The boom cylinder is on the bench with the piston nut off, and the job stops because nobody remembers the torque. This book has it: 491 Nm on a 70 mm piston, up to 2060 Nm on a 180 mm one.
This is Liebherr Service Manual ID No. 8502675, Issue July 1997, for the R900, R902, R912, R922, R932 and R942 Litronic. These are the machines built before the C generation. The full set runs to 1343 pages. It covers the engine, splitterbox, hydraulics and Litronic electrics, then swing gear, swing ring, travel gear, track components and tank arrangement.
The sections follow the factory order. Go to Hydraulic System for pressure charts or to Swing Ring for axial play without paging through the engine chapters. The text is in English, and the sheet headers are in German, English and French.
What's Inside This Liebherr R900–R942 Litronic Manual
| System | Pages | Key Topics |
|---|---|---|
| General Information | 2-50 | Safety, Conversion Factors, General Tightening Torques, ISO Tolerances, Repair Welding, Lubricants and Fuels |
| Tools | 51-153 | Special Tools and Testing Devices |
| Technical Data / Maintenance Guidelines | 154-210 | Technical Data, Maintenance and Inspection Schedules, Adjustment Values and Quantities |
| Engine | 211-233 | Deutz BF4L913 (R900) and Liebherr D904 / D914 / D906 / D916 / D924 / D926 Diesel Engine Data, Lubrication, Fuel, Cooling |
| Coupling / Splitterbox | 234-250 | Engine Coupling and Pump Splitterbox |
| Hydraulic System | 251-447 | Function Schematics of the Hydraulic System, Pressure Charts, Checking and Adjusting Pressures |
| Hydraulic Components | 448-707 | LPVD Variable Displacement Double Pumps, Control Valves, Travel Motors, Hydraulic Cylinders and Tightening Torques |
| Electrical System | 708-836 | Electronic Horsepower Control, Testing Device, Electrical Diagrams, Components |
| Swing Gear | 837-881 | Swing Gear and Swing Motor |
| Swing Ring | 882-890 | Swing Ring Clearances, Axial Play and Mounting Torques |
| Travel Gear / Two Speed Gear Box | 891-953 | Travel Gear and Two Speed Gear Box, Travel Gear - Chart, Travel Gear "Trasmital", Travel Gear - Liebherr "FAT", Travel Brake, Slipring Seal |
| Track Components / Axles | 954-1010 | Track Components, Rollers, Axles |
| Special Attachments / Additional Hydraulic Installations | 1011-1279 | Additional Hydraulic Circuits and Electrical Diagrams for Special Attachments, Quick-Change Systems |
| Cab Heater / Air Conditioning System | 1280-1326 | Cab Heater and Air Conditioning, Heater D1LC, Supplementary Heater D5 W, Air Conditioning System "Konvekta" |
| Undercarriage / Uppercarriage Attachments | 1327-1335 | Undercarriage and Uppercarriage Attachments, Combinations, Tooth System, Tooth Installation / Removal, Distributor Block with Dual Shut Off Valve |
| Arrangement of Tanks | 1336-1343 | Hydraulic and Fuel Tank Arrangement |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| R900 engine | Deutz BF4L913, 4 cylinder turbocharged, air cooled, 4085 cm3 | p. 212 |
| Valve clearance, cold (D904 to D916) | intake 0.20 mm, exhaust 0.25 mm | p. 220 |
| Engine oil quantity with filter change (D904 to D916) | 18.5 liters (4 cylinder), 22.5 liters (6 cylinder) | p. 220 |
| Minimum engine oil pressure, oil at 100 C | 1 bar at 800 rpm, 2 bar at 1400 rpm, 3.5 bar at 2000 rpm | p. 221 |
| Coolant antifreeze content | at least 35 percent, not above 60 percent | p. 221 |
| Engines from serial number 4001 | D924T-E A1, D924TI-E A2, D926T-E A1; R942 with D926T-E A1 rated 164 kW | p. 224 |
| R900 Lpvd 64 Double Pump Pressure Cut-Off | 300 +/- 5 bar beginning, 310 +/- 5 bar end | p. 450 |
| Hydraulic cylinder piston and piston nut torque | 491 Nm on 70 mm piston (M36 x 1.5) up to 2060 Nm on 180 mm piston | p. 538 |
| Swing ring max. axial play | 1.4 mm, all models R900 to R942 | p. 885 |
Liebherr R900–R942 Litronic Common Problems This Manual Covers
Excavator will not travel straight
This is usually not the travel motor adjustment, so leave the motors alone at first. Check the servo control circuit, then confirm that regulation begin is exactly the same on both main pumps. Only then adjust the reduced displacement of the motors, with the oil at 50 to 70 C.
Manual Section: Hydraulic Components p. 528Main pumps drop to minimum flow (Qmin)
The electronic horsepower control does this on purpose when the hydraulic tank oil level is too low or the engine coolant has overheated. Check both of those first. If they are fine, follow the Electrical System section and test the control itself with testing device Id. No. 6202698 and a multimeter.
Manual Section: Electrical System p. 812Swing ring binds or is hard to turn
Measure the axial play as the Swing Ring section describes. The maximum is 1.4 mm on every model from R900 to R942. If the bearing binds, replace it even when the play is still under that limit. The same section gives the clearances and mounting torques for refitting.
Manual Section: Swing Ring p. 885Hydraulic cylinder leaking or drifting
Remove the cylinder and strip it down. Replace every seal on the piston and on the piston rod bearing, not just the one that was weeping. Torque the piston and piston nut to the table in Hydraulic Components. The values run from 491 Nm on a 70 mm piston (M36 x 1.5) up to 2060 Nm on a 180 mm piston.
Manual Section: Hydraulic Components p. 534Frequently Asked Questions
My main pumps keep dropping to minimum flow. Is there a fault code list for the Litronic control?
No, this book does not print a numeric fault code list. The electronic horsepower control sends the main pumps to Qmin when the hydraulic tank oil level is too low or the engine coolant has overheated. Check the oil level and the coolant before you start pulling connectors. The Electrical System section then shows how to test the control with testing device Id. No. 6202698 and a multimeter. p. 812
Which engine data applies to my machine?
The R900 runs a Deutz BF4L913. It is a 4 cylinder, turbocharged, air-cooled engine of 4085 cm3. The R902 to R942 use the Liebherr D904T / D904TB and D914T / D914TI (4 cylinder) or the D906T / D916T (6 cylinder). All of these are water cooled with a nominal speed of 2000 rpm. From serial number 4001 the book adds the D924T-E A1, D924TI-E A2 and D926T-E A1. An R942 with the D926T-E A1 is rated at 164 kW. Read your engine plate first, then open that engine's data in the Engine section. p. 220
What are the valve clearances and the oil fill on the D904 to D916?
Set the valves cold to 0.20 mm intake and 0.25 mm exhaust. An oil change with a new filter takes 18.5 liters on the 4 cylinder and 22.5 liters on the 6 cylinder. With the oil at 100 C, the minimum oil pressure is 1 bar at 800 rpm, 2 bar at 1400 rpm and 3.5 bar at 2000 rpm. Keep the coolant antifreeze between 35 and 60 percent. p. 220
Will this manual work for an R900C or R904C?
No. This is the July 1997 issue for the earlier R900 to R942 Litronic machines, built before the C generation. The pressures, wiring diagrams and engine data in it belong to those earlier machines. Do not carry them across to a C model. Get the C-series book for those machines. p. 1
My machine has an extra hydraulic circuit and a quick coupler fitted. Are those covered?
Yes. The Special Attachments / Additional Hydraulic Installations section has the additional hydraulic circuits and their electrical diagrams, plus the quick-change systems. Use it alongside the main Hydraulic System schematics when you trace a line the base machine never had. Having the add-on wiring on paper is a good reason to own the book. p. 1197
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