Liebherr R 900–942 Litronic Excavator Service Manual, 1990–1997 (P/N 8502675)
1,343 Pages • Printable PDF • 96.85 MB • Download
Liebherr Models Covered & Key Technical Specifications
Models: R 900, R 902, R 912, R 922, R 932, R 942; shared-component coverage: A 900, A 902, A 912, A 922, A 932
Models & Model Codes:
R 900 — STD (368); HD-SL (368, 596 in the undercarriage table from S/N 3001). Engines: Deutz BF 4 L 913 LK 49 from S/N 101, BF 4 L 913 LK 52 from S/N 176, and BF 4 M 1013 E from S/N 4001. Travel gear: Trasmital 709 C3 B 128 on type 368 in the early travel gear chart.
R 902 — 364; from S/N 3001, the technical data and track tables list STD (582) and HD-SL (364). Engines: Liebherr D 904 TB from S/N 101, D 904 T from S/N 3001, and D 924 T-E A1 from S/N 4001. Travel gears: Trasmital 709 C3 B 122 and 709 C3 B 128 in the early chart; FAT 350/032 from S/N 3001.
R 912 — Early types: 346, 379, 380, 387, 402, 416, 476. Types listed from S/N 2001: 417, 481, 482, 483, 484, 485, 496. Types listed from S/N 3001: 417, 481, 483, 491, 611. Engines: Liebherr D 904 T from S/N 101, with a revised rating from S/N 3001; D 924 T-E A1 from S/N 4001. Early travel gears: Trasmital 709 C3 B 97 and 709 C3 B 107, with a change at S/N 1289 for the LC, EW, Std, and Std-S types listed in the gear chart; 713 C3 B 107 on LC-S and early HD-SL; FAT 350/012 on HD and HD-S, and FAT 400/023 on the listed HD-S configuration. From S/N 3001, the travel gear chart lists FAT 350/022 for Std, HD-S, and HD-SL and FAT 400/063 for HD-EW (611).
R 922 — HD-SL (480). Engines: Liebherr D 914 T from S/N 101, with a revised rating from S/N 3001; D 924 T-E A1 from S/N 4001. Travel gears: Trasmital 713 C3 B 107 in the early chart; FAT 350/022 from S/N 3001.
R 932 — 365, 381, 405; types listed from S/N 3001: 571, 572, EW (590). Engines: Liebherr D 914 TI from S/N 101, with a revised rating from S/N 740; D 924 TI-E A2 from S/N 4001. Travel gears: FAT 400/023 in the early chart; FAT 400/063 from S/N 3001. Pump drive: PVG 350 B 381 splitterbox.
R 942 — HD-SL (366) and HD-S (382); from S/N 3001, HD-SL (574) and HD-S (573). Engines: Liebherr D 906 T from S/N 101, D 916 T from S/N 298, and D 926 T-E A1 from S/N 4001. The travel gear chart lists FAT 400/013 from S/N 101, FAT 450/064 from S/N 258, and FAT 400/073 from S/N 3001. Pump drive: PVG 350 B 381 splitterbox.
Shared A-series engine data: A 900 (Deutz BF 4 L 913 from S/N 101, revised rating from S/N 901; BF 4 M 1013 E from S/N 4001); A 902 (Liebherr D 904 TB from S/N 101, D 904 T from S/N 3001, D 924 T-E A1 from S/N 5001); A 912 (D 904 T from S/N 101, revised rating from S/N 3001; D 924 T-E A1 from S/N 5001); A 922 (D 914 T from S/N 101, revised rating from S/N 3001; D 924 T-E A1 from S/N 5001); A 932 (D 914 TI from S/N 101, revised rating from S/N 533; D 924 TI-E A2 from S/N 5001).
Sub-models / Variants: Litronic
Model Years: 1990–1997 (1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997)
Serial Numbers: R 900: Nr. 101–, R 902: Nr. 101–, R 912: Nr. 101–, R 922: Nr. 101–, R 932: Nr. 101–, R 942: Nr. 101–. Component-specific serial breaks apply; see the subgroup indexes.
-
Engine Speed: 2000 RPM nominal
-
Fuel Tank Capacity: 240–705 liters depending on R-series model and configuration
-
Engine Oil Specification Reference Range (API CD/SE 20W-20): -10°C to +20°C (+14°F to +68°F)
-
Cooling System Capacity: Approximately 21–45 liters depending on the liquid-cooled engine version
-
Hydraulic Pressure Gauge Ranges: 0–600 bar
-
Thread Standard Compatibility: Metric and UNC/UNF
Liebherr Manual Features & Selected Content Preview
This July 1997 service manual covers the 1990–1997 Liebherr R 900–942 Litronic excavators. It carries P/N 8502675, incorporates updates through No. 05–07/97, and covers shared components used on the listed A-series machines.
PDF Layout and Diagram Detail
Search and diagram detail: The PDF has no text search or embedded bookmarks. Zoom in to read small connector and pin labels. Some fine details in the heater wiring and swing-brake circuits remain hard to read where the vertical print stamp crosses them.
The printable 1,343-page PDF contains a one-page opening index, 835 pages for Volume 1 (groups 1–8), and 507 pages for Volume 2 (groups 9–12 and 16–19). These totals include the introductory pages, modification charts, and 173 pages that are blank apart from the print stamp.
Hydraulic Tests, Litronic Diagnosis, and Drive Repairs
The following selected topics show the scope of the service manual. Other sections include boom and bucket combination charts, bucket tooth selection, and fuel and hydraulic tank layouts.
-
Hydraulic diagnosis: Model-specific pressure checks, LPVD double-pump regulation, relief-valve adjustment, leakage testing, and hydraulic cylinder removal and resealing.
-
Litronic electrical controls: GLR and GLD horsepower control tests, engine speed sensor checks, low-idle troubleshooting, swing-brake diagnosis, and subsystem wiring diagrams.
-
Swing and travel repair: SAT swing gear service, Trasmital and FAT travel gear resealing, brake disc replacement, swing ring installation, and track wear checks.
-
Engine and pump drive: Deutz and Liebherr diesel specifications, engine speed adjustment, coupling replacement, and step-by-step procedures for PVG splitterbox disassembly and assembly.
-
Attachment hydraulics: Load-holding valves, AS/ASH/AHS installation kits, flow reduction, overload warning tests, centralized lubrication, adjustable cabs, and quick-change couplers.
-
Cab climate systems: D1LC heater removal and component repair, D5W fuel delivery tests and fault charts, and KONVEKTA air conditioning service information.
Written for skilled mechanics already familiar with excavator repair, this manual assumes access to standard workshop equipment and the special tools identified in its procedures.
Model Coverage and Engine Service
Use the subgroup indexes and modification charts to match the procedure to the machine’s serial number and installed components. A-series coverage is limited to shared assemblies. Dedicated wheeled-machine steering, oscillating axle stabilizer, axle overhaul, brake, and two-speed gearbox repair sections are outside this manual’s scope.
Engine data distinguish the air-cooled Deutz BF4L 913, the liquid-cooled BF4M 1013 E, and Liebherr diesel variants. The engine chapter provides adjustment values and wear limits, along with engine speed and sensor-controlled low-idle coverage. A full internal diesel engine overhaul is outside its scope. Maintenance schedules, lubricant charts, and Fleetguard DCA4 coolant guidance are included; routine maintenance procedures are in the separate Operation and Maintenance Manual.
Hydraulic Pumps, Valves, and Cylinders
Pressure tables are paired with adjustment checklists and test point locations. The LPVD section covers installation, startup, and pressure cut-off; its leakage chart distinguishes a worn but usable pump from one beyond the wear limit. The A4V swing pump has its own adjustment section. FMF and FMV motor sections explain operation and testing, with separate instructions required for motor resealing and internal repair.
The manual covers main control valve troubleshooting, pilot controls, and cylinder guide rings and cushioning arrangements. It also explains how filter kit 9368172 is used on the R 932/R 942 closed swing loop, whose oil bypasses the machine’s return filter.
Electrical Tests and Wiring Scope
The GLR and GLD sections use test device 6202698 to check pump solenoid circuits, the inductive engine speed pickup, and regulator response. The fault charts help distinguish a control fault from a hydraulic problem when the engine loses speed under load. Running without the battery or jump-starting with the battery disconnected from the alternator can damage the controller’s voltage protection circuit.
Illustrations include LPVD pump section views, boom, stick, and bucket hydraulic circuit diagrams, low-idle sensor schematics, the swing-brake control circuit, and D1LC heater wiring. Component views identify connector and terminal positions. Basic machine wiring sections provide legends and cross-references; the actual schematics cover individual subsystems and attachments. Complete basic machine wiring sheets are outside this PDF’s scope.
Couplings, Travel Gears, and Tracks
Coupling instructions distinguish Centaflex and other torsional vibration damper arrangements and cover installation position and PVG 350 B 381 splitterbox service. Twisting the Centaflex aluminum segments during fastening can loosen the screws and destroy the coupling.
The travel gear chapters distinguish Trasmital and FAT units by type and bearing arrangement. They cover gear removal, resealing, brake discs, and slipring seals; full internal gear overhaul is covered in separate repair instructions. Swing ring work includes clearance checks and mounting orientation. Track sections cover chains, pads, idlers, tension units, track rollers, carrier rollers, and wear limits.
Attachment Circuits and Cab Equipment
The AS, ASH, and AHS kit sections match hydraulic circuits and pressure adjustments to grapple, cylinder, and hammer installations. Related sections cover boom and travel pressure cut-in, movable and elevated cabs, and coupler circuits. The cab climate chapters distinguish D1LC and D5W heater service and give refrigerant data for R12 and R134a KONVEKTA systems.
Workshop References and Tools
Reference tables cover metric and UNC/UNF tightening values, ISO bore and shaft fits, fluid capacities, and electrical test specifications. The manual also lists conversion factors, structural steel and electrode requirements for repair welding, and tools for connector service, injector removal, and brake housings. The Litronic Measure System (LMS) section explains measurement inputs and calibration controls.
Observe the manual’s pressure-relief, attachment-support, and mechanical-locking precautions before maintenance or repair.
Cold Valve Clearance Examples
The Deutz BF4L 913 table for the A/R 900 lists 0.15 mm cold clearance at both the intake and exhaust valves. The BF4M 1013 E table for the A/R 900 from S/N 4001 specifies 0.30 mm at the intake and 0.50 mm at the exhaust, also measured cold. The engine type determines which table applies.
Customer Reviews
Read what our customers say about this Liebherr Excavator manual and share your own experience.