Fits the Liebherr R 900 C Litronic and R 904 C Litronic crawler excavators, both powered by the D 924 TI E A2 engine. The R900C runs an LPV 150 pump at 88 kW. The R904C gets a DPVO 165 and 99 kW. This is Liebherr order number 10069965, issue 01/2008, in English.
On a 20 t excavator, a guessed torque or pump setting can cost you a head gasket or a pump, plus a day with the crew standing still. This book gives you the factory figures, the test points and the adjustment check lists for both machines.
The main group index covers groups 1 to 18. It starts with general information and runs through the engine, LSC hydraulics, BST electrics, swing, travel, undercarriage, options and the schematic sheets. Find your group in the index, turn to it and start work.
What's Inside This Liebherr R900C, R904C Litronic Manual
| System | Pages | Key Topics |
|---|---|---|
| Service Manual Index | 1-5 | Main Group Index for Groups 1 to 18 |
| General Information | 6-59 | Safety Instructions, Servicing the Machine Safely, Crack Testing, Tightening Torques, Assembly of Pistons and Piston Nuts, Piston Rod Bearings, Preloads and Tightening Torques (DIN 13), Fuel and Lubricants |
| Tools | 60-121 | Special Tools for Maintenance and Repair, Special Tools for the Hydraulic System and Electrical Connectors, Common Tools, Hydraulic Cylinder Mounting Tools, Swing Gear Slotted Nut Wrench, Travel Gear Disc Brake Mounting Device |
| Technical Data and Maintenance Guidelines | 122-151 | Technical Data R 900 C Litronic and R 904 C Litronic, Maintenance and Inspection Chart, Lubrication Charts R900C and R904C |
| Diesel Engine | 152-157 | Technical Data D 924 TI-E, Performance Data, Filling Amounts, Cooling System Values, Tightening Torques on the Diesel Engine, Cylinder Head Torque Schedule |
| Coupling and Splitterbox | 158-163 | Elastic Coupling (Torsion Damper) Job Definition, Design and Function, Removal and Installation of the Coupling |
| Hydraulic System | 164-241 | Adjustment Check Lists R 900 C and R 904 C Litronic, LSC System, Layout of the Hydraulic System, Setting Instructions, Checking and Adjusting the Variable Displacement Pumps, Hydraulic Scheme Basic Excavator |
| Hydraulic Components | 242-449 | Variable Displacement Pumps LPV and DPVO, Fixed Displacement Motor FMF, Variable Displacement Motor FMV, Hydraulic Cylinders, Extension and Retraction Speeds, 1-Way, 2-Way and 4-Way Servo Controls, LSC Control Valve Block, Rotary Connections, TC Valve, Travel Motor Brake Valve |
| Electrical System | 450-610 | Arrangement of Components, Excavator Control BST, Monitoring Display Upwards of V5.5 with Error Code Charts, Control Unit S2, Summary of Error Codes, Faults and Remedies, Electrical Scheme Basic Excavator |
| Swing Gear | 611-630 | Swing Gear SAT, Swing Gear Brake |
| Swing Ring | 631-640 | Ball Swing Ring |
| Travel Gear | 641-660 | Travel Gear Transmission, Travel Gear Brake |
| Track Components | 661-696 | Wear of Track Components, Dismantling and Installing Track Components, Berco Idler, Tensioning Unit, Track Roller, Carrier Roller |
| Options | 697-936 | Load Holding Valves for Hoist Cylinders, Hydraulic Installation Kits AHS 11 and AHS 12 with and Without Tool Control, Hydraulic Schematics for Options, Electric Schematics for Options |
| Cab, Heater and Air Conditioning | 937-994 | Auxiliary Heating with Troubleshooting by Fault Code, Heating and Air-Conditioning System |
| Central Lubrication | 995-1044 | Centralized Lubrication System, Lubrication Pump, Progressive Distributors SX-E and MX-F |
| Schematic Sheets | 1045-1265 | Hydraulic and Electrical Schematic Sheets for the Basic Machine and Options, With Legend Sheets |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| R900C, R904C Litronic | ||
| Engine type | D 924 TI E A2 | p. 124 |
| Engine oil quantity (oil change with filter) | 23 l | p. 124 |
| Max. swing speed | 9,0 rpm | p. 125 |
| Swing gear oil quantity | 5,0 l | p. 125 |
| Operating voltage | 24 V | p. 125 |
| Batteries | 2 x 92 Ah (series connection) | p. 125 |
| Alternator | 28 V / 55 A | p. 125 |
| Starter | 24 V / 5.4 kW | p. 125 |
| Track pad width | 500 / 600 / 750 mm | p. 126 |
| All Models | ||
| Engine output (DIN ISO 9249) | 88 kW (120 HP) (R900C Litronic) / 99 kW (135 PS) (R904C Litronic) | p. 124 |
| Nominal engine speed | 1800 rpm (R900C Litronic) / 2000 min-1 (R904C Litronic) | p. 124 |
| Fuel tank | 300 l (R900C Litronic) / 340 l (R904C Litronic) | p. 124 |
| Max. pump flow | 270 l/min (R900C Litronic) / 330 l/min (R904C Litronic) | p. 124 |
| Max. travel speed (normal / fast) | 2.4 / 5.0 km/h (R900C Litronic) / 2,6 / 5,2 km/h (R904C Litronic) | p. 125 |
| Digging / breakout force | 100.6 / 125.7 kN (R900C Litronic) / 97 / 141 kN (R904C Litronic) | p. 124 |
| R904C Litronic | ||
| Max. engine torque | 730±10 Nm at 1000 min-1 | p. 128 |
| Hydraulic oil quantity (oil change with filter) | ca. 290 l | p. 128 |
| Travel gear oil quantity | 2x4,1 l | p. 129 |
| Operating weight (Std, type 984) | 20,6 t | p. 128 |
| R900C Litronic | ||
| Operating weight (Std, type 971) | 19,3 t | p. 124 |
Liebherr R900C, R904C Litronic Common Problems This Manual Covers
Track chain jumping off or skipping on the sprocket
Faults and remedies for the travel gears point to two causes: insufficient chain tension or a worn chain wheel. Adjust chain tension first. If the sprocket is worn, the track components group covers wear limits, the tensioning unit and the Berco idler. It also notes that sudden turns, one-sided loading and bad obstacle crossing speed up wear considerably.
Manual Section: Faults and remedies, travel gears / Track Components: wear of track components p. 544Hydraulic oil level keeps dropping between shifts
The hydraulic faults and remedies table treats a low oil level as loss of oil. Find the leak, replace damaged hoses and top up through the return-flow filter, not the nearest open port. If you are changing oil with the filter, the R904C takes ca. 290 l. Clean any piping and hoses before refitting them.
Manual Section: Faults and remedies, hydraulic system p. 543Swing torque weak or erratic while the rest of the hydraulics work normally
Look at the swing gear torque control valve in the LSC control valve block section. The manual says that when errors occur, you can unscrew and dismantle the valve to check for contamination or a broken spring, or replace it outright. The swing gear and FMF 45 swing motor have their own groups if the fault turns out to be downstream.
Manual Section: Hydraulic Components: LSC control valve block, swing gear torque control p. 399Instrument panel partly or completely dead
The electrical faults and remedies table covers failure of individual instruments or the whole panel. Secure or replace the plug connection, find and fix any short circuit, then replace the fuse or reset the automatic circuit breakers. The system runs on 24 V from 2 x 92 Ah batteries in series. Use the arrangement of components pages to find the connector before you start pulling panels.
Manual Section: Electrical System: faults and remedies, arrangement of components p. 544Frequently Asked Questions
Does this one book cover both the R900C and the R904C, or do I need two?
One book covers both. Technical data, lubrication charts and hydraulic adjustment check lists are printed separately for each model. That matters because the machines differ: 270 l/min pump flow on the R900C against 330 l/min on the R904C, and a 300 l fuel tank against 340 l. p. 124
How do I check pressures on the variable displacement pump without guessing where to plug in?
The setting instructions name the test points. Point 41 is pump pressure at control valve block 100, and point 44 is pump pressure at variable displacement pump 20. Warm the engine and hydraulic oil to operating temperature first, because cold oil makes the control unit react sluggishly. The special tools group lists the gauge set for measuring the differential pressure between pump pressure and LS pressure. p. 215
The monitoring display is throwing an E code. Where do I find out what it means?
The electrical group has error code charts for the monitoring display from V5.5 upwards. It also has a summary of error codes covering effect, cause and remedy. Some codes never appear in the EC field of the operator menu. Those can only be read out from menu list-S-Exxx, so check that list before you decide the system is clean. p. 494
How often does Liebherr want the machine crack tested?
The section on servicing the machine safely gives two intervals. The machine owner's maintenance personnel check every 250 operating hours. Authorised specialist personnel check every 500 operating hours. Having that in writing settles the argument with an owner who wants to skip it, and that alone justifies keeping the book in the shop. p. 20
Can I reset the service interval on the display, and what does it actually wipe?
Yes. The «reset service interval» function sits in menu levels 2 and 3 of the monitoring display. The manual warns that it deletes all records of service interval confirmations, not just the current reminder. Write the history down before you press it if anyone will ask for it later. p. 520
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