONS TOOLS CHECK
IDENTIFIED TO BE TAKEN
OFF
Basic machine assembly Personal injury A thorough Use a checklist to ensure all assemblies are Operator
18 Property damage, inspection of all checked. Ensure the operator has read and manual
Bleed hydraulic system height, hydraulic major components understood the operator ‘s manual.
Check electric system pressure & sub-assemblies
Start engine should be completed
prior to any start up
or testing.

Attachment Work in teams as harness

19 Connect boom arch hoses Weight required
Lower attachment to pins Falling object Use safety harness if
boom cylinder required

Attachment Large moving Stand clear of photo Harness

20 Connect stick to boom equipment suspended load. Man lift
Connect hydraulic hoses Weight Use correct lifting
from bucket cylinder Height gear & lifting
Pinched fingers techniques
Keep fingers and
hand clear of bores

Prepared by : Factory : Equipment : SWP Number :

B.Bedo Mgs! R9350 Face Shovel 4.03.001
Inspected by : Title : Date of issue : Validated by the safety site officer :
F. Gresser ASSEMBLY PROCEDURE (Standard) 18/09/2006 Page 7 of 8
Service Manual Safe Work procedure

SAFE WORK PROCEDURE – N°4.03.001

HAZARD PRECAUTIONS
STEP WORK PROCEDURE ILLUSTRATIONS TOOLS CHECK
IDENTIFIED TO BE TAKEN
OFF
Attachment Height Use a small crane to
21 Pin bucket to stick Weight lift & locate pins
Pin bucket cylinder to Heavy component Keep fingers and
bucket hands clear of bores
Wear harness

Machine commissioning Use service manual

22 Electrical commissioning Property damage for all testing Service
Control fire suppression manual

Machine commissioning Engine noise Use service manual Hear

23 Hydraulic commissioning Property damage for all testing and plug
Adjust dampening system Height, hydraulic adjusting procedures
oil projection
Machine commissioning Slippery Be careful
24 Wash machine with hot
water pressure cleaner to
remove paraffin

Prepared by : Factory : Equipment : SWP Number :

B.Bedo Mgs! R9350 Face Shovel 4.03.001
Inspected by : Title : Date of issue : Validated by the safety site officer :
F. Gresser ASSEMBLY PROCEDURE (Standard) 18/09/2006 Page 8 of 8
 R9350 Standard Assembly Plan
This is an example base on 12 h/day, 6 persons it has to be adapted to the site

Task name Duration 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21

Transport component to site X
Machine assembly 21 days Assembly Commissioning

Unload component on site 2 day

Undercarriage 1,66 day

position left track frame 2 hrs
position right track frame 2 hrs
position central part beetween track frame 4 hrs
install track frame bolts 2 hrs
tension track frame bolts 4 hrs
connect undercarriage hydraulic hoses 6 hrs

Attachment 2,5 day

position boom on stand 6 hrs
fit stick cylinders, pins and caps 8 hrs
fit boom cylinders, pins and caps 8 hrs
install pipework & arch hoses 8 hrs

Uppercarriage 8,6 days

rotating deck preparation 4 hrs
Lift rotating deck and fit on undercarriage 4 hrs
Fit stud & tension on slew ring 16 hrs
Position Power pack on uppercarriage 6 hrs
position fuel tank 4 hrs
Fit the boom on the uppercarriage 12 hrs
position cab elevation 4 hrs
position hydraulic tank 4 hrs
tension all module assembly bolts 8 hrs
fit the cab 4 hrs
 Task name Duration 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21
Fit cabin side walkway and handrail 6 hrs
fit Catwalk boxes left 4 hrs
fit Catwalk boxes right 4 hrs
connect electrics 12 hrs
connect hydraulics hoses 12 hrs

Basic machine assembly 3,6 days

connect rotary connection hoses 6 hrs
install counterweight 4 hrs
tension counterweight bolts 4 hrs
fill hydraulic with oil 6 hrs
bleed hydraulic system 4 hrs
check electric system 12 hrs
start engine 8 hrs

Attachment 2,4 days

connect boom arch hoses 6 hrs
Lower attachment to pins boom cylinder 6 hrs
connect stick to boom 6 hrs
connect hydraulic from bucket cylinder 4 hrs
pin bucket to stick 4 hrs
pin bucket cylinder to bucket 3 hrs

Machine commissioning 5 days

Electrical commissioning 2 days
Hydraulic commissioning 2 days
Wash done machine 1 days
MJFCIFSS!GSBODF!TBT Assembly Manual

SITE LAYOUT
60 Meters

50 Meters

Prepared by : Factory : Equipment :

4.01.001
B.Bedo Mgs! R994 B
Inspected by : Title : Date of issue : Validated by the safety site officer :
F. Gresser SITE LAYOUT 21/09/2005 Page 1 of 1
Service Manual Technical Data

2 Component lifting

2.1 Lifting point location

2.1.1 Threads and lugs for lifting purposes

These are indicated with on the assembly drawing.

2.1.2 Lifting instructions

Lift the product only:

- with the provided lifting appliances
- with adequate and approved lifting devices of other kind (cables, chains, carrying straps)
if necessary
- after mounting the lifting appliances in accordance with the regulations
- at the declared threads or lugs shown on the assembly drawing
- always at two points at the same time
- with the best possible equal load distribution
- be sure that the part which is lifted has been already dismounted

Attention!
Do not lift the product with one lifting appliance only!
βmaximal = 45° (see Fig. 1)

Fig. 1

R 994B Litronic LIEBHERR 3.01-8

From Date: 04 / 2003
Service Manual Technical Data

2.2 Uppercarriage
Total weight of the uppercarriage : 109109 kg
For the lifting of the complete uppercarriage without counterweight, you can use the special tool (id.
10000910). The lifting is shown Fig. 2.

Fig. 2

R 994B Litronic LIEBHERR 3.01-9

From Date: 04 / 2003
Service Manual Technical Data

2.2.1 Powerpack

2.2.1.1 Complete powerpack

Weight
Weight: 19 952 kg

Lifting of the powerpack

Fig. 3

For the lifting of the complete powerpack, put shackles in the four lugs (see Fig. 3) of the powerpack.
These lugs are used to lift the complete powerpack. In order to show clearly the lugs, the power pack
on the Fig. 3 is not complete. With an appropriate four halves chain, you can lift the powerpack. Be
very careful of the maximal angle (see the part Component lifting and Fig. 1), and see the part
center of gravity of the powerpack (Fig. 4) before lifting the powerpack.

R 994B Litronic LIEBHERR 3.01-10

From Date: 04 / 2003
Service Manual Technical Data

Center of gravity

Fig. 4

R 994B Litronic LIEBHERR 3.01-11

From Date: 04 / 2003
Service Manual Technical Data

2.2.2 Counterweight

2.2.2.1 Weight
• Weight : 25 320 kg
2.2.2.2 Lifting

Fig. 12

Put two shackles on the top of the counterweight, as show on Fig. 12. With a two halves chain you
can lift the counterweight, and only the counterweight. Be very careful of the maximal angle (see the
part Component lifting and Fig. 1), and see the part center of gravity of the counterweight before lifting
the counterweight.

R 994B Litronic LIEBHERR 3.01-18

From Date: 04 / 2003
Service Manual Technical Data

2.2.2.3 Center of gravity

Fig. 13

R 994B Litronic LIEBHERR 3.01-19

From Date: 04 / 2003
Service Manual Technical Data

2.2.3 Rotating deck

2.2.3.1 Weight
• Weight : dry 27 400 kg
• With rotary connection and control valve console : 37 000 kg
2.2.3.2 Lifting

Fig. 14

With a four halves chain you can lift the rotating deck. Be very careful of the maximal angle (see the
part Component lifting and Fig. 1), and see the part center of gravity of the rotating deck before lifting
the rotating deck.
2.2.3.3 Center of gravity

R 994B Litronic LIEBHERR 3.01-20

From Date: 04 / 2003
Service Manual Technical Data

Fig. 15

R 994B Litronic LIEBHERR 3.01-21

From Date: 04 / 2003
Service Manual Technical Data

2.2.4 Control valve console for excavator till SN 9750

2.2.4.1 Weight
• Total weight : 2 412 kg
2.2.4.2 Lifting

Fig. 16

For the lifting of the control valve console, use the hooks as shown on the Fig. 16 and a two halves
chains. The hooks use for the lifting of the control valve console permit to lift the complete console. Be
very careful of the maximal angle (see the part Component lifting and Fig. 1).

R 994B Litronic LIEBHERR 3.01-22

From Date: 04 / 2003
Service Manual Technical Data

2.2.5 Control valve console for excavator from SN 9776

2.2.5.1 Weight
• Total weight : 3 637 kg
2.2.5.2 Lifting

Fig. 17
For the lifting of the control valve console, use the hooks as shown on the Fig. 17 and a two halves
chains. The hooks use for the lifting of the control valve console permit to lift the complete console. Be
very careful of the maximal angle (see the part Component lifting and Fig. 1).

R 994B Litronic LIEBHERR 3.01-23

From Date: 04 / 2003
Service Manual Technical Data

2.2.6 Tanks

2.2.6.1 Hydraulic tank

Weight
• Weight : 7 870 kg

Lifting

Fig. 18
The four lugs on the upper part of the hydraulic tank (see Fig. 18) permit to lift the complete hydraulic
tank installation. Use a four half chain with lifting shackles at the extremities of the halves to lift the
tank. Be very careful of the maximal angle (see the part Component lifting and Fig. 1) and see the
part center of gravity before lifting the hydraulic tank.

R 994B Litronic LIEBHERR 3.01-24

From Date: 04 / 2003
Service Manual Technical Data

Center of gravity

Fig. 19

R 994B Litronic LIEBHERR 3.01-25

From Date: 04 / 2003
Service Manual Technical Data

2.2.6.3 Fuel tank

Weight
• Weight : 3 700 kg

Lifting

Fig. 21

The four lugs on the upper part of the fuel tank (see Fig. 21) permit to lift the complete fuel tank
installation. Use a four half chain with lifting shackles at the extremities of the halves to lift the tank. Be
very careful of the maximal angle (see the part Component lifting and Fig. 1) and see the part
center of gravity before lifting the fuel tank.

R 994B Litronic LIEBHERR 3.01-28

From Date: 04 / 2003
Service Manual Technical Data

Center of gravity

Fig. 22

R 994B Litronic LIEBHERR 3.01-29

From Date: 04 / 2003
Service Manual Technical Data

2.2.7 Cab elevation

2.2.7.1 Weight
• Weight : 3 300 kg
2.2.7.2 Lifting

Fig. 23

For the lifting, screw lugs in the four spots where the cab has to be fixed (see Fig. 23) and with a four
halves chain you can lift the complete cab elevation. Be very careful of the maximal angle (see the
part Component lifting and Fig. 1).

R 994B Litronic LIEBHERR 3.01-30

From Date: 04 / 2003
Service Manual Technical Data

2.2.7.3 Center of gravity

Fig. 24

R 994B Litronic LIEBHERR 3.01-31

From Date: 04 / 2003
Service Manual Technical Data

2.2.8 Cab

2.2.8.1 Weight
• Weight : 2 800 kg
2.2.8.2 Lifting

Fig. 25

For the lifting of the cab use the four lugs which are on the roof of the cab (Fig. 25). Install shackles in
these lugs, and with a four halves chain you can lift the complete cab. Be very careful of the maximal
angle (see the part Component lifting and Fig. 1).

R 994B Litronic LIEBHERR 3.01-32

From Date: 04 / 2003
Service Manual Technical Data

2.2.11 Catwalk boxes

2.2.11.1 Catwalk box left

Weight
• Weight : 1 900 kg

Lifting

Fig. 28

The two lugs on the upper part of the catwalk box left (see Fig. 28) permit to lift the complete catwalk
box left. Use a two halves chain with lifting shackles at the extremities of the halves to lift the catwalk
box. Be very careful of the maximal angle (see the part Component lifting and Fig. 1) and see the
part center of gravity before lifting the catwalk box left.

R 994B Litronic LIEBHERR 3.01-36

From Date: 04 / 2003
Service Manual Technical Data

Center of gravity

Fig. 29

R 994B Litronic LIEBHERR 3.01-37

From Date: 04 / 2003
Service Manual Technical Data

2.2.11.2 Catwalk box right

Weight
• Weight : 800 kg

Lifting

Fig. 30

The two lugs on the upper part of the catwalk box right (see Fig. 30) permit to lift the complete catwalk
box left. Use a two half chain with lifting shackles at the extremities of the halves to lift the catwalk box.
Be very careful of the maximal angle (see the part Component lifting and Fig. 1) and see the part
center of gravity before lifting the catwalk box right.

R 994B Litronic LIEBHERR 3.01-38

From Date: 04 / 2003
Service Manual Technical Data

Center of gravity

Fig. 31

R 994B Litronic LIEBHERR 3.01-39

From Date: 04 / 2003
Service Manual Technical Data

2.3 Undercarriage
• Total weight : 108 492 kg

2.3.1 Central part

2.3.1.1 Weight
Total weight 25 663 kg
Dry weight 25 340 kg
Rotary connection 133 kg
Rotary connection installation 190 kg
2.3.1.2 Lifting

Fig. 32
For the lifting of the central part, install four shackles in the lugs show on the Fig. 32. Then with a four
halves chain, you can lift the complete central part. Be very careful of the maximal angle (see the
part Component lifting and Fig. 1), and see the part center of gravity of the central part before lifting
the central part.
2.3.1.3 Center of gravity
The center of gravity is situated on the vertical axis that is shown on the Fig. 32.

R 994B Litronic LIEBHERR 3.01-41

From Date: 04 / 2003
Service Manual Technical Data

2.3.2 Side frame

2.3.2.1 Weight
• Weight of the side frame: 12 320 kg
2.3.2.2 Lifting

Fig. 33
The four lugs showed on the Fig. 33 permit to lift the boom. Install shackles in every lugs. Then with a
four halves chain, you can lift the complete boom. Be very careful of the maximal angle (see the part
Component lifting and Fig. 1).

R 994B Litronic LIEBHERR 3.01-42

From Date: 04 / 2003
Service Manual Technical Data

2.3.2.3 Center of gravity

Fig. 34

R 994B Litronic LIEBHERR 3.01-43

From Date: 04 / 2003
Service Manual Technical Data

2.4 Attachment

2.4.1 Weight
Ident. Nr. Type of equipment Weight (kg)

9839536 Complete shovel boom 6,75 m 24 770 (approx.)

9983156 Shovel boom 20 002
9211969 Crowd cylinder 1 470

9829248 Complete gooseneck boom 9,30 m 30 926 (approx.)

9823341 Gooseneck boom 22 130
9211975 Backhoe stick cylinder 2 010

9008935 Complete gooseneck boom 9,30 m 28 823 (approx.)

9007873 Gooseneck boom 21 970
9211975 Backhoe stick cylinder 2 010

9988741 Complete gooseneck boom 9,30 m 31 000 (approx.)

9823341 Gooseneck boom 22 130
9211970 Backhoe stick cylinder 2 010

9839541 Complete crowd 4,20 m 16 773 (approx.)

9983590 Crowd 10 832
9004865 Shovel bucket cylinder 2 014

9820125 Complete stick 4,20 m 18 939 (approx.)

9868640 Backhoe stick 11 244
9211972 Backhoe bucket cylinder 1 470
9958001 Backhoe bucket cylinder 1 470
3
9873264 Backhoe bucket 15,3 m , 3 200 mm 17 280
3
9009628 Backhoe bucket 15,3 m , 3 400 mm 17 073
3
9873255 Backhoe bucket 15,3 m , 3 400 mm, AVT bolts 17 135
3
9006056 Backhoe bucket 17 m , 3 400 mm 17 786
3
9878744 Backhoe bucket 17 m , 3 500 mm 18 337
3
9009643 Backhoe bucket 18 m , 3 400 mm 18 155
3
9839540 Shovel bucket 15,3 m , 4 100 mm 28 432
9806703 Shovel sole 12 557
9877704 Shovel back 13 584
9914724 Shovel bucket cylinder 522
9921042 Shovel bucket cylinder 522
3
9008335 Shovel bucket 17 m , 4 100 mm 29 154
9006064 Shovel sole 13 258
9877704 Shovel back 13 584
9914724 Shovel bucket cylinder 522
9921042 Shovel bucket cylinder 522
3
9010102 Shovel bucket 20,5 m , 4 100 mm 29 816
9010034 Shovel sole 14 012
9877704 Shovel back 13 584
9914724 Shovel bucket cylinder 522
9921042 Shovel bucket cylinder 522

R 994B Litronic LIEBHERR 3.01-50

From Date: 04 / 2003
Service Manual Technical Data

2.4.2 Lifting of the boom

2.4.2.1 Shovel attachment

Fig. 43

The four lugs showed on the Fig. 43 permit to lift the boom. Install shackles in every lugs. Then with a
four halves chain, you can lift the complete boom. Be very careful of the maximal angle (see the part
Component lifting and Fig. 1).
• Center of gravity : Type of shovel boom : 6,75 m, weight 20 002 kg

Fig. 44

R 994B Litronic LIEBHERR 3.01-51

From Date: 04 / 2003
Service Manual Technical Data

2.4.2.2 Backhoe attachment

Fig. 45
The four lugs showed on the Fig. 45 permit to lift the boom. Install shackles in every lugs. Then with a
four halves chain, you can lift the complete boom. Be very careful of the maximal angle (see the part
Component lifting and Fig. 1).
• Center of gravity : Type of gooseneck boom : 9,30 m, weight 24 921 kg

Fig. 46

R 994B Litronic LIEBHERR 3.01-52

From Date: 04 / 2003
Service Manual Technical Data

2.4.3 Lifting of the stick

2.4.3.1 Shovel attachment

Fig. 47

The four lugs showed on the Fig. 47 permit to lift the stick. Install shackles in every lugs. Then with a
four halves chain, you can lift the complete stick. Be very careful of the maximal angle (see the part
Component lifting and Fig. 1).
• Center of gravity : Type of shovel stick : 4,20 m weight : 16 773 kg

Fig. 48

R 994B Litronic LIEBHERR 3.01-53

From Date: 04 / 2003
Service Manual Technical Data

2.4.3.2 Backhoe attachment

Fig. 49
The four lugs showed on the Fig. 49 permit to lift the stick. Install shackles in every lugs. Then with a
four halves chain, you can lift the complete stick. Be very careful of the maximal angle (see the part
Component lifting and Fig. 1).
• Center of gravity : Type of backhoe stick : 4,20 m , weight 18 939 kg

Fig. 50

R 994B Litronic LIEBHERR 3.01-54

From Date: 04 / 2003
Service Manual Technical Data

2.4.4 Lifting of the bucket

2.4.4.1 Shovel attachment

Fig. 51

For the lifting of the shovel back, install shackles in the different holes (see Fig. 51). With a four
halves chain, you can lift the complete shovel back (configuration 1). For the lifting of the complete
shovel solve or the complete shovel bucket, install shackles in the two holes (see Fig. 51), and use a
two halves chain (configuration 2). Be very careful of the maximal angle (see the part Component
lifting and Fig. 1).

R 994B Litronic LIEBHERR 3.01-55

From Date: 04 / 2003
Service Manual Technical Data

3
• Type of bucket : capacity 15,3 m , width 4 100 mm, weight 28 432 kg, ident.: 9839540
Center of gravity:

Fig. 52
G1: center of gravity of the shovel back
G2: center of gravity of the shovel solve
G3: center of gravity of the complete shovel bucket
3
• Type of bucket : capacity 17 m , width 4 100 mm, weight 29 154 kg, ident.: 9008335
Center of gravity:

Fig. 53

G1: center of gravity of the shovel back

G2: center of gravity of the shovel solve
G3: center of gravity of the complete shovel bucket

R 994B Litronic LIEBHERR 3.01-56

From Date: 04 / 2003
Service Manual Technical Data

3
• Type of bucket : capacity 20,5 m , width 4 100 mm, weight 29 816 kg, ident.: 9010102
Center of gravity:

•
Fig. 54

G1: center of gravity of the shovel back

G2: center of gravity of the shovel solve
G3: center of gravity of the complete shovel bucket

R 994B Litronic LIEBHERR 3.01-57

From Date: 04 / 2003
Service Manual Technical Data

2.4.4.2 Backhoe attachment

Fig. 55
For the lifting of the complete backhoe bucket, install shackles in the two holes (see Fig. 55), and use
a two halves chain. You can use too a three halves chain, the third lifting point is a lug (see the upper
round on the left of the Fig. 55). Be very careful of the maximal angle (see the part Component
lifting and Fig. 1).
3
• Type of bucket : capacity 15,3 m , width 3 200 mm, weight 17 280 kg, ident.: 9873264
Center of gravity:

Fig. 56

R 994B Litronic LIEBHERR 3.01-58

From Date: 04 / 2003
Service Manual Technical Data

3
• Type of bucket : capacity 15,3 m , width 3 400 mm, weight 17 073 kg, ident.: 9009628
Center of gravity:

Fig. 57
3
• Type of bucket : capacity 15,3 m , width 3 400 mm, weight 17 135 kg, AVT bolts with ring,
ident.: 9873255
Center of gravity :

Fig. 58
3
• Type of bucket : capacity 17 m , width 3 400 mm, weight 17 786 kg, ident.: 9006056
Center of gravity :

Fig. 59

R 994B Litronic LIEBHERR 3.01-59

From Date: 04 / 2003
Service Manual Technical Data

3
• Type of bucket : capacity 17 m , width 3 500 mm, weight 18 337 kg, ident.: 9878744
Center of gravity :

Fig. 60
3
• Type of bucket : capacity 18 m , width 3 400 mm, weight 18 155 kg, ident.: 9009643
Center of gravity :

Fig. 61

R 994B Litronic LIEBHERR 3.01-60

From Date: 04 / 2003