Liebher D9508 A7 SCR Diesel Engine Operator's Manual 2013140001 - PDF DOWNLOAD

Operator's manual

en

Diesel engine D9508 A7 SCR with exhaust aftertreatment system SCR (selective catalytic reduction)from serial number 2013140001

Order number: Issue: Version: Author:

10142241 /0 /20 0 LMB/department ED5

Manufacturer: Type:

LIEBHERR MACHINES BULLE S.A. D9508 A7 SCR with exhaust aftertreatment system SCR (selective catalytic reduction)

Type no.: from serial no.:

2013140001

Address Address:

LIEBHERR MACHINES BULLE S.A. 45, rue de l'Industrie CH-1630 BULLE SWITZERLAND

Machine data: Complete the following data upon receipt. * This information can be found on the company nameplate of your machine. It will also be useful when ordering spare parts.

* Year of manufacture:

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Date of initial commissioning:

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Preface

This operator's manual has been written for the operator and maintenance personnel of the diesel engine.

It contains descriptions for: – Technical data – Safety regulations – Handling and operation – Maintenance The operator's manual is to be carefully read and applied before commissioning and later at regular time intervals by each person who is assigned to work with/on the diesel engine.

Work with or on the diesel engine is e.g.: Handling, Servicing, including maintenance, inspection.

This facilitates familiarization with the diesel engine for the operator and prevents malfunctions due to improper handling.

You will understand that we cannot recognize warranty claims that arise due to

Liebherr will cancel all possible obligations undertaken by Liebherr and/or its dealers, such as guarantee commitments, service agreements etc., without prior notice if parts other than original Liebherr parts or spare parts purchased from Liebherr are used for maintenance and repair.

Under extreme conditions, more frequent maintenance than scheduled in the inspection plan can be required.

Changes, conditions, copyright: – We reserve the right to make changes to technical details of the diesel engine

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– Warranty and liability conditions of the general terms and conditions of Liebherr are not extended through the preceding information.

– Information and images in this manual may not be duplicated or distributed, nor used for competition purposes. All rights according to the copyright law are expressly reserved.

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Operator's manual

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Preface

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Content

1

Product description 1.1

1.2

2

Technical description

9

1.1.1

Design overview

9

1.1.2

Explanation of the type designation

10

1.1.3

Design features

13

1.1.4

Diesel engine special equipment

15

Technical data

16

1.2.1

Diesel engine

16

1.2.2

Standard cylinder head

16

1.2.3

Cylinder head with engine auxiliary brake system (ABS)

16

1.2.4

Coolant pump

17

1.2.5

Coolant thermostat

17

1.2.6

Alternator

17

1.2.7

Starter

17

1.2.8

Flywheel housing

17

1.2.9

Wabco air compressor 293 cm3

17

1.2.10 Knorr air compressor 720 cm3

18

Safety instructions 2.1.1

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9

Labeling of warnings

19 19

2.2

General safety instructions

20

2.3

Intended use

20

2.4

Information to prevent crushing and burns

21

2.5

21

2.6

Safety measures when starting

22

2.7

Measures for safe maintenance

22

2.8

Safety measures for diesel engines with electronic control units

23

2.9

Safety and emergency operation program for diesel engines with electronic control units

24

2.10 Special instructions for work on the common rail system

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5

Content

Operator's manual

26

2.12

27

2.13 Exhaust aftertreatment system (SCR)

27

Handling, operation

29

3.1

Control and operating elements

29

3.2

Operation

30

3.2.1

Preparing for initial commissioning

30

3.2.2

Initial commissioning / test run

30

3.2.3

Starting the diesel engine

31

3.2.4

Starting at freezing temperatures

32

3.2.5 3.2.6

4

5

32 Exhaust aftertreatment (SCR)

33

Malfunctions

43

4.1

43

Faults - Cause - Remedy

Maintenance

49

5.1

Maintenance and inspection plan

49

5.2

Fill quantities, lubrication schedule

52

5.2.1

Fill quantities table

52

5.2.1

Lubrication schedule

52

5.3

54 54

5.3.1

6

5.3.2

Environmental protection measures

54

5.3.3

Disposal of waste materials

54

5.3.4

Diesel fuels

54

5.3.5

Lubricating oils for the diesel engine

56

5.3.6

Diesel engine coolant

57

5.4

Special tools for maintenance activities

61

5.5

Preparatory maintenance activities

64

5.6

Maintenance activities (daily) every 10 operating hours

65

5.6.1

Checking the engine oil level

65

5.6.2

Visual inspection (tightness, impurities, damage)

65

5.6.3

Checking the coolant level

66

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2.11

Operator's manual

Content

5.7

5.6.4

66

5.6.5

68

Maintenance activities (weekly) every 50 operating hours

69

5.7.1

5.8

69

Maintenance activities every 500 operating hours

70

5.8.1

70

5.8.2

70

5.8.3

Checking and replacing the V-ribbed belt

74

5.8.4

Checking the intake and exhaust system for condition, leaks

78

5.8.5

Checking the cooling and heating system for leaks and condition

79

5.8.6

Checking the lubricating and fuel system for leaks and condition

79

5.8.7

79

5.8.8

81

5.11

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5.12

5.13

5.14

Checking the batteries and cable connections

83

5.8.11 Checking sensors, actuators, cable holders and plugs for condition

83

Maintenance activities every 1000 operating hours

84

5.9.1

84

5.9.2

86

5.9.3

88 Checking and setting the valve clearance

88

Maintenance activities every 2000 operating hours

94

5.10.1 Checking the anticorrosive antifreeze agent concentration in the coolant

94

Maintenance activities every 4500 operating hours

97

5.11.1

97

Maintenance activities every 6000 operating hours

99

5.12.1 Replacing the coolant

99

Maintenance activities every 10000 operating hours

102

5.13.1

102

Maintenance activities as needed

103

5.15 5.16

82

5.8.10 Checking the control unit mounting for condition

5.9.4 5.10

69

5.7.2

5.8.9

5.9

Draining water and sediment in the fuel tank

104 Ventilating the fuel system

105

5.17

107

5.18

108

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Content

Operator's manual

5.19 Transport and storage

6

109

5.19.1 Suspension device

109

5.19.2 Storage up to 6 months

109

5.19.3 Storage over 6 months up to 24 months

110

Supplemental Information USA 6.2.1 6.3

111 111

EPA/CARB Fuel label

Emission control warranty Statement warranty rights and obligations

112

6.3.1

Manufacturer's warranty coverage

112

6.3.2

Owner's warranty responsibilities

112

6.3.3

Warranty coverage

113

6.3.4

Warranted parts

113

115

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Index

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1 Product description

1.1 Technical description 1.1.1

Design overview

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This section contains an overview of the diesel engine with names of the parts shown

Fig. 1: Parts of the diesel engine / left view 1 2 3 4 5

Alternator Air conditioning compressor Vibration damper Water pump Coolant manifold

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6 7 Crankcase ventilation 8 9 10 Exhaust gas turbocharger

11 12 13 14 15

Heat protection plate Starter Oil level sensor Oil drain plug

9

Product description

Operator's manual

Technical description

Fig. 2: Parts of the diesel engine / right view 1 2 3 4 5

Alternator Air conditioning compressor Vibration damper Water pump Coolant manifold

6 7 Crankcase ventilation 8 9 10 Exhaust gas turbocharger

11 12 13 14 15

Heat protection plate Starter Oil level sensor Oil drain plug

1.1.2 Explanation of the type designation Type designation Description 95

08

A7

SCR

D

Engine type designation Engine type: D = diesel engine

95

Hole: 128 mm / stroke: 157 mm 08

Number of cylinders A7

Injection system: A7 = Common Rail SCR

Exhaust aftertreatment system: SCR

Tab. 1

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D

Operator's manual

Product description Technical description

Diesel engine type plate The diesel engine type plate is attached on the left crankcase side viewed from the the diesel engine).

Fig. 3: Type plate

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Diesel engine number

Fig. 4: Diesel engine number 1 2

Year Number of cylinders (14=8 cylinders)

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Sequential number

11

Product description

Operator's manual

Technical description

Engine control unit type plate

Fig. 5: Example of engine control unit type plate 1 2 3 4 5

Date of delivery 2D codebar Engine type Control unit designation

Note

6 7 8 9 10

Engine serial number Revision index Software version Control unit serial number

The information on the motor control unit type plate corresponds to the delivery condition (ex works Liebherr Machines Bulle). Depending on may no longer be current. The actual information can be called up on the device display or read out by means of the Liebherr Sculi diagnostics and service tool.

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Tab. 2

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Operator's manual

Product description Technical description

ATEX type plate

Fig. 7: Example of ATEX type plate 1 2 3 4

Manufacturer's address System designation Drawing number

5 6 7 8

Year of manufacture Description number

Cylinder designation, direction of rotation

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Fig. 8: Cylinder designation / direction of rotation

1.1.3 Design features Diesel engine construction Water-cooled, 8 cylinder V-diesel engine with common rail (CR) direct injection, exhaust gas turbocharging and charge air cooling.

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Product description

Operator's manual

Technical description

Diesel engine characteristics A robust basic construction and generous dimensions form the basis for high operational safety and a long life. Minimal fuel consumption, low noise and exhaust emissions through a combustion process especially aligned to high demands.

Minimal maintenance cost on easily accessible parts and a multitude of mounting diesel engine.

Driving gear The 8 cylinder V-diesel engine has a 5-fold mounted, forged steel crankshaft with inductively hardened running surfaces and 6 bolted counterweights. A torsional vibration damper is attached on the fan side to the crankshaft. Precisely forged cracked connecting rod, driving gear mounting system in leaded bronze, three-layer friction bearings or sputter bearings. Steel Monotherm piston with stage support and cooling channel. Replaceable, wet cylinder liners.

Crankcase vermicular cast iron and a bedplate out of spheroidal graphite iron as the crankcase bottom. 4-valve single cylinder heads with a swirl duct and replaceable valve seat rings and valve guides. Flywheel housing, front ancillary support housing and oil pan on the bottom close the diesel engine.

Drive control Two inlet and outlet valves per cylinder hanging in the cylinder head. Actuated through 5-fold mounted steel camshaft via roller tappet, push rod and rocker arm.

Drive from camshaft, high pressure pump, fuel feed pump, air compressor and auxiliary hydraulic pumps from the crankshaft via case-hardened gear wheels on housing side.

Cooling Thermostatically controlled liquid cooling with coolant pump. Individual supply of each cylinder unit via distribution channels molded in the crankcase. Piston cooling through the cooling channel from the lubricating oil circuit of the diesel engine.

Pressure lubrication with two lubricating oil pumps for crankshaft, connecting rod and camshaft bearings as well as piston pin bushings, roller tappet and rocker

connected to the diesel engine lubricating oil circuit.

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Lubrication

Operator's manual

Product description Technical description

Injection system

Electronic diesel engine control The electronic diesel engine controller (EDC) is used for speed, spray start and torque regulation on the diesel engine. The EDC consists primarily of sensors and the control unit. Equipment on the diesel engine side and vehicle side is connected via cable harnesses to the EDC control unit.

Electronic sensors on the engine side Charge air pressure sensor, fuel pressure sensor, rail pressure sensors, oil pressure sensor, temperature sensor for coolant and speed sensors are interfaces for external monitoring and control functions. The individual functions and error messages are described in the respective user documentation.

Mounting options for pumps Mounting hydraulic pumps is possible on two auxiliary outputs.

1.1.4 Diesel engine special equipment Diesel engine brake and auxiliary brake system

Air compressor lubrication of the air compressor is connected to the corresponding circuits of the diesel engine.

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Air conditioning compressor The air conditioning compressor can be directly mounted to the diesel engine and can be driven via a magnetic coupling with a V-ribbed belt. When the air conditioning system is turned on, the magnetic coupling is active and the compressor works.

Cold package are already integrated.

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Product description

Operator's manual

Technical data

1.2 Technical data 1.2.1 Diesel engine Name

Unit Value

Construction

V-diesel engine

Number of cylinders

8

Firing order

1-5-7-2-6-3-4-8

Hole

mm 128

Stroke

mm 157

Displacement

I 16.16

Compression ratio

21:1

Direction of rotation of the diesel engine

left

Power group

LG1 to LG5

Power rating according to

see type plate

Rated power

see type plate

Rated speed

see type plate

Emission limits

see type plate

Diesel engine weight, dry

kg 1530

1.2.2 Standard cylinder head Name

Unit Value

Valve clearance, inlet, cold

mm

Valve clearance, outlet, cold

mm

1.2.3 Cylinder head with engine auxiliary brake system (ABS) Name

Unit Value

Valve clearance, inlet, cold LMB/11213244/02/01.12.2014/en

Valve clearance, outlet valve bridge / rocker arm, cold Valve clearance, outlet valve bridge / counterholder, cold

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Product description Technical data

1.2.4 Coolant pump Name

Unit Value

Output (at rated speed of 1900 rpm and counter-pressure of 0.6 bar)

l/min 940

1.2.5 Coolant thermostat Name

Unit Value

Start of opening

°C 82

Completely opened

°C 92

1.2.6 Alternator Name

Unit Value

Voltage

V 28

Current type 1

A 100

Current type 2

A 110

Current type 3

A 140

1.2.7 Starter Name

Unit Value

Voltage

V 24

Power output per starter system

kW 7.8 or 2x 8.4

1.2.8 Flywheel housing Name Connection

Unit Value SAE 1

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1.2.9 Wabco air compressor 293 cm3 Name

Unit Value

Output at rated speed of 1900 rpm and 8 bar

l/min 410

Name

Unit Value

Transmission ratio

1 : 1.303

Water-cooled

yes

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Product description

Operator's manual

Technical data

Knorr air compressor 720 cm3 Name

Unit Value

Output at rated speed of 1900 rpm and 8 bar

l/min 1040

Name

Unit Value

Transmission ratio

1 : 1.229

Water-cooled

yes

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1.2.10

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2 Safety instructions

Work on the diesel engine involves dangers to life and limb which you can encounter as an operating company, machine operator or maintenance technician.

If the various safety instructions are always carefully read and followed, dangers and accidents can be prevented.

This applies in particular to personnel working only occasionally, during maintenance, on the diesel engine.

Safety regulations are listed below, the conscientious adherence thereof will ensure your safety and that of others and prevent damage to the diesel engine.

For the description of work which can cause dangers for persons or the diesel engine, the necessary safety measures are described in this book.

2.1.1 Labeling of warnings

This is the warning sign. It warns of a potential risk of injury.

Follow all measures that are indicated with this warning sign in order to prevent injuries or death.

Tab. 3 The warning sign always appears in connection with the signal words DANGER WARNING CAUTION DANGER that will result in death or serious bodily injuries if it is not avoided.

WARNING

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in death or serious bodily injuries if it is not avoided.

CAUTION result in minor or moderate bodily injuries if it is not avoided.

ATTENTION in property damage if it is not avoided.

Tab. 4

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Safety instructions

Operator's manual

Intended use

Additional labels Note

Tab. 5

Additional rules and directives Following this information does not relieve you from adhering to additional rules and directives!

2.2 General safety instructions 1.

2.

Familiarize yourself with the operator's manual before commissioning the machine.

Make sure that you have in your possession the additional instructions associated with the special equipment for your machine or have read and understood them.

Only persons who are expressly authorized to do so may operate, maintain or repair the machine.

Observe the legally permissible minimum age!

3.

4.

5.

6.

the personnel for operation, set-up, maintenance and repair.

Only allow personnel to be trained, taught, instructed or those placed in an apprenticeship to work on the diesel engine under the constant supervision of an experienced person.

Regularly check the safety and hazard-conscious work of the personnel in compliance with the operator's manual.

Wear safe work clothing when you are working on the diesel engine. Avoid etc. A risk of injury exists due to e.g. getting caught or pulled in.

2.3 Intended use

2.

3.

This diesel engine has been built exclusively for the purpose corresponding to use beyond this is deemed improper use. The manufacturer is not liable for any damages resulting from this. The risk for this will be born solely by the user.

Intended use also includes adherence to the operating, maintenance and repair conditions prescribed by the manufacturer. The diesel engine may only be used, maintained and repaired by persons who are familiar with it and are instructed about the dangers.

Unauthorized changes to the diesel engine rule out any liability of the manufacturer for property damage and personal injury resulting from this.

legal environmental requirements is then no longer ensured.

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1.

Operator's manual

Safety instructions Intended use

2.4 Information to prevent crushing and burns 1.

2.

3.

4.

5.

6.

Do not use take-up devices, such as ropes or chains, that are damaged or Wear work gloves when handling wire ropes.

When the diesel engine is running, make sure that no objects come in contact with the fan.

Objects that have fallen or protruded into the fan will be hurled back or destroyed and can damage the fan.

The diesel engine cooling system is hot and under pressure near the operating temperature.

Avoid contact with parts carrying cooling water. A risk of burns exists!

Check the cooling water level only when the end cover of the expansion tank

The diesel engine oil is hot near the operating temperature. Avoid skin contact with hot oil or parts carrying oil.

Wear safety goggles and work gloves when you are working on the battery.

2.5 explosion 1.

2.

3.

4.

Eliminate the leaks immediately and replace faulty parts.

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5.

6.

batteries are being charged.

Always start the diesel engine according to the provisions of the operator's manual.

Check the electrical system.

Immediately eliminate all errors, such as loose connections and frayed cables.

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Safety instructions

Operator's manual

Measures for safe maintenance

2.6 Safety measures when starting 1.

2.

If no other instructions are received, start the diesel engine according to the provisions in the operator's manual.

Start the diesel engine and then check all display devices and control equipment.

3. ventilation. supply.

2.7 Measures for safe maintenance 1.

2.

Do not perform any maintenance or repair work that you have not mastered.

Adhere to the prescribed times, or the times stated in the operator's manual, for recurring checks or inspections.

To perform the maintenance measures, workshop equipment appropriate for the work is absolutely necessary.

3. at the end of this operator's manual.

The machine operator or maintenance personnel may only perform the work

4.

5.

6.

7.

appropriate training.

Spare parts must meet the technical requirements established by the manufacturer. This is always ensured with original spare parts.

Wear safe work clothing during the maintenance.

If nothing else is stated in this operator's manual, perform all maintenance Tighten the screw connections released with the prescribed tightening torque during maintenance and repair work.

8. of oil, fuel and care products at the start of the maintenance or repair. Do not use any aggressive cleaning agents. Use lint-free cleaning cloths.

Before cleaning the machine with water, steam jet (high pressure cleaner) or other cleaning agents, cover or glue shut all openings into which, for safety or functional reasons, no water, steam or cleaning agents may penetrate.

Especially at risk are the crankcase ventilation, electronics box, starter, alternator and exhaust after-treatment system.

Additional procedure: • After cleaning, remove the covers or adhesions completely.

• After cleaning, inspect all fuel, diesel engine oil, and hydraulic oil lines for leaks, loosened connections, abrasion marks and damage.

• Rectify defects discovered immediately.

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9.

Operator's manual

Safety instructions Safety measures for diesel engines with electronic control units

10. Observe the safety regulations that are applicable for the product when handling oils, greases and other chemical substances.

11. auxiliary materials as well as exchange parts.

12. burns and scalding).

13. can penetrate the skin.

14.

15. before starting in a closed room. Follow the provisions applicable for the respective operation site.

16. for this.

Procedure: • Fasten and secure individual parts and larger assemblies carefully to lifting equipment during the replacement, so that no danger exists here.

• Residing and working under suspended loads is prohibited.

17.

Wear work gloves when handling wire ropes.

18. Work on electrical equipment of the machine may only be carried out by a skilled electrician, or by instructed persons under the direction and supervision of a skilled electrician, according to the electrical regulations.

19. Disconnect the battery when you are working on the electrical system and also remove the plug from the control unit when you are carrying out electric welding last.

2.8 Safety measures for diesel engines with electronic control units 1.

2.

3.

4.

5.

LMB/11213244/02/01.12.2014/en

6.

7.

8.

9.

Start the diesel engine only with permanently connected batteries.

Do not disconnect batteries when the diesel engine is running.

Start the diesel engine only with the control unit connected.

Do not use a rapid charger to start the diesel engine. Starting aid only with separate batteries.

To rapidly charge the batteries, the battery terminals must be removed. Follow the operating instructions for the rapid charger.

During welding work, the batteries must be disconnected and the two cables (positive and negative) must be securely connected to one another.

Furthermore, the connecting plugs must be disconnected for all control units.

The connections of the control units may only be removed or attached when the tight with the prescribed tightening torque.

Incorrect polarity of the control unit supply voltage (e.g. through incorrect polarity of the batteries) can lead to destruction of the control units.

Screw connections on the injection system tight with the prescribed tightening torque.

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Safety instructions

Operator's manual

Special instructions for work on the common rail system

10. If temperatures above 80 °C are expected (e.g. drying oven), the control units must be removed.

11. Use only suitable test leads for measurements on plug connections.

12. Sensors or actuators may not be connected individually or between external voltage sources for either inspection or testing purposes, but only in connection with the electronic control unit, since otherwise a risk of destruction or a danger of a malfunction of the diesel engine exists.

13. when the mating connector is mounted and attached. If the mating connector water.

14. Telephone and radio equipment which is not connected to an external antenna can lead to malfunctions of the vehicle electronics and thereby endanger the operational safety of the diesel engine.

2.9 Safety and emergency operation program for diesel engines with electronic control units 1.

The diesel engine has an electronic control system, which monitors both the diesel engine and itself (self-diagnosis).

As soon as a fault is detected, one of the following measures is automatically initiated after assessment of the fault that arose: • Output of an error message with error code.

• In connection with the vehicle diagnosis system, the error code is directly output via a display.

• Changeover to an appropriate substitute function for further, but limited operation of the diesel engine (e.g. constant emergency operation speed).

Have faults immediately resolved by the responsible LIEBHERR customer service.

1.

2.

When the diesel engine is running, the lines are constantly under a fuel pressure of up to 2200 bar.

• common rail system when the diesel engine is running.

The fuel escaping under pressure can penetrate the skin of the person and • • •

24

After stopping the diesel engine, observe at least a one minute waiting period until the pressure in the rail system has been relieved.

Avoid residing near the diesel engine when it is running.

Persons with pacemakers may not get closer than 20 cm to the running diesel engine.

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2.10 Special instructions for work on the common rail system

Operator's manual

Safety instructions Special instructions for work on the common rail system

Do not touch live parts on the electrical connection of the injectors when the diesel engine is running.

Modern components of the diesel injection today consist of highly precise parts that are subjected to extreme loads. Due to this high precision technology, the utmost cleanliness is to be ensured during all work on the fuel system.

Even particles of dirt larger than 0.2 mm can lead to failure of components.

Therefore, before starting the work, the subsequently described measures are to be followed at all costs: • Before work on the clean side of the fuel system, the diesel engine and the •

3.

4.

must be closed while doing so.

Perform a visual inspection for leaks or damage to the fuel system.

Do not spray the steam jet directly at electrical parts, or attach covers.

Bring the diesel engine into a clean area of the workshop, in which no work is being performed that could cause dust to be dispersed (grinding, welding work, brake repairs, brake and power tests etc.).

• Avoid air movements (possible dust turbulence through starting the diesel engines, the workshop ventilation or heating system, through drafts, etc.).

• The area of the fuel system still closed is to be cleaned and dried using compressed air.

• Remove loose dirt particles, such as paint chippings and insulating materials, with a suitable suction device (industrial vacuum cleaner).

• Hang a new and clean protective sheet over areas of the diesel engine compartment from which dirt particles could come loose.

• Before starting dismantling work, hands must be washed and clean work clothes must be put on.

When performing the work, the subsequently described measures are to be followed at all costs: • After opening the clean side fuel system, the use of compressed air for cleaning is not permitted.

• Loose dirt is to be removed during the assembly work using a suitable suction device (industrial vacuum cleaner).

• Only lint-free cleaning cloths may be used on the fuel system.

• Tools and work equipment must be cleaned before starting the work.

• Only tools that have no damage (cracked chrome coatings) may be used.

• When removing and installing components, no materials such as cloths, cardboard or wood may be used since these can deposit particles and • • •

5.

•

If paint chippings arise when unfastening connections (due to possible overcoating), these paint chips are to be carefully removed

•

All parts removed from the clean side fuel system are to be immediately closed at their connection opening with appropriate sealing caps.

This sealing material must be packed dust-tight until use and is to be disposed after one-time use.

Then all parts are to be carefully stored in a clean, sealed container.

Never use used cleaning or test liquids for these parts.

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• • •

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Safety instructions

Operator's manual

• • •

1.

2.

New parts may only be removed from the original packaging immediately before use.

Work on removed components may only be performed at a work station equipped for this.

If removed parts are being shipped, always use the original packaging for the new part.

Risk of injury through moving parts Rotating and/or linear moving parts can cause serious injuries.

• Do not reach into moving parts or handle moving parts during operation.

• Do not open covers during operation.

• Note the follow-up time: Before opening the covers, make sure that no parts are still moving.

• Risk of death through falling load Loads can fall down during lifting procedures. This can cause serious injuries up to and including death.

• Use the transport devices only for transporting the engine without additional attachments.

• Diagonal pulling is not permitted, therefore use a suspension device.

3. serious or fatal injuries.

• Do not smoke inside the danger zone and in the immediate surroundings.

• •

Report suspicious substances, liquids or gases immediately to those responsible.

• 4.

all-clear signal is given.

Risk of injury due to hazardous coolants lead to serious poisoning, allergies, skin irritations and eye damage.

• Observe safety sheets of the manufacturer.

• Always wear protective work clothes, chemical-resistant protective gloves •

Avoid spillage and fog formation.

5.

6.

7.

26

Risk of burns due to hot surfaces Contact with hot parts can cause burns.

• Always wear protective work clothes and protective gloves for all work near hot parts.

• Make sure that parts have cooled down to the ambient temperature before all work.

Hearing damage due to noise

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burns upon contact.

•

Operator's manual

Safety instructions Exhaust aftertreatment system (SCR)

8.

9.

The noise level occurring in the work area can cause serious hearing damage.

• Always wear hearing protective when working.

• Only reside in the danger zone where required.

Risk of injury on edges and corners Sharp edges and pointed corners can cause abrasions and cuts to the skin.

• Always proceed with caution when working near sharp edges and pointed corners.

• When in doubt, wear protective gloves Risk of tripping due to dirt and objects lying around Dirt and objects lying around can lead to slipping and tripping and cause • • •

Always keep the work area clean.

Remove objects that are no longer needed.

Mark tripping hazards with yellow and black tape.

2.12 1. ground, sewage system or water.

2. containers.

3.

4.

Before disposing or recycling waste materials, ask about the correct method at the responsible environmental or recycling center. Incorrect waste disposal can damage the environment and ecology.

2.13 Exhaust aftertreatment system (SCR) ATTENTION Water, steam or other cleaning agent gets into the SCR module!

Substrate coating detaches.

NOX sensor defective. cleaning.

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module.

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Safety instructions

Operator's manual

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Exhaust aftertreatment system (SCR)

28

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3 Handling, operation

3.1 Control and operating elements The control and operating elements are an integral part of the device and are described in the documentation from the manufacturer.

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Via the electronic interfaces on the diesel engine, data, for example, for oil pressure, coolant temperature, speed, operating hours and service code, is transmitted to the device for the handling and control of the diesel engine.

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Handling, operation

Operator's manual

3.2 Operation 3.2.1 Preparing for initial commissioning

– Diesel engine oil

– Coolant – Diesel fuel Depending on the time of year, use summer or winter fuel. Diesel fuels must

– Reduction agent (water/urea solution)

WARNING Fire and explosion.

chapter).

3.2.2 Initial commissioning / test run Start diesel engine.

Check oil pressure gauge immediately after starting the diesel engine.

30

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Check batteries (for procedure, see documentation from the device manufacturer).

Operator's manual

Handling, operation Exhaust aftertreatment system (SCR)

Troubleshooting No oil pressure is achieved within 5 seconds?

speed until the operating temperature is reached.

ATTENTION Impermissible loading of the diesel engine in cold condition!

Damage of the diesel engine.

Warm up diesel engine.

Coolant temperature > 60 °C

Performing work after the test run Make sure that:

3.2.3 Starting the diesel engine

Start diesel engine in neutral with the ignition key or starter button.

Troubleshooting The diesel engine will not start?

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If the diesel engine does not start up after three starting procedures:

Troubleshooting No oil pressure is achieved within 5 seconds?

ATTENTION Impermissible loading of the diesel engine in cold condition! Damage of the diesel engine.

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Handling, operation

Operator's manual

Operation

Coolant temperature > 60 °C

3.2.4 Starting at freezing temperatures

Fig. 14: Winter operation The following precautionary measures improve the starting performance at low temperatures.

Precautionary measures: – Check battery charging.

– Recharge battery if needed.

– Preheating of the intake air (see documentation from the device manufacturer).

WARNING Use of start-up aids containing ether! Risk of explosion.

ATTENTION Impermissible loading of the diesel engine in cold condition! Damage of the diesel engine.

3.2.5

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WARNING continues to run some time without oil supply).

Risk of damage of the diesel engine.

idle.

32

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Operator's manual

Handling, operation Operation

3.2.6 Exhaust aftertreatment (SCR)

Fig. 15: Simple schematic representation of the SCR system 1 2 3

Reduction agent supply / mixing section Diesel engine Reduction agent tank

4

Dosing / SCR urea pump

5

SCR module

The SCR exhaust aftertreatment (selective catalytic reduction) describes a technique for the conversion or reduction of nitrogen oxides (NO x) in the exhaust into nitrogen (N2) and water (H2O) by adding a reduction agent (water/urea solution).

Reduction agent Designations: – AdBlue® in Europe

ATTENTION Operation without reduction agent!

Legally prescribed emission limits are not observed.

Operator is liable to prosecution.

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with reduction agent.

– DIN 70 070

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Handling, operation

Operator's manual

Operation

Use / handling CAUTION Reduction agents can lead to eye injuries and allergic skin reactions.

Note If reduction agent comes in contact with painted surfaces or aluminum surfaces when refueling:

ATTENTION Adding special additives and diluting the reduction agent (e.g. with tap water) is not permitted.

Legally prescribed emission limits are not observed. Destruction of the exhaust aftertreatment system.

Note diesel fuel tank.

ATTENTION not start the diesel engine.

The reduction agent must remain absolutely pure.

Disposal Dispose of the reduction agent in an environmentally friendly manner. For

Storage suitability / temperature resistance See documentation from the manufacturer.

34

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If, for example, the reduction agent is pumped out of the tank during a repair, it may no longer be used, since the purity of the liquid is no longer guaranteed.

Operator's manual

Handling, operation Operation

Availability Reduction agent can be purchased at gas stations, service stations or manufacturing and retailing companies. Purchase locations in Europe can also be For reduction agent procurement in the USA, please contact Liebherr Newport News, VA, (757) 245-5251, info.lme@liebherr.com or www.discov-erdef.com.

Consumption The reduction agent consumption of the diesel engine is based on the use of the level is shown via a tank display in the device cabin. For procedure or information

Control and warning lamps The various states of the SCR system are shown to the operator through the illumination of the corresponding display lamps.

Control and warning lamps: Lamp

Designation

Meaning

Remedy

MIL lamp (Malfunction Indicator Lamp)

MIL lamp (used at LWE)

Exhaust aftertreatment system malfunction or level not OK

call Liebherr customer service

DEF lamp

Tab. 6: SCR control and warning lamps

Warning and malfunction strategies LMB/11213244/02/01.12.2014/en

The SCR system is monitored by a diagnostics system. If the diagnostics system agent quality, malfunction of an SCR component or a manipulation on the SCR system, a warning or malfunction strategy is activated. requirements (emissions legislation according to EU Stage HIB or according to US EPA/CARB Tier4i) and with respect to the device application of the diesel engine.

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Handling, operation

Operator's manual

Operation

The various warning and malfunction strategies are shown in the following tables.

EU strategies (Stage IIIB)

Application

Display

DEF yellow

Stationary applications of mobile cranes (superstructure)

System status

or malfunction of exhaust aftertreatment system 0 h - 50 h

Restriction

No restriction

Acoustic signal

MIL yellow

DEF red

or malfunction of exhaust aftertreatment system greater than 50 h

No restriction

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Acoustic signal

36

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Operator's manual

Handling, operation Operation

Application

Display

DEF yellow

On-road applications of mobile cranes (chassis)

System status

or malfunction of exhaust aftertreatment system 0 h - 50 h

Restriction

No restriction

Acoustic signal

DEF yellow

or malfunction of exhaust aftertreatment system greater than 50 h

No restriction

Acoustic signal

DEF yellow

or malfunction of exhaust aftertreatment system 0 h - 50 h

No restriction

Acoustic signal applications

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MIL yellow

DEF red

or malfunction of exhaust aftertreatment system greater than 50 h

No restriction

Acoustic signal Tab. 7: EU strategies (Stage IIIB) D9508 D9508 A7 SCR A7 SCR with exhaust with exhaust aftertreatment aftertreatment system system SCR SCR (selective (selective catalytic catalytic reduction) reduction) / / 2013140001 2013140001

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Handling, operation

Operator's manual

Operation

US-EPA/CARB strategies (Tier4i) Application

Display

DEF yellow

System status

or malfunction of exhaust aftertreatment system 0 min 60 min

Restriction

No restriction

Acoustic signal

MIL yellow

DEF yellow

Stationary applications of mobile cranes (superstructure)

or malfunction of exhaust aftertreatment system 60 min 170 min

Torque limitation to

Acoustic signal

MIL yellow

DEF red

or malfunction of exhaust aftertreatment system 170 min 200 min

Torque limitation to

MIL red

DEF red

or malfunction of exhaust aftertreatment system greater than 200 min

Torque limitation to

Acoustic signal

38

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Acoustic signal

Operator's manual

Handling, operation Operation

Application

Display

DEF yellow

System status

or malfunction of exhaust aftertreatment system 0 min 60 min

Restriction

No restriction

Acoustic signal

DEF yellow

On-road applications of mobile cranes (chassis)

or malfunction of exhaust aftertreatment system 60 min 170 min

Vehicle speed maximum 45 mph

Acoustic signal

DEF yellow

or malfunction of exhaust aftertreatment system 170 min 200 min

Vehicle speed maximum 5 mph

Acoustic signal

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MIL yellow

DEF yellow

or malfunction of exhaust Vehicle speed maxiaftertreatment mum 5 mph system greater than 200 min

Acoustic signal

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Handling, operation

Operator's manual

Operation

Application

Display

DEF yellow

System status

or malfunction of exhaust aftertreatment system 0 min 60 min

Restriction

No restriction

Acoustic signal

MIL yellow

DEF yellow

or malfunction of exhaust aftertreatment system 60 min 170 min

Torque limitation to

Acoustic signal applications

MIL yellow

DEF red

or malfunction of exhaust aftertreatment system 170 min 200 min

Torque limitation to

MIL red

DEF red

or malfunction of exhaust Torque limitation to aftertreatment system greater than 200 min

Acoustic signal Tab. 8: US-EPA/CARB strategies (Tier4i)

40

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Acoustic signal

Operator's manual

Handling, operation Operation

Note The restrictions do not occur suddenly, rather via a ramp. If the urea tank is empty, the engine cannot be started.

indicator light.

LMB/11213244/02/01.12.2014/en

DANGER Low vehicle speed during on-road applications of mobile cranes (chassis)!

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Handling, operation

Operator's manual

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Operation

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4 Malfunctions

- Remedy table for possible diesel engine problems with suspected cause and corrective measure.

Note

Diesel engine faults are displayed for diagnosis by means of error codes on the device display.

The explanation and remedy are described in the respective device documentation.

Tab. 9 The basic mental steps for diagnosis are contained in the following list: – Know the diesel engine and the associated systems.

– Thoroughly study the problem.

– Relate the symptoms with knowledge about the diesel engine and the systems.

– Diagnose the problem, wherein the easiest assumptions are used.

– Verify before disassembly is started.

– Determine causes and perform repair work thoroughly.

– After the diesel engine has been repaired, let it run under normal operating conditions and check whether the problem and cause have been remedied.

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4.1 Faults - Cause - Remedy Fault / error

Cause

Remedy

Starter does not crank

Main fuse blown

Replace fuse

Battery connections loose or corroded

Clean and tighten loose connections

Battery voltage too low

Charge or replace battery

Starter current interrupted or contacts corroded

Call Liebherr customer service

Starter defective

Call Liebherr customer service

Battery voltage too low

Charge or replace battery

Battery connections loose or corroded

Clean and tighten loose connections

Outside temperature too low

Follow measures for winter operation

Starter cranks slowly

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Malfunctions

Operator's manual

Faults - Cause - Remedy

Fault / error

Cause

Diesel engine does not start or stops Fuel tank empty again immediately

Remedy Refuel, ventilate fuel system

Fuel line, pre-cleaner or sieve in fuel Clean and ventilate fuel system tank clogged Seal and ventilate Air in the fuel system

Ventilate fuel system

Fuel not cold-resistant winter fuel

Diesel engine starts poorly

Outside temperature too low

Follow measures for winter operation

temperatures)

necessary

Leak or too low pressure in the fuel low pressure circuit

checked by Liebherr customer service

Diesel engine compression too low

Call Liebherr customer service

temperatures)

necessary

Fault in the electronics

Read error memory of the engine control unit, call Liebherr customer service

Voltage supply interrupted

Call Liebherr customer service

Leak or too low pressure in the fuel low pressure circuit

Read error memory of the engine control unit, call Liebherr customer service

LMB/11213244/02/01.12.2014/en

Fault in the electronics

checked by Liebherr customer service

44

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Operator's manual

Malfunctions Faults - Cause - Remedy

Fault / error

Cause

Remedy

Poor diesel engine performance (performance defect)

Defect on the fuel system (clogged, leaking)

Visual inspection for leaks, replace

Charging pressure too low

Loose brackets, defective seals and has no power

Charge air temperature too high (automatic power reduction through engine control unit)

Charge air cooler dirty, poor fan performance, ambient temperature too high, call Liebherr customer service

Coolant temperature too high (automatic power reduction through engine control unit)

Check cooler for contamination, check fan and thermostat, check coolant level, call Liebherr customer service

Fuel temperature too high (automatic Call Liebherr customer service power reduction through engine control unit)

Poor diesel engine brake performance

Job site more than 1800 m above sea level

No remedy, diesel engine performance was automatically reduced

Injectors stick or do not spray

Call Liebherr customer service

Diesel engine compression too low

Call Liebherr customer service

Fault in the electronics

Read error memory of the engine control unit, call Liebherr customer service

Exhaust aftertreatment system clogged

Call Liebherr customer service

function

Liebherr customer service

Fault of the electronics

Call Liebherr customer service

LMB/11213244/02/01.12.2014/en

Diesel engine gets too hot (according Too little coolant to coolant temperature display)

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Clean or decalcify

Thermostat defective

Check, replace if necessary, call Liebherr customer service

Coolant temperature sensor defective

Check, replace if necessary, call Liebherr customer service

Fan too low speed (only hydrostatic fan drive)

Check fan drive, replace if necessary, call Liebherr customer service

45

Malfunctions

Operator's manual

Faults - Cause - Remedy

Fault / error Charging current indicator light illuminates when diesel engine is running

Cause

Remedy Check belt tension, replace tension pulley if necessary

V-ribbed belt torn

Replace V-ribbed belt

Cable connections loose or disconnected

Fasten or replace cable Call Liebherr customer service

defective Diesel engine smokes black

Exhaust aftertreatment system defective

Call Liebherr customer service

Exhaust gases are blue

Oil level in diesel engine too high

Correct oil level

Lubricating oil gets into the combustion chamber and is burned

Call Liebherr customer service

Compressor-side seal on the exhaust gas turbocharger defective

Call Liebherr customer service

Crankcase breather system defective

Check, replace if necessary

Spray start too late

Call Liebherr customer service

temperatures)

necessary

Diesel engine rattles

Combustion faults

Call Liebherr customer service

Diesel engine knocks

Valve clearance too large

Set valve clearance

Injectors faulty or coked

Call Liebherr customer service

Bearing damage

Call Liebherr customer service

Piston rings worn or broken, piston

Call Liebherr customer service

Leak on intake and exhaust pipes causes whistling noise

Eliminate leak, possibly replace seal

Rubbing of the turbine or

Call Liebherr customer service

Exhaust gases are white

Abnormal noises

foreign object in the compressor or

Lubricating oil pressure too low

Oil level in the oil pan too low

Fill up oil to the prescribed mark

Lubricating oil too thin (oil dilution through diesel fuel)

Drain oil, pour in prescribed oil

Pressure sensor defective

Check oil pressure and replace faulty customer service

46

End control valve does not work correctly or dirt in the end control valve

Call Liebherr customer service

Bearing play due to wear too great or bearing damage

Call Liebherr customer service

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rotating parts

Operator's manual

Malfunctions Faults - Cause - Remedy

Cause

Remedy

Lubricating oil in the cooling system

Oil cooler or oil cooler plate is leaking

Call Liebherr customer service

Cooling water in the lubricating oil

O-rings on the cylinder liners are leaking

Call Liebherr customer service

Oil cooler or oil cooler plate is leaking

Call Liebherr customer service

LMB/11213244/02/01.12.2014/en

Fault / error

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Malfunctions

Operator's manual

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Faults - Cause - Remedy

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5 Maintenance

5.1 Maintenance and inspection plan Abbreviations used in this section: Oh or h = operating hours maintenance work into two groups.

Here the machine operating company or its maintenance personnel is responsible for performing the maintenance work.

Table with circle, box, star - empty means:

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perform or guide the maintenance and inspection work. Concerns the maintenance intervals: upon delivery and every 500, 1000, 2000 operating hours (h) and special intervals.

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Maintenance

Operator's manual

Maintenance and inspection plan Customer:..............................Type/type no.: ........................................Serial no.: ................... Operating hours: ........................Date:....................................

Activities to be performed

every 3000 h

By maintenance personnel

other intervals

every 2000 h

every 500 h

every 1000 h

every 50 h

every 8-10 h

upon delivery

Maintenance / inspection at operating hours

One-time activity Repetition interval As needed Annually at the beginning of the cold season

By authorized specialists One-time activity Repetition interval As needed

Diesel engine Check engine oil level (or according to the oil level sensor display the device cabin) Visual inspection (tightness, impurities, damage) Replace diesel engine oil (at least 1 x year)

Check belt drive condition, replace if necessary / check V-ribbed belt tension, adjust if necessary Check intake and exhaust system for condition, fastening and leaks

10000h Cylinder head valves Check / set valve clearance Cooling system Check coolant level Check cooling and heating system for leaks and condition Check anticorrosive and antifreeze agent concentration in the coolant (however, at least 1 x year) 6000h Replace coolant (at least every 4 years) Fuel system

Draining water and sediment in the fuel tank

Ventilate fuel system (injection pipes may not be detached)

annually)

50

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Check lubricating oil and fuel system for leaks and condition

Operator's manual

Maintenance Maintenance and inspection plan

Customer:..............................Type/type no.: ........................................Serial no.: ................... Operating hours: ........................Date:....................................

Activities to be performed By maintenance personnel

other intervals

every 3000 h

every 2000 h

every 1000 h

every 50 h

every 500 h

every 8-10 h

upon delivery

Maintenance / inspection at operating hours

One-time activity Repetition interval As needed Annually at the beginning of the cold season

By authorized specialists One-time activity Repetition interval As needed

element / annually) Electrical system Check batteries and cable connections Check control unit mounting for condition Check sensors and cable connections for condition Electrical system 4500h

LMB/11213244/02/01.12.2014/en

2 years)

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Maintenance

Operator's manual

Fill quantities, lubrication schedule

5.2 Fill quantities, lubrication schedule 5.2.1 Fill quantities table Name

Recommended lubricant

Engine oil

Liebherr Motoroil 10W-40 E6 (low ash)

Quantity

Liebherr Antifreeze OS Mix Coolant

Reduction agent

Liebherr Antifreeze OS Concentrate Reduction agent according to ISO 22241

43 I

See documentation from the device manufacturer

Tab. 10: Fill quantities table

5.2.1 Lubrication schedule The lubrication schedule serves as an overview of the location of the maintenance points on the diesel engine and the period of the maintenance intervals.

Detailed information can be found about:

LMB/11213244/02/01.12.2014/en

section.

52

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Operator's manual

Maintenance Fill quantities, lubrication schedule

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Fig. 77: Lubrication schedule

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Maintenance

Operator's manual

5.3.1 increases the reliability and service life of the machine. are observed.

The various instructions on the prescribed intervals can be found in the The various instructions for performing the lubrication, level checking and changing

Observe the environmental regulations and rules for handling lubricating and

5.3.2 Environmental protection measures Always take and observe environmental protection measures. before draining them.

5.3.3 Disposal of waste materials This concerns waste materials and hazardous waste such as, for example: – Oils, lubricants, refrigerants of air conditioning systems etc.

– Coolant – Fuels

Procedure Note Danger to the environment and health. disposing of waste materials.

Dispose of all waste materials in an environmentally friendly manner, only at

5.3.4 Diesel fuels

listed below.

54

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Collect and store waste materials separately in suitable containers.

Operator's manual

Maintenance

– DIN EN 590 – ASTM D 975-1D S15 and 2D S15

Sulfur content in the diesel fuel permitted.

Diesel fuel - lubricity The diesel fuel lubricity must be a maximum of 460 um according to the HFRR (60)

Inclusion of any additives should be carried out by the supplier - in its capacity as the entity responsible for the quality of the fuel. Addition of secondary lubricity additives by the customer is not recommended.

Note

Ignitability Cetane number of at least 45 is required for ASTM D 975 fuels. A cetane number above 50 is preferable, especially at temperatures lower than 0 °C (32 °F).

Diesel fuel at low temperatures (winter operation) diesel engine is no longer ensured.

DANGER Lubricity decreases.

Gasoline or kerosene may not be mixed with the diesel fuel.

If the machine is used in Arctic climate:

LMB/11213244/02/01.12.2014/en

WARNING Risk of damage to parts! Risk of fuel leak! heaters, radiant heaters, hot air blowers or blowtorches!

If the outside temperature falls below -20 °C:

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Maintenance

Operator's manual

5.3.5 Lubricating oils for the diesel engine Lubricating oil quality Today, only high-alloyed lubricating oils are used for modern diesel engines.

They consist of base oils with additives mixed in.

The lubricating oil requirement for Liebherr diesel engines is based on the

Name E6 Constructeurs Europeens de l'Automobile) CJ-4 Institute) Attention: Observe reduced oil change intervals.

Lubricating oil viscosity The lubricating oil viscosity (toughness) is selected according to the SAE The ambient temperature is decisive for the correct selection of the SAE class. quality of a lubricating oil.

Fig. 80: Temperature-dependent selection of the SAE class The following diesel engine oil is recommended for an ambient temperature of -20 °C (-4 °F) to 45 °C (113 °F): Liebherr Motoroil 10W-40 low ash,

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exceeded or fallen below for a short time.

Operator's manual

Maintenance

The following diesel engine oil is recommended for an ambient temperature of -30 °C (-22 °F) to 30 °C (86 °F): Liebherr Motoroil 5W-30 low ash,

Lubricating oil change intervals Oil change depending on climate zone, sulfur content in fuel and oil quality, according to the following table.

Various maintenance interval.

– Frequent cold starts – Operating temperature change must be carried out according to the following table.

Oil quality CJ-4 Sulfur content in the fuel up to 15 ppm

E6

Interval (h = operating hours) 250 h

500 h

5.3.6 Diesel engine coolant General recommendations Coolant is a mixture of water with additives for corrosion protection and antifreeze.

Coolant: – Can be independently mixed with products listed below.

The cooling system only works reliably under pressure. Keep the cooling system

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Maintain the required coolant level.

Anticorrosive agents approved by Liebherr: – Ensure adequate cold, corrosion and cavitation protection.

– Do not attack seals and hoses.

– Do not foam.

Coolants cause cavitation or corrosion damage in the cooling system if they contain unsuitable anticorrosive agents or are prepared incorrectly. Heat-insulating deposits on heat-transferring parts lead to overheating and failure of the diesel engine.

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Water (fresh water) Colorless, clear, drinkable tap water, free of mechanical impurities, with the following limited analytical values is suitable.

Seawater, brackish water, brine and industrial wastewater are unsuitable.

Name

Value

Sum of alkaline earths (water hardness) 0.6 mmol/dm3 to 3.6 mmol/dm3 (3 to 20 °d) pH value at 20 °C

6.5 to 8.5

Chloride ion content

maximum 80 mg/dm3

Sulfate ion content

maximum 100 mg/dm3

Tab. 13: Fresh water quality Ask for water analyses from the relevant municipal authorities.

Coolant - mixing ratio all year round.

Outside temperature up to

Mixing ratio Water %

Anticorrosive antifreeze agent %

-37 °C (-34.6 °F)

50

50

-50 °C (-58 °F)

40

60

Tab. 14: Temperature-dependent mixing ratio of water and anticorrosive antifreeze agent ATTENTION Proportion of anticorrosive antifreeze agent in the coolant too high!

Diesel engine will overheat and can be damaged.

Product designation

Manufacturer

Liebherr Antifreeze OS Concentrate

Liebherr

Tab. 15: Approved anticorrosive antifreeze agents Note If Liebherr coolant is not available on-site:

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Approved anticorrosive antifreeze agents

Operator's manual

Maintenance

Note coolant to deteriorate.

circumstances, since this can lead to damage in the cooling system!

Approved ready-mixed anticorrosive antifreeze agents Product description

Manufacturer

Liebherr Antifreeze OS Mix

Liebherr

Tab. 16: Approved ready-mixed coolants

Note If Liebherr coolant is not available on-site:

Note coolant to deteriorate.

circumstances, since this can lead to damage in the cooling system!

Approved anticorrosive agents (inhibitors) without antifreeze In exceptional cases and with constant ambient temperatures above freezing point, for example in tropical areas, where it can be proven that no approved anticorrosive antifreeze agent is available, water must be mixed with the following anticorrosive agents as coolant: – Product DCA 4 Diesel Coolant Additives – Product Caltex XLI / Delo XLI / Texaco XLI / Havoline XLI LMB/11213244/02/01.12.2014/en

In this case, replace coolant annually.

As part of maintenance work, check the concentration and correct it if necessary.

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Maintenance

Operator's manual

Note deteriorate.

circumstances, since this can lead to damage in the cooling system!

When switching between anticorrosive antifreeze agent and anticorrosive agent and vice versa:

Product designation

Manufacturer

DCA 4 Diesel Coolant Additives

Fleetguard / Cummins Filtration

CaltexXLI/DeloXLI

Caltex (Asia)

Texaco XLI / Havoline XLI

Chevron (North and South America)

Havoline XLI

Arteco (Asia and Europe)

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Tab. 17: Approved anticorrosive agents (inhibitors) without antifreeze

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Operator's manual

Maintenance Special tools for maintenance activities

5.4 Special tools for maintenance activities

Fig. 82: Turning device — air compressor mounting special tool no. 30 to 30c Turning device special tool no. 30 is optional.

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must point to the air compressor.

No.

ID no.

Name

30

9078688

Turning device

30a

10117021

Intermediate section

30b

4980868

M6 x 20 cylinder screw

30c

10030519

See section

Checking / setting valve clearance

M8x20 hex head screw

Tab. 18

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Special tools for maintenance activities

Fig. 83: Turning device — vibration damper mounting special tool no. 31 Turning device special tool no. 31 is optional and is only included with the diesel engine in special cases.

No.

ID no.

Name

See section

31

10490350

Turning device

Checking / setting valve clearance

Tab. 19

No.

ID no.

Name

32

10123791

Turning device

See section

Tab. 20

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Turning device special tool no. 32 is optional and is only included with the diesel engine in special cases.

Operator's manual

Maintenance Special tools for maintenance activities

Fig. 85: V-belt measuring device Krikit 2 — special tool no. 8

No.

ID no.

Name

8

8042829

V-belt measuring device Krikit 2

See section

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Tab. 21

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Maintenance

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Preparatory maintenance activities

5.5 Preparatory maintenance activities Before performing the various maintenance work, the diesel engine must be brought into the maintenance position if nothing else is stated in the description.

Various maintenance work is, for example: – Oil level check or oil change.

– Filter change and setting and repair work.

Safety measures for maintenance The following safety regulations are to be observed when performing maintenance Maintenance position The diesel engine is in the maintenance position if: – The diesel engine is horizontal.

– The diesel engine is cold.

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pulled out.

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Operator's manual

Maintenance Maintenance activities (daily) every 10 operating hours

5.6 Maintenance activities (daily) every 10 operating hours Make sure that: The diesel engine is in the maintenance position.

5.6.1 Checking the engine oil level

neck is located on the oil pan, on the air compressor or on the cylinder head cover.

Pull out oil dipstick 1 up to the limit stop.

Pull out the oil dipstick again and determine the oil level. The oil level must be

Note Check engine oil level according to oil level sensor display.

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If the oil level is too low: 2.

5.6.2 Visual inspection (tightness, impurities, damage) Check diesel engine through a visual check for tightness.

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Maintenance activities (daily) every 10 operating hours

Check lines and hoses through a visual check for tightness.

Check lines and hoses for undamaged condition, that they are laid without rubbing and are properly fastened.

5.6.3

Checking the coolant level DANGER Burns.

Perform maintenance and inspection work on the cooling system only when the Wear protective equipment.

For procedure to check the coolant level, see documentation from the device manufacturer.

5.6.4 Checking / draining the water separator on the fuel Make sure that: A collection container with the necessary capacity is available.

device design.

WARNING

on the fuel system.

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Perform maintenance and inspection work only when the diesel engine is

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Operator's manual

Maintenance Maintenance activities (daily) every 10 operating hours

Troubleshooting

1 by two revolutions (counterclockwise).

2 and turn counterclockwise 90° at the same time.

When the water has drained: 2 90° clockwise (the toggle engages again automatically).

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Note

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Maintenance

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Maintenance activities (daily) every 10 operating hours

Turn mark 2a Actuate manual feed pump 2b until a stronger resistance is noticeable.

In order to be able to start the diesel engine: Turn mark 2c

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the device manufacturer.

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Operator's manual

Maintenance Maintenance activities (weekly) every 50 operating hours

5.7 Maintenance activities (weekly) every 50 operating hours Make sure that: The diesel engine is in the maintenance position.

5.7.1

Draining water and sediment in the fuel tank WARNING Fire and explosion. work on the fuel system.

Perform maintenance and inspection work only when the diesel engine is

For procedure to drain the water and sediment in the fuel tank, see documentation from the device manufacturer.

When refueling, keep the fuel level in the tank high to avoid condensation as far as possible.

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the device manufacturer.

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Maintenance activities every 500 operating hours

5.8 Maintenance activities every 500 operating hours Make sure that: The diesel engine is in the maintenance position.

One diesel engine brake is installed on each of the left and right sides of the diesel engine, on the turbocharger.

1 WARNING Diesel engine damage

Check and grease the joints of the actuating cylinder.

Make sure that: The diesel engine is horizontal.

The diesel engine is hot.

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actuation.

Operator's manual

Maintenance Maintenance activities every 500 operating hours

A collection container with the necessary capacity is available.

A suitable drain hose from the device manufacturer is available.

The oil drain valve is on the diesel engine at the bottom or side of the oil pan.

Draining the diesel engine oil

1 until the upper o-ring is visible.

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CAUTION Hot engine oil!

Burns.

Avoid skin contact with the engine oil.

Wear protective gloves when changing the engine oil.

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Maintenance

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Maintenance activities every 500 operating hours

Fig. 91: Drain valve with drain hose Unscrew sealing cap on the oil drain valve on the oil pan.

Screw oil drain hose onto the oil drain valve.

Let oil drain into the container provided.

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Unscrew oil drain hose and screw sealing cap onto the oil drain valve.

1.

4

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Operator's manual

Maintenance Maintenance activities every 500 operating hours

Troubleshooting Guide tube 2

4?

2

1.

chapter).

Install new sealing rings 3 and 5 and sealing rings 5.

4.

1

4 and tighten with 40+10 Nm.

1.

3. chapter).

Install new sealing ring 2.

3.

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1 and tighten with 150 Nm.

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Maintenance

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Maintenance activities every 500 operating hours

Filling the diesel engine oil

Fig. 94 2 to within the min and max on the oil dipstick 1.

2 and tighten.

Start diesel engine.

Check oil pressure (diesel engine oil pressure display unit) and tightness on the

After 2 minutes to 3 minutes, check the oil level on the dipstick.

Troubleshooting Oil level is not within min and max?

5.8.3 Checking and replacing the V-ribbed belt Damages to the V-ribbed belt are: – Broken ribs – Rubber lumps on the bottom of the belt – Deposits of dirt or stones – Ribs detached from the bottom of the belt – Transverse cracks on the back – Transverse cracks in multiple ribs Depending on the diesel engine, the V-ribbed belt run varies, for example, alternator drive with or without air conditioning compressor.

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The belt drive is located on the front of the diesel engine.

Operator's manual

Maintenance Maintenance activities every 500 operating hours

Checking the V-ribbed belt WARNING Rotating parts!

are still moving.

Troubleshooting Did you discover damages?

Replacing the V-ribbed belt (with automatic tensioning device) Make sure that: New V-ribbed belt is available.

A socket wrench set with a lever is available.

WARNING Rotating parts!

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are still moving.

Fig. 95: V-ribbed belt drive Attach wrench socket with lever to the tensioning pulley screw (tensioning pulley screw has left-hand thread).

Swivel back the tensioning device clockwise against the spring force to the limit stop.

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Maintenance

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Maintenance activities every 500 operating hours

example, worn out bearings of the tensioning pulley as well as tread wear of the belt pulleys).

Troubleshooting Did you discover damages?

Troubleshooting V-ribbed belt not seated correctly?

Replacing the V-ribbed belt (without automatic tensioning device) Applies to diesel engines without automatic tensioning device.

Release screws 1, 2, 3.

Turn back hex nut 2 until V-ribbed belt is loose.

Remove V-ribbed belt.

Check belt pulleys.

Troubleshooting Tread wear of the belt pulley?

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Fig. 96

Operator's manual

Maintenance Maintenance activities every 500 operating hours

Troubleshooting V-ribbed belt not seated correctly?

4 against it, turn hex nut 2 to the right until the correct V-ribbed belt tension is achieved.

1, 2, 3.

Diesel engine has been run in 10 minutes to 15 minutes:

Checking the V-ribbed belt tension (without automatic tensioning device) Make sure that the following tools are ready: A measuring device Measuring points: In the middle between crankshaft belt pulley — alternator belt pulley In the middle between crankshaft belt pulley — air conditioning compressor belt pulley Recommended measuring device: Krikit 2 (special tool no. 8) Measured values for tension check by hand: 10 mm impression depth for the alternator drive 10 mm impression depth for the air conditioning compressor drive V-ribbed belt

New V-ribbed belt KG scale

Used V-ribbed belt KG scale

8 grooves, width approx. 28 mm.

50

40 to 50

Tab. 22: Measured values for tension check with measuring device “Krikit 2” (special tool no. 8)

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Check V-ribbed belt tension at the measuring points.

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Maintenance activities every 500 operating hours

Fig. 97: Krikit 2 measuring device (special tool no. 8) 1

Troubleshooting The value read does not match the table?

5.8.4 Checking the intake and exhaust system for condition, leaks

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Note Control interval is 1000 hours.

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Maintenance Maintenance activities every 500 operating hours

5.8.5 Checking the cooling and heating system for leaks and condition DANGER Burns.

leaks. undamaged condition, and that they are laid without rubbing and are properly fastened. clogged with dirt.

Troubleshooting If leaks are discovered on the cooling system:

5.8.6 Checking the lubricating and fuel system for leaks and condition

condition, and that they are laid without rubbing and are properly fastened.

Troubleshooting Did you discover leaks on the oil and fuel system?

5.8.7 LMB/11213244/02/01.12.2014/en

Make sure that: A collection container with the necessary capacity is available.

device design.

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Maintenance

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Maintenance activities every 500 operating hours

WARNING Fire and explosion. the fuel system.

separator Unscrew screws 2 and remove cover 3 with seal 4.

5 together with spring cassette 7.

WARNING Dirt!

Destruction of Common Rail System.

Observe special instructions for work on the common rail system, see

5.

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5.

Operator's manual

Maintenance Maintenance activities every 500 operating hours

Check seal 4

Make sure that: A collection container with the necessary capacity is available.

A suitable drain hose from the device manufacturer is available.

WARNING Fire and explosion. the fuel system.

If a kick plate is present: Remove kick plate.

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Fig. 99: Fuel drain line Put a collection container under the fuel drain line.

1.

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Maintenance

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Maintenance activities every 500 operating hours

Release both housing covers 1 from the fuel service center using a suitable tool.

Open cover until the respective ventilation hole becomes free.

3

1.

Replace sealing ring 2 and clean housing cover if necessary.

WARNING Dirt!

Destruction of Common Rail System.

5.8.9 Checking the batteries and cable connections Note Control interval is at 1000 h.

For procedure to check the batteries and cable connections, see documentation from the device manufacturer.

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20+5 Nm).

Operator's manual

Maintenance Maintenance activities every 500 operating hours

5.8.10 Checking the control unit mounting for condition

Troubleshooting Did you discover damaged bearings?

5.8.11

Checking sensors, actuators, cable holders and plugs for condition Note Control interval is at 1000 h.

condition.

Check all cables and cable harnesses for undamaged condition, and that they are laid without rubbing and are properly fastened.

LMB/11213244/02/01.12.2014/en

Troubleshooting Did you discover damage to cable connections, cables harnesses or sensors?

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Maintenance

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Maintenance activities every 1000 operating hours

5.9 Maintenance activities every 1000 operating hours Make sure that: The diesel engine is in the maintenance position.

V arrangement) Make sure that: The oil separators are installed on the left and right side of the front of the diesel

Pull hose clamps 1 and hose 2

5.

Unscrew screws 3 and bring holder 4 into open position.

Remove regulating valve (cover).

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6.

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Operator's manual

Maintenance Maintenance activities every 1000 operating hours

7

6 with clean fuel or oil.

Note The arrows 8 must be aligned with the screws 3. axis).

Insert new o-ring 10 on regulating valve (cover).

Lubricate o-ring with clean fuel or oil.

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Attach regulating valve (cover), ancillary support housing side alignment

Fig. 103: Filter insert installed

Push on hose and tighten hose clamps.

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Maintenance

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Maintenance activities every 1000 operating hours

arrangement) Make sure that: The oil separators are installed on the left and right side of the front of the diesel

Pull hose clamps 1 and hose 2

4.

Release screws 3.

Remove regulating valve (cover).

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6.

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Maintenance Maintenance activities every 1000 operating hours

Lubricate o-ring 7

6 with clean fuel or oil.

Insert new o-ring 5 on regulating valve (cover).

Lubricate o-ring with clean fuel or oil.

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Attach regulating valve (cover), ancillary support housing side alignment

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Maintenance activities every 1000 operating hours

Fig. 106: Filter insert installed Fix regulating valve using screws.

Push on hose and tighten hose clamps.

5.9.3 Checking the oil pan, engine mount and diesel engine

tighten screws if necessary.

5.9.4 Checking and setting the valve clearance Make sure that:

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Note

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Operator's manual

Maintenance Maintenance activities every 1000 operating hours

Fig. 107: Valves of the cylinder A = outlet valve E = inlet valve Valves of the cylinder D9508 A7 SCR overlap

1

5

7

2

6

3

4

8

set

6

3

4

8

1

5

7

2

Tab. 23: Valves of the cylinder D9508 A7 SCR

Checking and setting standard valve clearance Dismantle cylinder head covers.

Mount turning device.

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Turn crankshaft with the turning device in the direction of rotation until the

Fig. 108: Checking / setting the inlet valve clearance

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Maintenance activities every 1000 operating hours

Fig. 109: Checking / setting the outlet valve clearance clearance.

Troubleshooting Does the clearance not match the settings chapter)? rocker arm and correct setting.

Check setting again.

After checking and/or setting all valves, attach cylinder head covers with seals that have been checked to ensure they are not damaged.

Remove turning device.

Checking and setting the valve clearance with engine auxiliary brake system (ABS) Checking and setting the inlet valve clearance Dismantle cylinder head covers.

Mount turning device.

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Turn crankshaft with the turning device in the direction of rotation until the valves belonging to the cylinder

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Maintenance Maintenance activities every 1000 operating hours

Fig. 110: Checking / setting the inlet valve clearance clearance.

Troubleshooting Does the clearance not match the settings chapter)? rocker arm and correct setting.

Check setting again.

After checking and/or setting all valves, attach cylinder head covers with seals that have been checked to ensure they are not damaged.

Remove turning device.

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Checking the outlet valve clearance

Fig. 111: Valve bridge / rocker arm valve clearance screw and check valve clearance.

Troubleshooting Does the clearance not match the settings chapter)?

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Maintenance

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Maintenance activities every 1000 operating hours

Fig. 112: Valve bridge / counterholder valve clearance screw and check valve clearance.

Troubleshooting Does the clearance not match the settings chapter)?

Setting the outlet valve clearance

Fig. 113: Valve bridge / rocker arm valve clearance Turn back adjusting screw 2 until the contact surface of the adjusting screw disappears in the counterholder.

Screw in adjusting screw 1 until the piston in the outlet valve bridge reaches the limit stop and the feeler gauge clamps.

Loosen adjusting screw 1 until the feeler gauge feeler can be pulled out against moderate resistance (suction).

Tighten lock nut of adjusting screw 1 with 45 Nm.

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Turn back adjusting screw 1 until the feeler gauge corresponding to the setting can be inserted.

Operator's manual

Maintenance Maintenance activities every 1000 operating hours

Fig. 114: Valve bridge / counterholder valve clearance With the feeler gauge inserted that corresponds to the settings, screw in adjusting screw 2 until the piston of the valve bridge reaches the limit stop and the feeler gauge clamps.

Loosen adjusting screw 2 until the feeler gauge feeler can be pulled out against moderate resistance (suction).

Tighten lock nut of adjusting screw 2 with 45Nm. The push rod must have play.

Check settings again.

After checking and/or setting all valves, attach cylinder head covers with seals that have been checked to ensure they are not damaged.

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Remove turning device.

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Maintenance activities every 2000 operating hours

5.10 Maintenance activities every 2000 operating hours Make sure that: The diesel engine is in the maintenance position.

5.10.1 Checking the anticorrosive antifreeze agent concentration in the coolant

antifreeze agent corresponds to freeze protection up to approx. -37° C.

Checking the anticorrosive antifreeze agent concentration DANGER Hot coolant!

Burns.

If the analysis shows a lower frost protection:

Correcting the anticorrosive antifreeze agent concentration If the anticorrosive antifreeze agent concentration is too low: calculation formula below.

50 liters

Measured concentration Anticorrosive antifreeze agent 14.8 liters This amount should normally be drained beforehand! (corresponds to –15 °C)

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Coolant content (total)

Operator's manual

Maintenance Maintenance activities every 2000 operating hours

ATTENTION Proportion of anticorrosive antifreeze agent in the coolant too high!

Diesel engine will overheat and can be damaged.

Use of anticorrosive agents without antifreeze Use of DCA 4 Take a coolant sample and analyze it using test kit CC 2602 M from Fleetguard.

If the analysis does not yield a DCA 4 concentration between 0.6-1.06 units per liter:

Use of water-soluble anticorrosive agents – – – –

Caltex XLI Delo XLI Texaco XLI Havoline XLI

Take a coolant sample and analyze it using refractometer 2710 from Gefo.

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Checking the mixing ratio with a refractometer

Fig. 115: Gefo refractometer 2710 1

Refractometer

2

Eyepiece

Measuring procedure Thoroughly clean cover and prism.

Place 1-2 drops of the coolant sample on the prism.

2 against a bright background and focus the scale.

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Maintenance activities every 2000 operating hours

Adjust visual acuity by turning the eyepiece 2.

Read Brix values at the blue dividing line in eyepiece 2.

2

3 quantity (liters) Auxiliary lines

4

Coolant quantity (liters) in the cooling system

line 2 (starting from the measured value 1 Brix) down to the left to the vertical line, Coolant quantity in the cooling system 4 (50 liters), and from this point, horizontally to the outside left (2.4 liters of pure anticorrosive agent 1 quantity of pure anticorrosive agent 1 that must be added in order to get back to the required value of 2.8 Brix.

To re-establish the correct mixing ratio, at least the (previously) determined quantity must be drained from the cooling system.

Pour in the determined quantity of pure anticorrosive agent. drained coolant.

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Maintenance Maintenance activities every 4500 operating hours

5.11 Maintenance activities every 4500 operating hours Make sure that: The diesel engine is in the maintenance position.

pump Make sure that: New drain plug is available.

A collection container with the necessary capacity is available.

Fig. 117: SCR urea pump Disconnect electrical connection.

Put a collection container under the SCR urea pump.

Open ventilation screw 1.

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Unscrew drain plug 6.

5 with socket wrench or pipe wrench.

3 and foam element 2 and dispose in an environmentally Remove old sealing ring 4.

Lubricate new sealing ring 4 with clean water or reduction agent and install on

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Maintenance activities every 4500 operating hours

Tighten new drain plug with 2.5 Nm. Tighten ventilation screw with 1.5 Nm. Check leakage from aeration pump.

Re-establish electrical connection.

Start diesel engine.

Check pump during starting sequence (priming) for leaks.

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Troubleshooting Did you discover leaks?

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Operator's manual

Maintenance Maintenance activities every 6000 operating hours

5.12 Maintenance activities every 6000 operating hours Make sure that:

5.12.1 Replacing the coolant Make sure that: Heating taps, if present, are open.

A collection container with the necessary capacity is available.

A drain hose is available.

The necessary quantity of coolant is available.

A coolant drain valve and a screw plug are located on the right and left sides of the Both drain valves and screw plugs must be opened to replace the coolant.

Draining the coolant DANGER Hot coolant!

Burns.

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circumstances.

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Maintenance activities every 6000 operating hours

Fig. 118: Draining the coolant 1 slightly counterclockwise until overpressure can escape, then open it.

CAUTION Coolant can lead to eye injuries and allergic skin reactions!

Avoid skin contact with coolant at all costs.

Follow the manufacturer's instructions.

When mixing coolant, wear rubber gloves and safety goggles.

Wash splatters in the eyes or on the skin out with water immediately.

2 of the drain valve on the left and right of the diesel

3 on the same side of the crankcase.

container 3 on this side.

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engine.

Operator's manual

Maintenance Maintenance activities every 6000 operating hours

When the coolant has also drained on this side, unscrew the drain hose from the drain valve.

Screw on both protecting caps, install drain plug on the cooler and the two screw plugs on the crankcase.

Filling the coolant

Fill cooling system up to maximum.

Place sealing cap on the expansion tank and close it.

Start the diesel engine, let it warm up.

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necessary.

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Maintenance activities every 10000 operating hours

5.13 Maintenance activities every 10000 operating hours Make sure that: The diesel engine is in the maintenance position.

Make sure that: The diesel engine is in the maintenance position.

the battery.

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battery.

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Maintenance Maintenance activities as needed

5.14 Maintenance activities as needed

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Make sure that: The diesel engine is in the maintenance position.

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Make sure that: A ohmmeter or multimeter is available.

1 is installed on the diesel engine at the inlet of the air intake

the battery.

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Troubleshooting

the battery.

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Maintenance Ventilating the fuel system

5.16 Ventilating the fuel system

Emptying the fuel tank Initial commissioning of the diesel engine WARNING Dirt!

Destruction of Common Rail System.

WARNING

the fuel system.

ATTENTION

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ventilated.

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Ventilating the fuel system

Fig. 121: Manual feed pump 2a 2b.

In order to be able to start the diesel engine: 2c

Troubleshooting The starting procedure remains unsuccessful after about 20 seconds?

If you have repeated this procedure three times:

Low pressure circuit (LPC) of the engine is vented through permanently installed throttle holes, no additional measures are necessary.

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Note

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Maintenance

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device manufacturer.

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the device manufacturer.

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Maintenance Transport and storage

5.19 Transport and storage 5.19.1 Suspension device DANGER Falling load!

Risk of death. attachments.

To lift the diesel engine, attach correct suspension devices to the transport devices provided for this.

Fig. 122: Suspension device

5.19.2 Storage up to 6 months

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normal storage in a dry, ventilated place, the duration of the conservation protection is 6 months. outdoors for up to one month.

The cover must be waterproof and lie loosely against the diesel engine so that the air can circulate around the diesel engine and the formation of condensation is prevented.

If the aforementioned stipulations are deviated from, in which the conserved diesel engine is subjected to more unfavorable conditions (longer placement outdoors or storage in damp, unventilated places etc.), a shortening of the duration of the conservation protection is to be expected.

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Transport and storage

5.19.3 Storage over 6 months up to 24 months

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For storage over 6 months up to 24 months, contact LIEBHERR service or a LIEBHERR authorized dealer.

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Index

A

Additional labels 20 Additional rules and directives 20 Air compressor 15 Air conditioning compressor 15 Alternator 17 Approved anticorrosive agents (inhibitors) without antifreeze 59 Approved anticorrosive antifreeze agents 58 Approved ready-mixed anticorrosive antifreeze agent 59 ATEX type plate 13 Availability 35

B SCR urea pump 97 Checking / draining the water separator on the fuel

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Checking and replacing the V-ribbed belt 74 Checking and setting standard valve clearance 89 Checking and setting the inlet valve clearance 90 Checking and setting the valve clearance 88 Checking and setting the valve clearance with engine auxiliary brake system (ABS) 90 Checking sensors, actuators, cable holders and plugs for condition 83 Checking the anticorrosive antifreeze agent concentration 94 Checking the anticorrosive antifreeze agent concentration in the coolant 94 Checking the batteries and cable connections 82 Checking the control unit mounting for condition 83 Checking the coolant level 66 Checking the cooling and heating system for leaks and condition 79 Checking the engine oil level 65 Checking the intake and exhaust system for condition, leaks 78 Checking the lubricating and fuel system for leaks and condition 79 Checking the oil pan, engine mount and diesel

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Checking the outlet valve clearance 91 Checking the V-ribbed belt 75 Checking the V-ribbed belt tension (without automatic tensioning device) 77 Cold package 15 Consumption 35 Control and operating elements 29 Control and warning lamps 35 Coolant - mixing ratio 58 Coolant pump 17 Coolant thermostat 17 Cooling 14 Cooling system 50 Correcting the anticorrosive antifreeze agent concentration 94 Crankcase 14 Cylinder designation, direction of rotation 13 Cylinder head valves 50 Cylinder head with engine auxiliary brake system (ABS) 16

D

Design features 13 Design overview 9 Diesel engine 16, 50 Diesel engine brake and auxiliary brake system 15 Diesel engine characteristics 14 Diesel engine construction 13 Diesel engine coolant 57 Diesel engine number 11 Diesel engine special equipment 15 Diesel engine type plate 11 Diesel fuel - lubricity 55 Diesel fuel at low temperatures (winter operation) 55 Diesel fuels 54 Disposal 34 Disposal of waste materials 54 Draining the coolant 99 Draining the diesel engine oil 71 Draining water and sediment in the fuel tank 69 Drive control 14 Driving gear 14

E

Electrical system 51 Electronic diesel engine control 15 Electronic sensors on the engine side 15 Emission control warranty Statement warranty rights and obligations 112 Engine control unit type plate 12 Environmental protection measures 54 EPA/CARB Fuel label 111 EU strategies (Stage HIB) 36

115

Index Exclusions 113 Exhaust aftertreatment (SCR) 33 Exhaust aftertreatment system (SCR) 27 Explanation of the type designation 10

F

Faults - Cause - Remedy 43 Fill quantities table 52 Fill quantities, lubrication schedule 52 Filling the coolant 101 Filling the diesel engine oil 74

Operator's manual Maintenance activities every 500 operating hours 70 Maintenance activities every 6000 operating hours 99 Maintenance and inspection plan 49 Malfunctions 43 Manufacturer‘s warranty coverage 112 Measures for safe maintenance 22 Checking the mixing ratio with a refractometer 95 Mounting options for pumps 15

O

Flywheel housing 17 Fuel system 50

Operating hours 65 Operating hours 69 Operation 30 Owner‘s warranty responsibilities 112

G

P

H

R

General recommendations 57 General safety instructions 20

Handling, operation 29

I

Performing work after the test run 31 Preparatory maintenance activities 64 Preparing for initial commissioning 30 Product description 9 Reduction agent 33 Replacing the coolant 99

Ignitability 55 Index 115 Information to prevent crushing and burns 21 Initial commissioning / test run 30 Injection system 15

Labeling of warnings 19 Lubricating oil change intervals 57 Lubricating oil quality 56 Lubricating oil viscosity 56 Lubricating oils for the diesel engine 56 Lubrication 14 Lubrication schedule 52

M

Maintenance 49 Maintenance activities (daily) every 10 Maintenance activities (weekly) every 50 Maintenance activities as needed 103 Maintenance activities every 1000 operating hours 84 Maintenance activities every 10000 operating hours 102 Maintenance activities every 2000 operating hours 94 Maintenance activities every 4500 operating hours 97

116

arrangement) 86 Replacing the V-ribbed belt (with automatic tensioning device) 75 Replacing the V-ribbed belt (without automatic tensioning device) 76

S

Safety instructions 19 Safety measures for diesel engines with electronic control units 23 Safety measures when starting 22 SCR system 51 Setting the outlet valve clearance 92 Special instructions for work on the common rail system 24 Special tools for maintenance activities 61

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Index

Starting at freezing temperatures 32 Starting the diesel engine 31 Storage over 6 months up to 24 months 110 Storage suitability / temperature resistance 34 Storage up to 6 months 109 Sulfur content in the diesel fuel 55 Supplemental Information USA 111 Suspension device 109

T

Technical data 16 Technical description 9 Test run 30 Transport and storage 109 Type designation 10

U

Use / handling 34 Use of anticorrosive agents without antifreeze 95 Use of DCA 4 95 Use of water-soluble anticorrosive agents 95 US-EPA/CARB strategies (Tier4i) 38

V Ventilating the fuel system 105 Visual inspection (tightness, impurities, damage) 65

W

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Warning and malfunction strategies 35 Warranted parts 113 Warranty coverage 113 Water (fresh water) 58

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Index

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