Liebherr D936 A7-00 D946 A7-00 MCC Diesel Engine Operator's Manual 2019040001 - PDF DOWNLOAD

Operator's manual Diesel engine D936 A7-00 / D946 A7-00 / MCC From serial number 2019040001

en

Document ID Order number: Issued: Version: Author:

ORIGINAL OPERATOR'S MANUAL 13422361 19.03.2021 01 LMB / KD32

Product ID Product type: Product designation: From Serial no.:

Manufacturer Liebherr Machines Bulle SA Rue Hans-Liebherr 7 CH-1630 Bulle Schweiz

Diesel engine D936 A7-00 / D946 A7-00 / MCC 2019040001

Only for the United States

WARNING

WARNING

This product can expose you to chemicals including lead and lead compounds, which are known to the State of California to cause cancer.

For more information go to www.P65Warnings.ca.gov

Breathing diesel engine exhaust exposes you to chemicals known to the State of California to cause cancer and birth defects or other reproductive harm.

- Always start and operate the engine in a well-ventilated area.

- If in an enclosed area, vent the exhaust to the outside.

- Do not modify or tamper with exhaust system.

- Do not idle the engine except as necessary.

WARNING

For more information go to www.P65warnings.ca.gov/diesel

LMB/01/19.03.2021/enus

This product can expose you to chemicals including lead and lead compounds, which are known to the State of California to cause birth defects or other reproductive harm.

For more information go to www.P65Warnings.ca.gov

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Operator's manual

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Change history

Version From serial number

Changes included

Issue

00

Document newly created

5/11/2020

2019 04 0001

01

Fuel for diesel engines without emission type approval chapter revised. (Limit values remain unchanged) (For more information see: 5.10.4 Fuel for diesel engines without emission type approval, page 118.)

Changing the engine oil and oil filter chapter. New interval: 1000h/2 years (For more information see: 5.4.3 Changing the engine oil, page 70.)

03/19/2021 Replacing the oil separator filter insert chapter revised. New interval: 1000h/2 years (For more information see: 5.4.4 Replacing the oil separator filter insert, page 76.)

Checking and setting the valve clearance chapter revised.

New interval: 1000h (For more information see: 5.5.1 Checking and setting the valve clearance, page 79.)

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Change history

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Operator's manual

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Preface

About the document Contents The descriptions for maintenance and care of the engine can be found in these operating instructions.

Work instructions A prerequisite for proper maintenance is a flawless and complete basic set of tools and the necessary devices and special tools.

Only use clean and undamaged tools. Replace damaged tools in a timely manner. Cleanliness and order contribute to safety at the workplace.

Clean the diesel engine, in particular connections and screw fittings, of oil, fuel and care products at the start of the repair. Do not use any aggressive cleaning agents. Use lint-free cleaning cloths.

Do not use any flammable liquids to clean the diesel engine.

Sealing material (e.g. o-rings, seals, etc.) must always be replaced.

Removed parts should always be checked for their reusability and replaced, if necessary.

If no specific torques or tightening instructions are specified, screwed assemblies are to be tightened according to the standard torques; these are included in the “Appendix” section.

Spare parts Only original LIEBHERR parts or spare parts purchased from LIEBHERR may be used for maintenance of LIEBHERR diesel engines.

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.

LMB/01/19.03.2021/enus

All part information in this operator's manual, e.g. identification numbers, thread sizes, dimensions, etc., are only informational. Spare part orders may only be carried out by means of the spare parts catalog pertaining to the scope of delivery.

Lubricating and operating fluids Only lubricating and operating fluids approved by LIEBHERR may be used for the operation of LIEBHERR diesel engines.

LIEBHERR will cancel all possible obligations undertaken by LIEBHERR and/or its dealers, such as guarantee commitments, service agreements etc., without prior notice if lubricating and operating fluids other than those approved by LIEBHERR are used.

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Preface

Operator's manual

About the document

Usage instructions Illustrations in this operator's manual may have details that differ from your diesel engine. The work concerned should then be performed analogously to the work description at hand.

Improvements that are carried out on the diesel engine may result in changes, which may not yet be mentioned in this operator's manual.

If you require any further explanations or information, the customer service and customer service training departments of LIEBHERR are available to you. The operating instructions are not subject to an updating service. Depending on the technical requirements, the operating instructions are revised and are then published in the current version.

LMB/01/19.03.2021/enus

The service information released by Liebherr Machines Bulle serves as a supplement after the publication of a version of the operator's manual.

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Operator's manual

Preface Graphic symbols in these instructions

Graphic symbols in these instructions Symbol

Meaning Note Identifies useful information and tips.

Prerequisite Identifies conditions for the following action steps.

Call to action Identifies action steps.

Result Identifies results of one or more action steps.

–

Itemization Identifies individual points of a list.

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Graphic symbols

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Preface

Operator's manual

Changes, conditions, copyright

Changes, conditions, copyright This document is subject to change in the interest of technical progress.

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ISO 16016 protection notice: “Transmission and duplication of this document, utilization and communication of its contents are prohibited, unless expressly permitted. Infringements will lead to compensation. All rights reserved in the event of patent, utility model or design registration.”

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Contents

1

Product description

15

1.1

Technical description

15

1.1.1

Engine components

15

1.1.2

Company nameplate

17

1.1.3

Firing order, cylinder designation and engine serial number

19

1.1.4

Direction of rotation

19

1.1.5

Engine control unit type plate (ECU2)

20

1.2

21

1.2.1

Diesel engine

21

1.2.2

Valve clearance

21

1.2.3

Valve clearance, auxiliary braking system (ABS)

21

1.2.4

Coolant thermostat

22

Safety

23

2.1

Labeling of warnings

23

2.1.1

23

Additional labels

2.2

Target group

24

2.3

Intended use

24

2.4

Foreseeable misuse

24

2.5

General safety instructions

25

2.6

Preventing personal injuries

27

2.6.1

Bruises

27

2.6.2

Burns and scalds

27

2.6.3

Fires and explosions

27

2.6.4

Poisoning

27

2.6.5

High-pressure injection (liquids at high pressure can squirt out)

28

2.6.6

Electrical energy

28

2.6.7

Danger due to noise

28

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2

Technical data

2.7

Personal protective equipment

28

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Contents

Operator's manual

2.9

3

5

29

2.8.1

Safety instructions

29

2.8.2

Operating areas

30

2.8.3

Maintenance areas

30

2.8.4

Securing and releasing the diesel engine against accidental start-up

31

2.8.5

Emergency stop

32

Signage

32

2.10 Preventing property damage

33

Transport and storage

35

3.1

Dimensions and weights

35

3.2

Lifting the engine

36

3.3

Transport

38

3.3.1

Transport attachment

38

3.3.2

Transport device

39

3.4

4

Operating areas and maintenance areas

Storage

41

3.4.1

Storage

41

3.4.2

Storage time

45

Operation

47

4.1

Preliminary work for the initial commissioning of the engine

47

4.2

Starting the engine

48

4.3

Turning off the engine

50

Maintenance

51

5.1

Maintenance schedule

51

5.2

Preliminary work

54

5.2.1

Bringing the engine into maintenance position

54

5.2.2

As needed

54

5.3

Diesel engine

56

5.3.1

Checking the V-ribbed belt for damage

56

5.3.2

Checking the V-ribbed belt for tension

56

5.3.3

Checking the belt drive

57

5.3.4

Replacing the belt drive

60

5.3.5

Checking the engine mount

63

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2.8

Operator's manual

Contents

5.4

5.5

5.6

5.7

5.8

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5.9

5.3.6

Checking the intake system for leaks and damage

64

5.3.7

Checking the exhaust system

65

Engine oil system

66

5.4.1

Checking the engine oil system for leaks and damage

66

5.4.2

Checking the engine oil level

69

5.4.3

Changing the engine oil

70

5.4.4

Replacing the oil separator filter insert

76

Cylinder head

79

5.5.1

79

Checking and setting the valve clearance

Cooling system

96

5.6.1

Checking the cooling system and heating system for leaks and damage

96

5.6.2

Checking the coolant level

97

5.6.3

Checking the concentration of the antifreeze agent in the coolant

97

5.6.4

Replacing the coolant

98

Fuel system

102

5.7.1

Checking the fuel system for leaks and damage

102

5.7.2

Replacing the fuel prefilter

103

5.7.3

Reducing the pressure in the fuel system

103

5.7.4

Replacing the fuel fine filter

103

5.7.5

Ventilating the fuel system

106

Air filter

108

5.8.1

Checking the air filter low pressure indicator

108

5.8.2

Cleaning the air filter dust discharge valve

108

5.8.3

Replacing the dry air filter main element

108

5.8.4

Replacing the dry air filter safety element

108

Electrical system

109

5.9.1

Checking the batteries

109

5.9.2

Checking the cable connections

109

5.9.3

Checking the engine control unit bearings for damage

109

5.9.4

Checking sensors, actuators, cable holders and plugs

110

5.9.5

Checking the heating flange

111

5.9.6

Replacing the heating flange

114

5.10 Lubricants and operating fluids

116

5.10.1 Fill quantities

116

5.10.2 Engine oil for diesel engines without emission type approval

116

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Operator's manual

6

7

117

5.10.4 Fuel for diesel engines without emission type approval

118

Malfunctions

119

6.1

119

Faults - Cause - Remedy

Tools and devices

125

7.1

125

7.2

Tools 7.1.1

Special tool

125

7.1.2

Assembly agents

125

7.1.3

Diagnostic tools

126

Devices

127

7.2.1

Lifting traverse with two-point-raising (basic version)

127

7.2.2

Lifting traverse with two-point-raising

128

7.2.3

Engine assembly stand

129

7.2.4

Transport device

130

Appendix

133

8.1

Tightening torques

133

8.1.1

For hex bolts / cylinder screws / external hex bolts

133

8.1.2

For locking screws and banjo bolts

135

8.1.3

Standard torques for metric flange connections

136

8.1.4

Metric screw connection series L (light) (up to 500 bar/7252 Psi)

137

8.1.5

Metric screw connection series S (heavy) (up to 800 bar/11603 Psi)

138

8.1.6

Inch screw connection series L (light) (up to 500 bar/7252 Psi)

138

8.1.7

Inch screw connection series S (heavy) (up to 800 bar/11603 Psi)

139

8.1.8

Metric thread unit series L (light) (up to 500 bar/7252 Psi) for aluminum

140

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5.10.3 Coolant

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1 Product description

1.1 Technical description 1.1.1 Engine components 9

10

11 8 7 6

12

5

13

4 3

14

2 15

1

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16

Fig. 1: Ancillary support housing side 1 2 3 4 5 6 7 8

Viscous damper Thermostat housing Tension pulley (self-tensioning) Coolant pump V-ribbed belt Suspension device Alternator Oil filter

9 10 11 12 13 14 15

Cylinder head cover seal Coolant ventilation line Exhaust manifold Exhaust gas turbocharger Exhaust gas stub Oil cooler Coolant manifold

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Product description

Operator's manual

Technical description

6

7

8

5 9 4 10

3 2 11 1

Fig. 2: Flywheel side Flywheel Cable harness Fuel high pressure pump Oil separator Crankcase breather system Cylinder head cover

7 8 9 10 11

Air intake pipe Heating flange Engine control unit Fuel fine filter Oil dipstick

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1 2 3 4 5 6

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Product description Technical description

1.1.2 Company nameplate

9 8 7 6 5 4

10 11 12 13 14

3 15 16 17 18 19

2 1 Fig. 3: Company nameplate Manufacturer Data matrix code US type approval information Engine power at rated speed Identification number Engine variant (Liebherr internal type) Engine type Capacity Engine serial number Date of manufacture

11 12 13 14 15 16 17 18 19

US performance category EU exemption Minimum requirements for fuel EU type approval information ECE type approval information Chinese engine family Chinese emission limit stage Chinese type approval number Liebherr

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1 2 3 4 5 6 7 8 9 10

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Product description

Operator's manual

Technical description

Attachment point 2

1

Fig. 4: Company nameplate on the crankcase and on the air intake pipe 1

Company nameplate on the crankcase

2

Company nameplate on the air intake pipe

Itemization of engine serial numbers The engine serial number is engraved on the company nameplate in the field SERIAL NO..

2019 04 0001 Engine serial number Year of manufacture 04

Type series: 04 = D936 / D946 LMB/01/19.03.2021/enus

2019

0001 Sequential production number Tab. 1: Engine serial number

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Product description Technical description

1.1.3 Firing order, cylinder designation and engine serial number 2

3 1

Fig. 5: Cylinder designation, engine serial number (example) and firing order 1 2

Engine serial number Firing order

3

Cylinder designation

1.1.4 Direction of rotation

1

2

1

2

3

4

5

6

Fig. 6: Cylinder designation and direction of rotation 1

Flywheel side

2

Unit carrier side

= Outlet valve LMB/01/19.03.2021/enus

= Inlet valve Cylinder 1 is located on the flywheel side 1.

Viewed from the flywheel 1, the crankshaft turns counterclockwise.

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Product description

Operator's manual

Technical description

1.1.5 Engine control unit type plate (ECU2)

5 4 6

3 2 1

Fig. 7: Engine control unit type plate ECU2 (example) 1 2 3

Supplier number Control unit serial number Creation date

4 5 6

Software version at delivery Control unit identification number 2D bar code

Attachment point

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1

Fig. 8: Type plate on engine control unit 1

Type plate on engine control unit

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Product description Technical data

1.2 Technical data 1.2.1 Diesel engine Description

Unit Value

Construction

In-line diesel engine

Number of cylinders

6

Firing order

1–5–3–6–2–4

Hole (D936)

mm 122

Hole (D946)

mm 130

Stroke

mm 150

Displacement (D936)

l 10.5

Displacement (D946)

l 11.95

Compression ratio (D936)

17.4:1

Compression ratio (D946)

17.5:1

Direction of rotation of the diesel engine

Viewed from the flywheel: counterclockwise

Power group

LG 0 to LG 2

Rated power

see company nameplate

Rated speed

see company nameplate

Emission limits

without emission type approval

1.2.2 Valve clearance Description

Unit Value

Valve clearance, inlet, cold

mm 0.3

Valve clearance, outlet, cold

mm 0.4

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1.2.3 Valve clearance, auxiliary braking system (ABS) Description

Unit Value

Valve clearance, inlet, cold

mm 0.3

Valve clearance, outlet, cold

mm 0.6

Valve clearance, counterholder, cold

mm 0.4

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Product description

Operator's manual

Technical data

1.2.4 Coolant thermostat Description

Unit Value °C 82

Completely opened

°C 92

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Start of opening

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2 Safety

2.1 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. 2 The warning sign always appears in connection with the signal words.

DANGER WARNING CAUTION DANGER

Identifies an immediately dangerous situation that will result in death or serious bodily injuries if it is not avoided.

WARNING

Identifies a dangerous situation that could result in death or serious bodily injuries if it is not avoided.

CAUTION

Identifies a dangerous situation that could result in minor or moderate bodily injuries if it is not avoided.

ATTENTION Identifies a dangerous situation that could result in property damage if it is not avoided.

Tab. 3

2.1.1 Additional labels

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Note Identifies useful information and tips.

Tab. 4

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Safety

Operator's manual

Foreseeable misuse

2.2 Target group These operating instructions have been written for the operator and the maintenance personnel, as well as for the authorized specialist personnel of the engine.

All other persons, including supervisors and trainees, are classified as “unauthorized personnel” for maintenance tasks.

Unauthorized personnel is prohibited from maintaining the engine or accessing the engine compartment or engine cowling.

2.3 Intended use The engine may not be continuously operated in a load range that would be assigned to another power category with lower emission limit values.

The engine may not be continuously operated in the device outside the test range (NTE range) for the corresponding engine category.

– Only use the diesel engine for its intended purpose.

– Observe the following conditions from the manufacturer: • Operating conditions • Servicing conditions • Maintenance conditions – Make sure that the following work is only carried out by personnel in accordance with the target audience definition: • Using the diesel engine.

• Servicing the diesel engine.

• Maintaining the diesel engine.

Install contactors and protective devices prior to commissioning and ensure their function.

Pay attention to the safety and operating instructions.

Only operate the engine if it is in perfect working order.

Only operate the engine in the speed range specified by the manufacturer.

Bolt the engine to the machine or the corresponding place of use by the fitted engine mounts and the corresponding tensioning instructions.

– If engine mounts are used that have not been fitted by the manufacturer these have to be approved by the manufacturer.

– The engine may only be operated in areas that cannot be accessed by the general public, in other words the engine may only be operated in conjunction with an enclosure or engine compartment cover.

2.4 Foreseeable misuse The operating and maintenance manual has been drawn up in accordance with applicable standards and regulations in accordance with state-of-the-art technology.

Liebherr assumes no liability for: – Failure to observe these instructions – Incorrect use – The employment of personnel who do not satisfy the target audience requirements.

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– – – – –

Operator's manual

Safety General safety instructions

– Alterations and conversions of the diesel engine that have been carried out without the consent of Liebherr.

– Operating and auxiliary materials that have not been approved by Liebherr.

– The use of non- Liebherr spare parts that have not been officially approved by Liebherr, including the resulting consequential damages.

– Circumvention of and non-compliance with the safety regulations – Failure to observe international and national regulations on occupational health and safety – Failure to observe international and national regulations on environmental protection – Unauthorized modifications to the diesel engine – Manipulation to the injection system and control system – Emergency operation with limited safety function is deemed improper use. The manufacturer is not liable for damages due to improper use.

EU type approval expires for: – Manipulation to the diesel engine – Manipulation to the injection system and control system – Manipulation to the exhaust aftertreatment system The actual scope of delivery of the engine can differ from the relevant information in these instructions due to situational adaptations to customer requirements.

2.5 General safety instructions

LMB/01/19.03.2021/enus

– Fulfill the requirements of the target groups for the work.

– In order to guarantee help in the event of an accident: • A second person is present.

• Ensure that the emergency situation will be detected and help with take place.

– Ensure that the personnel is familiar with the operator's manual before installation work.

– Only allow the following personnel to work on the engine under the constant supervision and responsibility of a technician in accordance with the target group definition.

• Personnel to be trained • Personnel to be taught • Personnel to be instructed • Personnel in apprenticeships – Check the safety and hazard-conscious work of the personnel under the following conditions: • Observe the accident prevention regulations.

• Observe the generally recognized safety and occupational health rules.

• Observe the operator's manual.

– Make sure that the personnel wear the prescribed work clothing. (For more information see: 2.7 Personal protective equipment, page 28.)

– Do not wear the following: • Rings • Wristwatches • Neckties • Scarves • Open jackets • Loose-fitting clothing – Make sure that the following equipment is available for the assembly, clean, complete and undamaged: • Basic tool kit • Required devices • Required special tools – Replace damaged tools.

– Keep the workplace clean and orderly.

– Make preparations for emergencies that could occur.

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Safety

Operator's manual

General safety instructions

Have a fire extinguisher and first aid kit ready.

Have emergency telephone numbers ready.

Make sure that the workplace has sufficient lighting.

Perform installation work only when the engine is secured.

Ensure that the engine is not started by unauthorized individuals.

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– – – – –

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Safety Preventing personal injuries

2.6 Preventing personal injuries 2.6.1 Bruises – Do not lift heavy parts by hand.

– Fasten and secure individual parts and larger assemblies carefully with suitable lifting gear during their replacement.

– Use Liebherr lifting gear according to the operator's manual.

– Observe the regulations on the lifting points.

– Do not use any load handling devices that are damaged or that have an inadequate carrying capacity.

– Only use load handling attachments with sufficient load bearing capacity.

– Make sure that no persons stand or walk under loads.

– When the engine is running, objects can be flung back: Make sure that no objects come in contact with moving parts.

2.6.2 Burns and scalds The diesel engine is hot at its operating temperature.

– Only work on the diesel engine after it has cooled down.

– Touch hot parts with thermal protection gloves for repair purposes.

Before work on the cooling system: – Let the engine cool down – Release the pressure in the cooling system on the device side.

– Avoid contact with parts carrying coolant.

The engine oil is hot when the diesel engine is at its operating temperature.

– Avoid any skin contact with hot oil or parts carrying oil.

2.6.3 Fires and explosions – – – –

Do not smoke in the immediate vicinity of the engine.

Avoid fires, sparks and open flames when handling fuel and flammable liquids.

Start the engine according to the provisions of the operator's manual and assembly instruction.

Fuel and oil escaping out of leaky spots can lead to fires. Eliminate leaks and replace defective parts.

– Remove rags that are soaked with flammable liquids.

– When working on the electrical system: Disconnect the electrical power supply.

– Immediately remove flammable/thermally insulating deposits on engine components.

2.6.4 Poisoning LMB/01/19.03.2021/enus

– Only allow the engine to run in closed rooms when there is sufficient ventilation.

– Never ingest operating fluids.

– Do not use beverage bottles to store operating fluids.

Escaping liquids can penetrate the skin and will lead to blood poisoning.

– Do not open any lines and hoses that are under pressure.

– Do not remove any lines and hoses that are under pressure.

– Protect hands, face and body against escaping liquids when searching for leaks on lines and hoses that are under pressure.

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Safety

Operator's manual

Personal protective equipment

2.6.5 High-pressure injection (liquids at high pressure can squirt out) When the Diesel engine is running the fuel lines are under a constant fuel pressure of up to 2400 bar. Escaping liquids can penetrate the skin and lead to injuries.

– Only work on the fuel and injection systems when the diesel engine has been switched off. Wait at least 20 minutes after turning the Diesel engine off until the pressure in the injection system has been released before starting work.

– Check the pressure reduction with the diagnostics software.

– Use suitable protective equipment during work on the fuel and injection system (e.g. safety gloves, safety goggles, etc.).

– Do not open any pressurized fuel lines or hoses.

– Do not disconnect any pressurized fuel lines or hoses.

– Protect hands, face and body against escaping liquids when looking for leaks in pressurized lines and hoses.

2.6.6 Electrical energy – Persons with pacemakers have no access to the safety zones around the operational diesel engine.

– Do not touch any live parts.

– Before work on the electrical system, disconnect the electrical power supply and secure it against being switched back on.

2.6.7 Danger due to noise Possible permanent hearing loss due to noise levels above 84dB(A). Sound levels up to 110dB(A) possible!

– Keep all sound-insulating protective devices for the system closed when the engine is running.

– Only reside near the running engine with hearing protection designed according to the noise level.

– Observe the hearing protection measures according to the operator's manual of the device manufacturer.

Access to the safety zones is prohibited for the operator and unauthorized personnel when the engine is ready for operation or in operation. However, if a technician must reside by the unprotected engine for troubleshooting, he must wear hearing protection which is designed according to the noise exposure.

– Wear protective equipment for direct access to engines.

– Make sure that: • Protective equipment is in good condition.

• Protective function is guaranteed.

The following protective equipment is required to access the engine: Protective work clothing – Tight-fitting protective clothing that is not tear-resistant to protect against injuries and simple chemical substances

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2.7 Personal protective equipment

Operator's manual

Safety Operating areas and maintenance areas

Safety helmet – Protection against • Falling or flying object • Bumping your head Wear a safety helmet in the immediate vicinity of the engine.

Safety shoes – Foot protection against • Falling objects • Pinching of the foot in heavy parts • Against slipping Wear safety shoes in the immediate vicinity of the engine.

Safety gloves – Protection against hot elements and chemicals Wear safety gloves when working with hot parts, for example, • shrinking the gear ring onto the flywheel.

• Working with operating fluids (See manufacturer's specifications for the operating fluids and safety data sheet for the operating fluid.)

Safety goggles – Protection against: • Flying fragments • Chemical splashes – Wear safety goggles when: • Handling operating fluids (See manufacturer's specifications for the operating fluids and safety data sheet for the operating fluid.)

• Wear during mechanical interventions, for example, using compressed air.

Hearing protection – Protection against noise

Wear hearing protection around the diesel engine when it is running.

2.8 Operating areas and maintenance areas 2.8.1 Safety instructions Trapping points and mechanical parts flying around when the engine is ready for operation or in operation LMB/01/19.03.2021/enus

Serious injuries and risk of death: – Keep away from the operational engine.

– Wear personal protective equipment.

– Technicians may reside in safety zone “A” for measurement purposes, if nothing else has been stated by the device manufacturer.

Hot parts when the engine is ready for operation or in operation.

Risk of burns: – Keep away from the operational engine.

– Wear personal protective equipment.

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Operating areas and maintenance areas

– Let the engine cool down sufficiently.

High electric short-circuit currents during maintenance work Risk of burns from electric shock: – Access to safety zones in maintenance condition, according to target group definition – Disconnect the electrical power supply.

– Wear personal protective equipment.

2.8.2 Operating areas A

D

B

B

B

B

C

E

a

b

Fig. 20: Safety zones for the engine that is ready for operation or in operation a

Horizontal plan (view from above)

b

Vertical plan (view from flywheel side)

Do not enter the following zones: – Safety zone for unit ancillary support housing side A – Safety zone next to the engine B – Safety zone for flywheel side C – Safety zone above the engine D – Safety zone below the engine E

2.8.3 Maintenance areas

WARNING Hot components on the engine!

Serious burns possible.

Let the engine cool down before any potentially hot components are touched. The engine must be cooled down to below 50 °C. Wear heat-resistant safety gloves and heat-resistant protective work gloves.

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Maintenance areas are the safety zones that are to be entered for maintenance work and troubleshooting.

Operator's manual

Safety Operating areas and maintenance areas

A

D

B

B

B

B

C

E

a

b

Fig. 21: Safety zones for maintenance and repairs a

Horizontal plan (view from above)

b

Vertical plan (view from flywheel side)

The following zones are accessible: – Safety zone for unit ancillary support housing side A – Safety zone next to the engine B – Safety zone for flywheel side C – Safety zone above the engine D Do not enter the following zones: – Safety zone below the engine E

2.8.4 Securing and releasing the diesel engine against accidental startup Access to the engine must be secured against unexpected start-up before entering the safety zones.

Procedure:

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Secure the engine against unexpected start-up: – Disconnect the diesel fuel supply.

– Label cut-off point.

– Disconnect electrical power supply and secure against reactivation.

– Label cut-off point.

Make the diesel engine ready for operation (release): – The following work has been completed: • Installation activities • Maintenance activities • Repair activities – Make sure that all foreign bodies have been removed.

– All of the protective devices are installed and are working properly.

– Make sure that no external persons stand or walk in the danger zones.

– The tags for the fuel supply are removed. copyright © Liebherr Machines Bulle SA 2021

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Signage

– Fuel supply is connected.

– Remove the label from the electrical power supply.

– Establish the electrical power supply.

2.8.5 Emergency stop An emergency stop is provided for hazardous situations that call for an immediate shutdown of the Diesel engine. The power supply to the Diesel engine is interrupted immediately. Only the engine control unit still receives current.

Examples of hazardous situations: – Fire – Persons having suffered an electric shock – Diesel engine does not stop – Diesel engine accelerates uncontrollably Only use the emergency stop in emergencies. Triggering an emergency stop can cause permanent damage to the Diesel engine. The emergency stop may not be used to stop the Diesel engine for operational purposes.

2.9 Signage Note The following required signs must be clearly visible and attached in the direct vicinity of the safety zones.

The following required signs must be able to withstand the ambient conditions. The end user must ensure that these are kept visible and legible over the entire life cycle.

Additional warnings or adaptations to product standards (ISO 8528-13) are possible.

ISO 7010 / W012 Warning against dangerous electrical voltage – Only persons who are familiar with the risks of electricity may work within the identified area.

Unauthorized persons may only enter the safety zone after the electrical power supply has been disconnected.

ISO 7010 / W025 Warning of entanglement hazard – There are potential trapping hazards on the engine in the area of the V-ribbed belts and alternator to charge the battery.

Attach a warning sign if traps are not secured through guards (optional).

Enter the safety zone only after the Diesel engine has been turned off.

Secure the Diesel engine against any unexpected start-up.

ISO 7010 / P007 No access for persons with pacemakers or implanted defibrillators – Possible EMC radiation that may affect heart pacemakers and implanted defibrillators.

People with a heart pacemaker or implanted defibrillator: keep a minimum distance of 20 cm from the operational Diesel engine.

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ISO 7010 / W017 Warning against hot surfaces – The Diesel engine has hot surfaces that are not immediately recognizable as such.

Wait for a sufficient time until the engine has cooled down.

Only touch components that may be hot with suitable protective gloves.

Operator's manual

Safety Preventing property damage

ISO 7010 / M002 Observe instructions – In order to ensure that all residual risks are known by the personnel, the system documentation must be read and understood.

Make sure that all residual risks according to the risk assessment of the system manufacturer are reflected in the system documentation.

Provide documentation to the personnel according to the “target audience” definitions without restrictions.

2.10 Preventing property damage

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– Replace sealing material, for example, o-rings and seals.

– Check removed, reusable parts for reusability, see corresponding information in the repair instruction.

– Replace removed, not reusable parts.

– If no specific torques and tightening instructions are specified: Tighten screwed assemblies according to the standard torques. For further information, see “Standard torques” chapter.

– Replace self-locking screwed assemblies.

– Thoroughly clean the engine, connections and screwed assemblies of oil, combustion residues or care products before installation.

– Use lint-free cleaning cloths.

– Do not touch electrical contacts. Connection will be affected by contamination or components will be destroyed by electrostatic discharge.

– Before cleaning the engine: Cover or seal openings into which no water, steam or cleaning agents may enter due to safety or functional reasons.

– Remove covers or adhesives after cleaning.

– Check gas-conveying lines, engine oil lines and hydraulic lines for the following defects: • Leaks • Loose connections • Abrasion points • Damage – Make sure that the electrical power supply is securely connected when starting.

– Before disconnecting the electrical power supply: Turn off engine.

– Use suitable test leads for measurements on plug connections.

– If no mating connector is attached: Protect the engine control unit against dust and water.

– When working on the electrical system: Disconnect the battery (if present).

– Disconnect the negative pole first and connect it last.

– During electric welding on the machine, remove the plug from the control unit.

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Preventing property damage

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3 Transport and storage

3.1 Dimensions and weights

2

1

3

Fig. 27: Dimensions 1 2

Width Height

3

Length

Description

Unit Value

Width

mm 843

Height

mm 1267

Length

mm 1429

Engine weight without operating fluids

kg 1219

Note

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The stated dimensions and the engine weight apply for an example application. For exact values, see technical data sheet.

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Lifting the engine

3.2 Lifting the engine DANGER Pulling out of the lifting devices on the engine and falling of the engine!

Will lead to death or serious injuries due to crushing.

Make sure that no one is standing or walking under suspended loads. Maintain safety distance.

Observe maximum weight for lifting points.

Maintain a maximum of a 10° deviation from the vertical to the engine axis.

Use a Liebherr lifting traverse. (For more information see: 7.2.1 Lifting traverse with two-pointraising (basic version), page 127.)

Take safety instructions / warning signs from the operator's manual of the lifting traverse into account.

Observe national and international guidelines for lifting heavy loads.

Make sure that no persons reside in the danger zone (see safety chapter).

Remove the gear box or other attachments before lifting the engine. max.10°

max.10°

4 1

4 5

3

4

5

3

3

5

1

1

1

2

B

2

2

D

C

A max.6° max.6°

E F

Fig. 28: Lifting the engine A

Transport device detail view

1

B

Front / rear view of two lateral transport devices Side engine view

2

Tolerance for maximum deviation of motor axis Crankcase

3

Lifting traverse

C

See next page for continuation of the image legend

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5

2

Operator's manual

Transport and storage Lifting the engine

D

Front / rear view of lateral transport device

4

E

Lifting traverse lifting point detail view

5

F

Take lifting traverse warning signs, lifting traverse operator's manual into account.

Engine lifting traverse lifting point (observe maximum total load) Tolerance for maximum horizontal deviation

LMB/01/19.03.2021/enus

Lift the engine: Attach correct lifting traverse 3 to the transport devices A provided for this.

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Transport

3.3 Transport 3.3.1 Transport attachment

Fig. 29: Transport attachment DANGER Instability during transport!

Leads to death or serious injuries.

Only use the original transport device.

Secure the transport device, including the mounted engine, against slipping and falling down.

Make sure that the transport device is in technically perfect condition.

Secure the transport device against slipping and falling down in all directions.

Observe the center of gravity.

Bolt the engine securely to the transport device.

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DANGER The engine can tip during loading or unloading!

Leads to death or serious injuries.

Make sure that only authorized personnel loads/unloads the engine.

Make sure that the crane or forklift is suitable for the weight to be lifted.

If the engine is being lifted with a crane: Use a lifting traverse.

Make sure that no persons reside in the danger zone during the loading / unloading.

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Operator's manual

Transport and storage Transport

3.3.2 Transport device Wood transport device DANGER Instability during transport!

Leads to death or serious injuries.

Only use the original transport device.

Secure the transport device, including the mounted engine, against slipping and falling down.

Make sure that the transport device is in technically perfect condition.

Secure the transport device against slipping and falling down in all directions.

Observe the center of gravity.

Bolt the engine securely to the transport device.

Fig. 30: Wood transport device LMB/01/19.03.2021/enus

Only transport the engine using the transport device.

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Transport

Steel transport device DANGER Instability during transport!

Leads to death or serious injuries.

Only use the original transport device.

Secure the transport device, including the mounted engine, against slipping and falling down.

Make sure that the transport device is in technically perfect condition.

Secure the transport device against slipping and falling down in all directions.

Observe the center of gravity.

Bolt the engine securely to the transport device.

Fig. 31: Steel transport device LMB/01/19.03.2021/enus

Only transport the engine using the transport device.

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Transport and storage Storage

3.4 Storage 3.4.1 Storage Note Liebherr recommends: Keep storage times as short as possible.

Immediately install repair kits, sealing kits and conversions kits, as well as engines.

Use the “first in first out” logistics method.

Make sure that the following prerequisites are met: Storage space in closed buildings (preferably brick or concrete buildings) No direct contact with atmospheric conditions (weather) Storage space well ventilated Storage space protected against frost Building is not in the immediate vicinity of fresh water or salt water resources Avoid direct sunlight, only low light irradiation permissible Falling below the dew point does not occur regularly Cover the engine with suitable aids to protect against UV exposure Storage at high storage locations in high-bay warehouses only permissible in fully air-conditioned storage spaces Recommended storage temperature: +18 °C to +23 °C (air-conditioned warehouse) Approved storage temperature: +5 °C to +35 °C Approved relative humidity 30 - 60% Engine stored shock-resistant, slip-resistant

Preservation with VCI corrosion protection film Products that are not painted or that have bare surfaces are also packed in VCI corrosion protection film to protect against water and oxygen. When the volatile corrosion inhibitor "VCI" diffuses from the film to the metallic product, an atmosphere consisting of amines and nitrides arises and protects the product against the formation of rust and verdigris. The substance, or rather the protective atmosphere, evaporates without residues after unpacking.

Make sure that the following prerequisites are met Perform packing in enclosed spaces with low humidity and constant temperatures.

Engine clean and dry Temperature of the engine identical to the ambient temperature (formation of condensation)

LMB/01/19.03.2021/enus

VCI film cover LxWxH ID no.

2100x1100x2150

10165707

1250x850x1500

10042128

1250x850x2100

11694088

990x540x1300

11067328

2000x1500x2000

11826670

3200x1500x2000

11826671

540x350x540

11067327

350x250x550

11067326

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Storage

VCI film cover LxWxH ID no.

850x650x800

10331822

Tab. 5: VCI film cover VCI bag LxW ID no.

300x200

11170517

345x260

11170521

Tab. 6: VCI bag Loosely apply the VCI corrosion protection film so it is sealed tight.

Air can circulate.

The protective atmosphere will have formed by 24h at the latest and the engine is protected.

Disposal CAUTION Chemical substances!

Skin contact with VCI corrosion protection film can lead to skin irritation.

Use protective gloves.

After using the VCI corrosion protection film and before eating: Wash hands.

Dispose of VCI corrosion protection film.

Observe national statutory provisions for the protection of the environment during the disposal.

VCI corrosion protection film de-preservation After preservation with VCI corrosion protection film, no de-preservation is necessary.

Preservation with corrosion protection wax All bare outer surfaces of an engine are particularly exposed to corrosive attack after use when the engine is decommissioned. The corrosion is comparable to wear and can shorten the life of the affected parts.

Make sure that the following points are observed when applying corrosion protection wax: Ambient temperature is at least 15 °C. Protective equipment is used.

Drying time is 3 hours.

Name

Description

ID no.

WAXOYL 120-4 Spray can 500 ml ) 8504472 Long-term protection for up to 2 years A

Tab. 7: Corrosion protection wax A)

A preservation surface of approximately 5 m² can be treated with one liter of Waxoyl. The low temperature resistance of WAXOYL 120-4 corrosion protection wax is above -40°C or -40°F.

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Preservation work is only to be performed by trained persons who are familiar with the work and informed about the dangers.

Operator's manual

Transport and storage Storage

NOTICE Decommissioning at freezing temperatures!

Damage to engine.

Contact customer service.

Remove the engine from the device or system.

Set the engine down on a level, dry and firm surface and simultaneously secure it against rolling away.

CAUTION Wax residues on the floor!

Slipping.

Watch out for wax residues on the floor.

Remove wax residues on the floor.

Clean engine.

Carefully dry electronic components and damp areas of the engine using a compressed air gun.

Make sure that the engine is clean and dry before starting the preservation.

Check the engine for damage.

Check the engine for paint damage.

If any damage exists: Repair the damage.

The following materials are synthetic materials: – Plastic parts – Hoses – Rubber Cover synthetic materials with suitable aids due to UV exposure.

Disposal Properly dispose of corrosion protection wax.

Observe national statutory provisions for the protection of the environment during the disposal.

Corrosion protection wax de-preservation See Cleaning chapter.

Cleaning LMB/01/19.03.2021/enus

Cleaning with cleaning agents NOTICE Impermissible cleaning agent!

Damage to surfaces and sealing elements.

Only use suitable, mild cleaning agents.

Only use lint-free cleaning cloths.

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Storage

Remove lubricant and contaminants.

Remove water residues.

Warm up the engine.

Cleaning with steam jet cleaner NOTICE Impermissible use of the steam jet cleaner!

Damage to the electronics and seals of the engine.

Do not use the steam jet cleaner until after the first two months following the curing time of the paint.

Prerequisites: Shafts and flanges are lubricated.

Openings are covered or taped with protecting caps and guards.

Seals and closures are tight.

Lance distance is at least 50 cm from the surface which is being cleaned.

Water temperature is a maximum of 60 °C. Standard motor vehicle cleaner used. (Neutral cleaner, added two to three percent) Note Liebherr recommends: Refrain from water on the regulator, electronic components and plug connections.

NOTICE Steam jet comes in contact with temperature sensors!

Activation of the extinguishing system.

Keep the hot steam jet away from the temperature sensors for the fire alarm and extinguishing system.

NOTICE High pressure cleaner comes in contact with sensitive components!

Damage to the electronics and seals of the engine.

Do not point the high pressure cleaner at sensitive components. (For example, rotary shaft lip seals, electrical connections, electronic components) Blow the engine dry with a compressed air gun.

Remove protective covers completely.

LMB/01/19.03.2021/enus

If defects exist: Inspect motor cables for leaks, loosened connections, abrasion points and damage.

Remove water residues.

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Transport and storage Storage

3.4.2 Storage time Condition

up to 1 month

1 to 6 months

New (as originally packDry, in a ventilated place aged) Outdoors, possible using VCI and Used

under UV-resistant tarpaulin

6 to 24 months

Possible using VCI corrosion protection film Dry, in a ventilated place Possible using corrosion protection wax Possible using VCI corrosion protection film Possible using corrosion protection wax

Tab. 8: Storage time

LMB/01/19.03.2021/enus

Observe the storage time.

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LMB/01/19.03.2021/enus

Storage

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4 Operation

4.1 Preliminary work for the initial commissioning of the engine Check engine for proper installation, see documentation from the device manufacturer.

Provide a suitable engine oil for the engine.

Fill the oil. (For more information see: Filling the engine oil, page 75.)

Check oil filter connection.

Provide coolant with the correct coolant composition. (For more information see: 5.6.3 Checking the concentration of the antifreeze agent in the coolant, page 97.)

Fill the coolant, see documentation from the device manufacturer.

Check coolant line connections..

Connect air intake, see documentation from the device manufacturer.

Connect exhaust aftertreatment system, see documentation from the device manufacturer.

Connect fuel supply, see documentation from the device manufacturer.

Provide diesel fuel with the approved fuel specification.

Fill the diesel fuel.

Ventilate the fuel system. (For more information see: 5.7.5 Ventilating the fuel system, page 106.)

Check fuel prefilter connection, see documentation from the device manufacturer.

Check fuel fine filter connection. (For more information see: Removing the fuel fine filter, page 103.)

Connect electrical power supply, see documentation from the device manufacturer.

LMB/01/19.03.2021/enus

Upload current software update to engine control unit. (For more information see: 1.1.5 Engine control unit type plate (ECU2), page 20.)

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Starting the engine

4.2 Starting the engine Make sure that the following prerequisites are met: During the initial commissioning: Preliminary work for the initial commissioning of the engine has been performed. (For more information see: 4.1 Preliminary work for the initial commissioning of the engine, page 47.)

Oil level is correct.

Coolant is filled, see documentation from the device manufacturer.

Charge air is connected, see documentation from the device manufacturer.

Exhaust gas disposal is ensured.

The electrical power supply is ready.

The fuel supply is connected.

Every eight operating hours: Perform the required activities from the maintenance schedule.

(For more information see: 5.1 Maintenance schedule, page 51.)

NOTICE High load on the engine Damage to the engine During the first 25 operating hours, run the engine at a maximum of 70% of the maximum power.

DANGER Unexpected movements!

Death or serious injuries possible.

Never bypass the starter.

Never activate the starter directly.

DANGER Unexpected movement of the system!

Death or serious injuries possible.

Make sure that no persons reside in the danger zones of the engine.

Bring all protective devices into the protective position.

Close the enclosure.

Secure external parts against unexpected movement.

Make sure that oil pressure builds up immediately after starting the engine.

If the oil pressure warning light does not go out within 5 seconds: Turn off the engine immediately.

Determine cause and rectify. (For more information see: 6.1 Faults - Cause - Remedy, page 119.)

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NOTICE Insufficient lubrication!

Damage to engine.

Operator's manual

Operation Starting the engine

NOTICE Continuous operation!

Damage to starter.

Let the starter run a maximum of 30 seconds.

Start the engine.

If the engine does not start: Wait at least two minutes until the next attempt.

Start the engine.

If the engine does not start with the second attempt: Wait at least five minutes until the next attempt.

Start the engine.

If the engine does not start with the third attempt: Determine cause and rectify. (For more information see: 6.1 Faults - Cause - Remedy, page 119.)

Check oil pressure gauge immediately after starting the engine.

If no oil pressure is built up within 5 seconds: Turn off the engine immediately.

Determine cause and rectify. (For more information see: 6.1 Faults - Cause - Remedy, page 119.)

NOTICE Impermissible loading of the engine in cold condition!

Damage to engine.

Let the engine warm up until the operating temperature is reached.

NOTICE Continuous operation at low speed!

Damage to the exhaust aftertreatment system For continuous (>15 h) operation at low speed Contact Liebherr Machines Bulle.

LMB/01/19.03.2021/enus

If the engine start was successful: Warm up the engine.

Coolant temperature >60 °C

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Turning off the engine

4.3 Turning off the engine NOTICE Turning off the engine at full load speed!

Damage to engine.

Turn off the engine at idling speed.

Reduce engine speed to idling speed.

Let the engine run for 15 s unburdened at an idle.

Turn off the engine.

Turn off ignition.

The blow-out function of the SCR system begins one minute after turning off the ignition.

NOTICE Blow-out function of the SCR system is not performed!

Damage to reduction agent lines and valves.

Do not actuate the emergency stop switch until at least five minutes after turning off the engine.

LMB/01/19.03.2021/enus

When the blow-out function of the SCR system is complete.

Turn off engine with emergency stop switch.

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5 Maintenance

5.1 Maintenance schedule Abbreviations h = operating hours Note When operating under less than ideal conditions, such as intense heat, dust-laden air or poor operating fluid quality, more frequent maintenance than scheduled in the inspection plan can be required.

Power groups Devices LG 0 - LG 2

Mobile construction cranes (MK cranes), mobile cranes, crawler cranes, dutycycle crawler cranes, crawler cranes, rotary drilling rigs, piling and drilling rigs (LRB series), hanging and swing leader (LRH series), reachstacker, maritime cranes

LMB/01/19.03.2021/enus

Tab. 9: Power groups

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Maintenance schedule Customer:................................................. Machine type:...................... Serial no.:............................ Operating hours:..................Date:..........

By authorized specialist staff Once-only activity Repeat interval If necessary

1000 h

Diesel engine Check V-ribbed belt.

56

1000 h

Check belt drive.

57

1000 h

Check the engine mount.

63

500 h

1000 h

Check the intake system.

64

500 h

1000 h 5000 h / every five years

Check exhaust system.

65

Replace belt drive.

60

Engine oil system Check engine oil system for leaks and damage.

66

Check engine oil level.

69

Replace engine oil and oil filter.

70

Replace oil separator filter insert.

76

10 h 10 h 1000 h / every two years 1000 h / every two years 1000 h 10 h 10 h 2000 h / annually 6000 h / every four years

Cylinder head Check and set valve clearance.

Cooling system Check cooling system and heating system for leaks and damage.

79 96

Check coolant level.

97

Check the concentration of the antifreeze agent.

97

Replace coolant.

98

10 h

Fuel system Check fuel system for leaks and damage.

102

1000 h

Replace the fuel prefilter.

103

1000 h

103

10 h

Replace fuel fine filter.

Air filter Check the air filter low pressure indicator.

50 h

Clean the air filter dust discharge valve.

108

Replace the dry air filter main element.

108 108

108

1000 h

Replace the dry air filter safety element.

Electrical system Check engine control unit bearings for damage.

500 h

1000 h

Check the batteries.

109

500 h

1000 h

Check cable connections.

109

109

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By maintenance staff Once-only activity Repeat interval If necessary Annually before the winter

See page

intervals (the earlier date is decisive)

Confirm tasks

Tasks to be performed

Operator's manual

Maintenance Maintenance schedule

Customer:................................................. Machine type:...................... Serial no.:............................ Operating hours:..................Date:..........

500 h

1000 h

By authorized specialist staff Once-only activity Repeat interval If necessary

Check sensors, actuators, cable holders and plugs for damage.

110

Check heating flange, if present.

111

Replace heating flange, if present.

114

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10000 h

By maintenance staff Once-only activity Repeat interval If necessary Annually before the winter

See page

intervals (the earlier date is decisive)

Confirm tasks

Tasks to be performed

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Preliminary work

5.2 Preliminary work 5.2.1 Bringing the engine into maintenance position Make sure that the engine is level.

If the engine is hot: Let the engine cool down to ambient temperature.

If a battery master switch is present: Turn off the battery master switch.

If a master switch key is present: Remove the master switch key.

5.2.2 As needed Preliminary work which must be performed for the various activities.

Removing the cover (two-piece) 4

5

6

3

2 1

1 2 3

External hex bolt (3x) External hex bolt (1x) External hex bolt (4x)

4 5 6

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Fig. 32: Removing the cover (two-piece) Cover Spacer (1x) Spacer (3x)

Unscrew external hex bolt 1.

Unscrew external hex bolt 2.

Unscrew external hex bolt 3.

Remove cover 4.

Remove spacer 5.

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Maintenance Preliminary work

Remove spacer 6.

3

2

1 Fig. 33: Removing the cover 1 2

External hex bolt (2x) Cover

3

Nut (3x)

Unscrew external hex bolt 1.

Remove cover 2.

LMB/01/19.03.2021/enus

Unscrew nut 3.

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Diesel engine

5.3 Diesel engine 5.3.1 Checking the V-ribbed belt for damage Make sure that the following prerequisites are met: Fan drive is removed (if present).

Cover is removed (if present). (For more information see: Removing the cover (two-piece), page 54.)

Engine is in maintenance position. (For more information see: 5.2.1 Bringing the engine into maintenance position, page 54.)

Fig. 34: Damages to V-ribbed belt Possible damages to the V-ribbed belt are: – Brittle ribs – Rubber lumps on the bottom of the belt – Dirt deposits – Stone deposits – Ribs detached from the bottom of the belt – Transverse cracks on the back – Transverse cracks in multiple ribs Check V-ribbed belt for damage.

If the V-ribbed belt is damaged: Replace V-ribbed belt.

Tension pulley (self-tensioning) Note Checking the tension of the V-ribbed belt is not necessary for belt drives that use a self-tensioning tension pulley.

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5.3.2 Checking the V-ribbed belt for tension

Operator's manual

Maintenance Diesel engine

1

Fig. 35: Tension pulley (self-tensioning) 1

Tension pulley (self-tensioning)

5.3.3 Checking the belt drive

LMB/01/19.03.2021/enus

Make sure that the following prerequisites are met: – Fan drive is removed (if present).

– Cover is removed (if present). (For more information see: Removing the cover (two-piece), page 54.)

– Engine is in maintenance position. (For more information see: 5.2.1 Bringing the engine into maintenance position, page 54.)

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Diesel engine

Checking the alternator belt drive Removing the V-ribbed belt

2

1 3

Fig. 36: Replacing the V-ribbed belt 1 2

Internal square V-ribbed belt

3

Tension pulley (self-tensioning)

Attach the 1/2” socket wrench transition piece (external square) with lever to the internal square 1 of the tension pulley (self-tensioning) 3.

Turn back the tension pulley (self-tensioning) 3 at the internal square 1 counterclockwise against the spring force to the limit stop.

The V-ribbed belt 2 is relaxed.

Remove V-ribbed belt 2.

LMB/01/19.03.2021/enus

Carefully turn back the tension pulley (self-tensioning) 3 at the internal square 1 clockwise to the limit stop.

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Checking the alternator belt drive 3

3

2 4

1

5

Fig. 37: Checking the alternator belt drive 1 2 3

Tension pulley (self-tensioning) Alternator belt pulley Deflection pulley

4 5

Coolant pump Belt pulley on the crankshaft

Check components for damage.

If components are damaged: Do not start engine.

LMB/01/19.03.2021/enus

Replace defective components, see repair instruction.

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Diesel engine

Installing the V-ribbed belt

2

1 3

Fig. 38: Installing the V-ribbed belt 1 2

Internal square V-ribbed belt

3

Tension pulley (self-tensioning)

Swivel back tension pulley (self-tensioning) 3 counterclockwise against the spring force to the limit stop.

Fit V-ribbed belt 2 with swiveled back tension pulley (self-tensioning) 3 on the belt pulleys of the crankshaft, alternator, coolant pump and other deflection pulleys.

Turn tension pulley (self-tensioning) 3 carefully into the original position.

The V-ribbed belt 2 is tensioned.

Make sure that the following prerequisites are met: – Fan drive is removed (if present).

– Cover is removed (if present). (For more information see: Removing the cover (two-piece), page 54.)

– Engine is in maintenance position. (For more information see: 5.2.1 Bringing the engine into maintenance position, page 54.)

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5.3.4 Replacing the belt drive

Operator's manual

Maintenance Diesel engine

Replacing the alternator belt drive Removing the V-ribbed belt

2

1 3

Fig. 39: Removing the V-ribbed belt 1 2

Internal square V-ribbed belt

3

Tension pulley (self-tensioning)

Attach the 1/2” socket wrench transition piece (external square) with lever to the internal square 1 of the tension pulley (self-tensioning) 3.

Turn back the tension pulley (self-tensioning) 3 at the internal square 1 counterclockwise against the spring force to the limit stop.

The V-ribbed belt 2 is relaxed.

Remove V-ribbed belt 2.

LMB/01/19.03.2021/enus

Carefully turn back the tension pulley (self-tensioning) 3 at the internal square 1 clockwise to the limit stop.

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Diesel engine

Replacing the belt drive 3

3

2 2

4 4 1

5 Fig. 40: Replacing the belt drive 1 2 3

Tension pulley (self-tensioning) Sleeve Deflection pulley

4 5

External hex bolt External hex bolt

Unscrew external hex bolt 4.

Remove deflection pulley 3.

Remove sleeve 2.

Unscrew external hex bolt 5.

Remove tension pulley (self-tensioning) 1.

Install new tension pulley (self-tensioning) 1.

Tightening instruction for hex head screw

Locking agent (thread)

LOCTITE 243

Screws

Not reusable

Stage

Tightening torque

1.

50 Nm

LMB/01/19.03.2021/enus

Lubricant (thread and head contact surface)

Tab. 10: Tightening instruction 10153373-100

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Maintenance Diesel engine

Tighten external hex bolt 5 according to tightening instruction.

Install sleeve 2.

Install new deflection pulley 3.

Coat hex head screw 4 with Loctite® 243.

Tighten external hex bolt 4.

Installing the V-ribbed belt

2

1 3

Fig. 42: Installing the V-ribbed belt 1 2

Internal square V-ribbed belt

3

Tension pulley (self-tensioning)

Swivel back tension pulley (self-tensioning) 3 counterclockwise against the spring force to the limit stop.

Fit the V-ribbed belt with swiveled back tension pulley on the belt pulleys of the crankshaft, alternator, coolant pump and other deflection pulleys.

LMB/01/19.03.2021/enus

Turn tension pulley (self-tensioning) 3 carefully into the original position.

The V-ribbed belt 2 is tensioned.

5.3.5 Checking the engine mount For procedure to check the engine mount, see documentation from the device manufacturer.

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Diesel engine

5.3.6 Checking the intake system for leaks and damage

4

5

3

2 1 Fig. 43: Checking the intake system 1 2 3

External hex bolt (6x) External hex bolt (6x) Seal

4 5

Air intake pipe Heating flange

Check device side suction lines between the air intake pipe and exhaust gas turbocharger, see documentation from the device manufacturer.

Check components for damage.

Check components for leaks.

Check components for tight fit.

If components are damaged: Do not start engine.

Replace damaged device side components, see documentation from the device manufacturer.

LMB/01/19.03.2021/enus

Replace damaged components, see repair manual.

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Maintenance Diesel engine

5.3.7 Checking the exhaust system

3

2

4

1

5

Fig. 44: Components to be checked 1 2 3

Exhaust gas stub Exhaust manifold seal Exhaust manifold

4 5

Exhaust gas turbocharger Engine brake flap actuator

Check components for damage.

Check components for leaks.

Check components for tight fit.

Check connection points between device side exhaust piping and exhaust gas stub 1, see documentation from the device manufacturer.

LMB/01/19.03.2021/enus

Check connection points between exhaust gas turbocharger 4 and device side connection line, see documentation from the device manufacturer.

If components are damaged: Do not start engine.

Replace damaged components, see repair manual or documentation from the device manufacturer.

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Engine oil system

5.4 Engine oil system 5.4.1 Checking the engine oil system for leaks and damage WARNING Hot engine oil!

Serious burns possible.

Let the engine cool down to ambient temperature.

Avoid skin contact with hot engine oil or parts carrying oil.

CAUTION When opening the lines of the engine oil system, possible lubricant contact with the environment, eyes, mouth or skin.

Damage to health and environmental damage possible.

Wear chemical safety gloves, chemical safety goggles, chemical work clothing and chemical safety shoes.

Make sure that no lubricants get into the environment.

LMB/01/19.03.2021/enus

Observe national and international guidelines for disposal.

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Maintenance Engine oil system

4

5

6

3

7

2 8

1

9

Fig. 45: Checking the engine oil system Oil cooler

6

2 3 4 5

Cylinder head gasket Oil filter Cylinder head cover seal Oil filler cap

7 8 9

Pipeline from oil separator to air intake pipe Oil supply line Oil return line Oil pan

LMB/01/19.03.2021/enus

1

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Engine oil system

2

3

4

1

5

Fig. 46: Checking the engine oil system 1 2 3

Oil line from oil separator to oil pan Suction line from cylinder head cover to oil separator Oil separator

4 5

Oil level sensor Oil dipstick

Check components for leaks.

Check components for damage.

Check components for proper fastening.

Check oil loss at other components.

If components are leaking or damaged: Do not start engine.

LMB/01/19.03.2021/enus

Determine cause and rectify.

Replace defective parts, see repair instruction.

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Maintenance Engine oil system

5.4.2 Checking the engine oil level CAUTION When opening the lines of the engine oil system, possible lubricant contact with the environment, eyes, mouth or skin.

Damage to health and environmental damage possible.

Wear chemical safety gloves, chemical safety goggles, chemical work clothing and chemical safety shoes.

Make sure that no lubricants get into the environment.

Observe national and international guidelines for disposal.

1

2

3

Fig. 47: Checking the engine oil level 1 2

Oil filler neck cover Oil filler neck

3

Oil dipstick

LMB/01/19.03.2021/enus

Start the engine.

Bring engine to operating temperature 80 ±2 °C. Turn off the engine.

Wait 5 minutes.

Pull out the oil dipstick 3.

Wipe engine oil off of oil dipstick 3 with a clean cloth.

Insert oil dipstick 3.

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Engine oil system

Pull out the oil dipstick 3.

1

2

Fig. 48: Oil dipstick 1

Maximum

2

Minimum

Check that the oil level is between Maximum 1 and Minimum 2 on the oil dipstick 3.

If the oil level is above the Maximum 1 mark: Drain oil.

If the oil level is below the Minimum 2 mark: Refill the oil. (For more information see: Filling the engine oil, page 75.)

Insert oil dipstick 3.

Check oil level again.

5.4.3 Changing the engine oil Make sure that the following prerequisites are met: The engine is level.

The engine is turned off.

The engine temperature is at least 20°C or ambient temperature.

A suitable drain hose is available.

A suitable collection container is available.

Engine oil is available.

Engine oil specification

Graphic representation

Description

Required number

Identification number

Drain hose

1

12690422

Drain hose 90°

1

12690423

Tab. 11: Special tool

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Draining the engine oil

Operator's manual

Maintenance Engine oil system

WARNING Hot components on the engine!

Serious burns possible.

Let the engine cool down before any potentially hot components are touched. The engine must be cooled down to below 50 °C. Wear heat-resistant safety gloves and heat-resistant protective work gloves.

CAUTION When opening the lines of the engine oil system, possible lubricant contact with the environment, eyes, mouth or skin.

Damage to health and environmental damage possible.

Wear chemical safety gloves, chemical safety goggles, chemical work clothing and chemical safety shoes.

Make sure that no lubricants get into the environment.

Observe national and international guidelines for disposal.

2

1

3 4

Fig. 51: Draining the engine oil

LMB/01/19.03.2021/enus

1 2

Oil drain plug (optional) Oil drain valve

3 4

Sealing cap Drain hose

Put a collection container under the oil drain plug 1 (optional).

Unscrew oil drain plug 1 (optional).

Let engine oil run into the collection container.

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Engine oil system

Tightening instruction for M14x1.5 oil drain plug (optional) Lubricant

-

Locking agent

-

Part contact surfaces

-

Screws

Reusable

Stage

Tightening torque

1.

27 Nm

Tab. 12: Tightening instruction Tighten oil drain plug 1 (optional) according to tightening instruction.

Clean oil drain plug 1 with a lint-free cloth (optional).

Put a collection container under the oil drain valve 2.

Unscrew sealing cap 3 from oil drain valve 2.

Install drain hose 4 on oil drain valve 2.

Oil drain valve 2 is opened.

Engine oil runs out.

Remove drain hose 4.

Tighten sealing cap 3 on oil drain valve 2.

Clean oil drain valve 2 with a lint-free cloth.

Replacing the oil filter Removing the oil filter WARNING Hot components on the engine!

Serious burns possible.

Let the engine cool down before any potentially hot components are touched. The engine must be cooled down to below 50 °C. Wear heat-resistant safety gloves and heat-resistant protective work gloves.

Wear chemical safety gloves, chemical safety goggles, chemical work clothing and chemical safety shoes.

Make sure that no lubricants get into the environment.

Observe national and international guidelines for disposal.

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CAUTION When opening the lines of the engine oil system, possible lubricant contact with the environment, eyes, mouth or skin.

Damage to health and environmental damage possible.

Operator's manual

Maintenance Engine oil system

2

1

Fig. 53: Removing the oil filter 1

Nozzle (2x)

2

Oil filter (2x)

Unscrew oil filter 2.

Cleaning Clean sealing surface with a lint-free cloth.

Installing the oil filter WARNING Hot components on the engine!

Serious burns possible.

Let the engine cool down before any potentially hot components are touched. The engine must be cooled down to below 50 °C. LMB/01/19.03.2021/enus

Wear heat-resistant safety gloves and heat-resistant protective work gloves.

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Engine oil system

CAUTION When opening the lines of the engine oil system, possible lubricant contact with the environment, eyes, mouth or skin.

Damage to health and environmental damage possible.

Wear chemical safety gloves, chemical safety goggles, chemical work clothing and chemical safety shoes.

Make sure that no lubricants get into the environment.

Observe national and international guidelines for disposal.

2

1

Fig. 54: Installing the oil filter 1

Nozzle (2x)

2

Oil filter (2x)

Coat seal on new oil filter 2 lightly with engine oil.

LMB/01/19.03.2021/enus

Screw on new oil filter 2.

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Maintenance Engine oil system

Tightening instruction for M30 x 2 oil filter Lubricant

-

Locking agent

-

Part contact surfaces

Engine oil

Screws

-

Stage

Tightening torque

1.

Screw on by hand until the seal is in contact

2.

3/4 - 1 revolution (20 ±5 Nm)

Tab. 13: Tightening instruction 9132092-002 Tighten new oil filter 2 according to the tightening instruction.

Filling the engine oil

1

2

LMB/01/19.03.2021/enus

3

Fig. 56: Filling the engine oil (example filling on cylinder head cover) 1 2

Oil filler neck Oil filler cap

3

Oil dipstick

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Engine oil system

Unscrew oil filler cap 2.

Fill oil via oil filler neck 1.

Check engine oil level. (For more information see: 5.4.2 Checking the engine oil level, page 69.)

Insert oil dipstick 3.

Check oil level again.

If a partial quantity of oil has been drained: Fill oil in small quantities.

Clean oil filler cap 2.

Put oil filler cap 2 on the oil filler neck 1 and tighten it.

Start the engine.

Check the oil pressure gauge, see documentation from the device manufacturer.

Note Resetting the oil change interval is a condition for active regeneration through post-injection.

Reset the oil change interval by means of diagnostics software or via machine display.

5.4.4 Replacing the oil separator filter insert Removing the oil separator filter insert WARNING Hot components on the engine!

Serious burns possible.

Let the engine cool down before any potentially hot components are touched. The engine must be cooled down to below 50 °C. Wear heat-resistant safety gloves and heat-resistant protective work gloves.

CAUTION When opening the lines of the engine oil system, possible lubricant contact with the environment, eyes, mouth or skin.

Damage to health and environmental damage possible.

Wear chemical safety gloves, chemical safety goggles, chemical work clothing and chemical safety shoes.

Make sure that no lubricants get into the environment.

LMB/01/19.03.2021/enus

Observe national and international guidelines for disposal.

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Maintenance Engine oil system

2 1

Fig. 57: Removing the housing cover 1

Housing cover

2

Screwdriver

3

Housing cover

Open housing cover 1 with a screwdriver 2.

3

2

LMB/01/19.03.2021/enus

1

Fig. 58: Replacing the oil separator filter insert 1 2

Oil separator filter housing Oil separator filter insert

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Engine oil system

Remove housing cover 3.

Remove oil separator filter insert 2.

Installing the oil separator filter insert WARNING Hot components on the engine!

Serious burns possible.

Let the engine cool down before any potentially hot components are touched. The engine must be cooled down to below 50 °C. Wear heat-resistant safety gloves and heat-resistant protective work gloves.

CAUTION When opening the lines of the engine oil system, possible lubricant contact with the environment, eyes, mouth or skin.

Damage to health and environmental damage possible.

Wear chemical safety gloves, chemical safety goggles, chemical work clothing and chemical safety shoes.

Make sure that no lubricants get into the environment.

Observe national and international guidelines for disposal.

3

2

LMB/01/19.03.2021/enus

1

Fig. 59: Replacing the oil separator filter insert 1 2

Oil separator filter housing Oil separator filter insert

3

Housing cover

Install new oil separator filter insert 2.

Tighten housing cover 3 by hand.

Clean housing cover 3 and oil separator filter housing 1 with a lint-free cloth.

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Operator's manual

Maintenance Cylinder head

5.5 Cylinder head 5.5.1 Checking and setting the valve clearance Removing the cylinder head cover 7

7

1

2 3 4 5

6

Fig. 60: Cylinder head cover 1 2 3 4

External hex bolt (5x) Cylinder head cover External hex bolt Electrical plug connection

5 6 7

Cylinder head cover seal Electrical connection for the injector M4 hex nut

LMB/01/19.03.2021/enus

Disconnect the electrical line from the electrical plug connection 4.

Unscrew the external hex bolt 3.

Unscrew the external hex bolts 1.

Remove the cylinder head cover 2.

Release the hex nuts 7.

Remove the seal 5.

Repeat the process for all cylinder head covers.

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Cylinder head

Checking and cleaning Check seal 5 for damage.

Clean the sealing surface of the cylinder head cover 2.

Clean the sealing surface of the cylinder head.

Clean the screwed assembly of the injector and hex nuts 7.

Removing the locking part 1

2

3

Fig. 61: Removing the locking part 1 3

Seal Locking part

3

External hex bolt

Unscrew external hex bolt 3.

LMB/01/19.03.2021/enus

Remove locking part 3.

Remove seal 1.

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Maintenance Cylinder head

Installing the turning device on the flywheel housing Graphic representation

Description

Required number

Identification number

Turning device

1

0524045

Tab. 14: Special tool

2

1 3

Fig. 63: Installing the turning device on the flywheel housing

LMB/01/19.03.2021/enus

1 2

Flywheel housing Turning device

3

External hex bolt (3x)

Install turning device 2 on flywheel housing 1.

Tighten external hex bolt 3.

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Cylinder head

Installing the turning device on the belt pulley Graphic representation

Description

Required number

Identification number

Turning device

1

10116805

Tab. 15: Special tool

1

2

3

Fig. 65: Installing the turning device on the belt pulley Cylinder screw (6x) Turning device

3

Belt pulley LMB/01/19.03.2021/enus

1 2

Install turning device 2 on belt pulley 3.

Tighten cylinder screw 1.

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Maintenance Cylinder head

Installing the turning device on the crankshaft Graphic representation

Description

Required number

Identification number

Turning device

1

10118801

Tab. 16: Special tool

2

1

Fig. 67: Installing the turning device on the crankshaft 1

Turning device

2

Crankshaft

Turning device 1 on crankshaft 2

Setting the cylinder to top dead center (TDC)

LMB/01/19.03.2021/enus

One cylinder is always in ignition TDC position and one cylinder is in overlapping TDC position at the same time.

TDC type

Ignition TDC

Overlapping TDC

Position of the piston

between “compressing” and “working” cycles

between “ejection” and “suction” cycles

Position of the valves

closed

overlapping

Rocker arms

do not press on the valve bridges press on the valve bridges

Rocker arm movable by hand.

Yes

No

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Cylinder head

TDC type

Ignition TDC

Overlapping TDC

Setting valve clearance possible.

Yes

No

Tab. 17: Differences between ignition TDC and overlapping TDC

LMB/01/19.03.2021/enus

Fig. 68: Valve overlap

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Maintenance Cylinder head

1

1

Fig. 69: TDC marks: Ignition TDC for cylinder 1 1

TDC marking on the flywheel and flywheel housing Turn crankshaft with the turning device counterclockwise.

TDC marking on the flywheel and flywheel housing 1 align.

Cylinder 1 is in ignition TDC position.

The valve clearance of cylinder 1 is ready to be checked.

Setting table Table shows in which cylinder valves overlap (overlapping TDC) and on which cylinder the valve clearance is to be set (ignition TDC).

LMB/01/19.03.2021/enus

Valves of the cylinder set (ignition TDC)

1 5 3 6 2 4

overlap (overlapping TDC) 6 2 4 1 5 3 Tab. 18: Valves of the cylinder

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Cylinder head

Setting cylinder 1 to ignition TDC Make sure that the following prerequisites are met: Turning device is installed. (For more information see: Installing the turning device on the flywheel housing, page 81.)

1

1

Fig. 70: TDC marks: Ignition TDC for cylinder 1 1

TDC marking on the flywheel and flywheel housing

Setting cylinder 2 to 6 to ignition TDC Turn crankshaft with the turning device counterclockwise.

Check if the cylinder rocker arm can be moved by hand. (For more information see: Setting table, page 85.)

The cylinder rocker arm can be moved by hand.

Cylinder is in ignition TDC position.

The valve clearance of the cylinder is ready to be checked.

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Turn crankshaft with the turning device counterclockwise.

TDC marking on the flywheel and flywheel housing 1 align.

Cylinder 1 is in ignition TDC position.

The valve clearance of cylinder 1 is ready to be checked.

Operator's manual

Maintenance Cylinder head

Checking and setting the valve clearance for the inlet valve and outlet valve Make sure that the following prerequisites are met: The engine is in the maintenance position. (For more information see: 5.2.1 Bringing the engine into maintenance position, page 54.)

The cylinder head covers are removed. (For more information see: Removing the cylinder head cover, page 79.)

The cylinder to be checked is at ignition TDC. (For more information see: Setting cylinder 1 to ignition TDC, page 86.) (For more information see: Setting cylinder 2 to 6 to ignition TDC, page 86.)

Settings for valve clearance: (For more information see: 1.2.2 Valve clearance, page 21.)

4

3

5 6

2 7

1

Fig. 71: Checking and setting the valve clearance 1 2 3 4

Feeler gauge Valve bridge Lock nut Allen wrench

5 6 7

Adjusting screw Tappet Torque wrench

LMB/01/19.03.2021/enus

Slide feeler gauge 1 between the valve bridge 2 and tappet 6.

Check the valve clearance.

If the valve clearance does not correspond to the settings: Release the lock nut 3 on the adjusting screw 5 of the tappet 6.

Correct the setting by turning the adjusting screw 5.

Hold onto the adjusting screw 5.

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Maintenance

Operator's manual

Cylinder head

Tightening instruction for lock nut Lubricant (thread and head contact surface) Locking agent (thread)

-

Screws

Reusable

Stage

Tightening torque

1.

45 Nm

Tab. 19: Tightening instruction 12452122-002 Tighten the lock nut 3 according to the tensioning instruction.

Check the setting again.

Repeat the process for all cylinders.

When the valves have been checked and set: Install cylinder head covers with inspected, intact seals.

Checking and setting the valve clearance for the outlet valve with auxiliary brake system (ABS) (optional) Make sure that the following prerequisites are met: The engine is in the maintenance position. (For more information see: 5.2.1 Bringing the engine into maintenance position, page 54.)

The cylinder head covers are removed. (For more information see: Removing the cylinder head cover, page 79.)

The cylinder to be checked is at ignition TDC. (For more information see: Setting cylinder 1 to ignition TDC, page 86.)

LMB/01/19.03.2021/enus

Settings for valve clearance: (For more information see: 1.2.2 Valve clearance, page 21.)

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Maintenance Cylinder head

5

4

3 6 7 2

8

1

9

Fig. 73: Checking and setting the valve clearance on the ABS outlet valve (optional) 1 2 3 4 5

ABS valve bridge Measuring point for feeler gauge on rocker arm Rocker arm lock nut Rocker arm adjusting screw ABS adjusting screw

6 7

ABS lock nut Counterholder

8 9

Measuring point for feeler gauge on ABS ABS piston

Checking and setting the valve clearance for the auxiliary brake system outlet valve rocker arm (optional) Release the rocker arm lock nut 3.

Unscrew the rocker arm lock nut 3 to the limit stop.

Release the ABS lock nut 6.

Unscrew the ABS adjusting screw 5.

The ABS adjusting screw 5 disappears into the counterholder 7.

Press on the ABS valve bridge 1 with your hand.

Oil escapes from the return hole on the ABS valve bridge 1.

Slide the feeler gauge on the measuring point for feeler gauge on ABS 8 between the counterholder 7 and the ABS valve bridge 1.

Tighten the rocker arm adjusting screw 4 with 0.3 Nm. ABS piston 9 goes to the limit stop.

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Tighten the rocker arm lock nut 3 with 45 Nm. Pull out the feeler gauge.

The valve clearance for the auxiliary brake system outlet valve rocker arm is set.

Checking and setting the valve clearance for the ABS adjusting screw (optional) Press on the ABS valve bridge 1 with your hand.

ABS piston 9 goes to the limit stop.

Slide the feeler gauge on the measuring point for feeler gauge on ABS 8 between the ABS adjusting screw 5 and the ABS valve bridge 1.

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Cylinder head

Tighten the ABS adjusting screw 5 with 0.3 Nm. ABS piston 9 goes to the limit stop.

Tighten the ABS piston 9 with 45 Nm. Pull out the feeler gauge.

Press on the ABS valve bridge 1 with your hand.

ABS piston 9 goes to the limit stop.

The push rod has play.

The valve clearance for the ABS adjusting screw (optional) is set.

Repeat the process for all cylinders.

Removing the turning device from the flywheel housing 2

1 3

Fig. 74: Removing the turning device from the flywheel housing Flywheel housing Turning device

3

External hex bolt (3x) LMB/01/19.03.2021/enus

1 2

Unscrew external hex bolt 3.

Remove turning device 2 from flywheel housing 1.

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Removing the turning device from the belt pulley 1

2

3

Fig. 75: Removing the turning device from the belt pulley 1 2

Cylinder screw (6x) Turning device

3

Belt pulley

Unscrew cylinder screw 1.

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Remove belt pulley 3 from turning device 2.

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Cylinder head

Removing the turning device from the crankshaft

2

1

Fig. 76: Removing the turning device from the crankshaft 1

Turning device

2

Crankshaft

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Remove turning device 1 from crankshaft 2.

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Installing the locking part 1

2

3

3

Fig. 77: Installing the locking part 1 2

Flywheel housing opening Locking part

3

External hex bolt

Install locking part 2.

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Tighten external hex bolt 3.

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Cylinder head

Installing the cylinder head cover 7

7

1

2 3 4 5

6

Fig. 78: Cylinder head cover 1 2 3 4

External hex bolt (5x) Cylinder head cover External hex bolt Electrical plug connection

5 6 7

Cylinder head cover seal Electrical connection for the injector M4 hex nut

Install the cylinder head cover seal 5.

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Connect the electrical connection for the injector 6.

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Maintenance Cylinder head

Tensioning instruction for M4 hex nut Lubricant

-

Locking agent

-

Part contact surfaces

-

Screws

-

Stage

Tightening torque

1.

1.8 +0.2 Nm

Tab. 20: Tightening instruction 12977315_001 Tighten the hex nuts 7 according to the tensioning instruction.

Install the cylinder head cover 2.

Tighten the external hex bolts 1.

Tighten the external hex bolt 3.

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Connect the electrical line to the electrical plug connection 4.

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Cooling system

5.6 Cooling system 5.6.1 Checking the cooling system and heating system for leaks and damage WARNING Hot cooler parts and hot coolant!

Serious burns possible.

Make sure that the engine has cooled down to 20 °C or ambient temperature before starting the maintenance activities.

Wear protective gloves and safety goggles.

5

6

7

4

8

3

9

2

10 11

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12

1

Fig. 80: Components to be checked 1 2 3 4 5 6

Coolant outlet Thermostat housing Coolant pump Expansion tank return Cylinder head gasket Coolant ventilation

7 8 9 10 11 12

Locking part Coolant outlet Oil cooler Cab heating supply Cab heating return Coolant manifold

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Maintenance Cooling system

Check components for leaks.

Check components for damage.

Check the expansion tank (device side), see documentation from the device manufacturer.

Check the coolant line connections (device side), see documentation from the device manufacturer.

Check the completeness of all components, see documentation from the device manufacturer.

If components are leaking or damaged: Do not start engine.

Replace damaged components, see repair instruction.

5.6.2 Checking the coolant level WARNING Hot cooler parts and hot coolant!

Serious burns possible.

Make sure that the engine has cooled down to 20 °C or ambient temperature before starting the maintenance activities.

Wear protective gloves and safety goggles.

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

If the coolant level is too low or too high: Do not start the engine.

Refill the coolant, see documentation from the device manufacturer. (For more information see: 5.6.3 Checking the concentration of the antifreeze agent in the coolant, page 97.) (For more information see: Filling the coolant, page 101.)

5.6.3 Checking the concentration of the antifreeze agent in the coolant Checking the concentration of the antifreeze agent WARNING Hot cooler parts and hot coolant!

Serious burns possible.

Make sure that the engine has cooled down to 20 °C or ambient temperature before starting the maintenance activities.

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Wear protective gloves and safety goggles.

Open sealing cap on filler neck. See documentation from the device manufacturer.

Take a coolant sample.

Analyze the sample using a suitable test method.

If necessary, correct the mixing ratio of the antifreeze agent in the coolant.

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Cooling system

Correcting the concentration of the antifreeze agent If necessary, calculate the missing quantity of antifreeze agent according to the calculation formula (see: fig. 81, page 98).

NOTICE Concentration of the antifreeze agent too high!

Damage to engine.

Make sure that the concentration of the antifreeze agent is between 50% and 60%.

1

50

2

29

50

-

29

=

21

100

-

29

=

71

x

50

:

71

=

14,8

3

Fig. 81: Calculation formula for refilling quantity of antifreeze agent, example 29 vol.% 1

Coolant fill quantity in liters

2

Measured concentration in vol. %

3

Refilling quantity of antifreeze agent in liters

Drain the calculated refilling quantity from the cooling system.

For coolant fill quantity, see documentation from the device manufacturer.

Fill the calculated refilling quantity of the antifreeze agent.

5.6.4 Replacing the coolant

Draining the coolant on the device Drain the coolant via the device side outlet, see documentation from the device manufacturer.

Draining the coolant on the engine Make sure that the following prerequisites are met: Heating valves are open.

A collection container with the necessary capacity is available.

A suitable drain hose is available, see documentation from the device manufacturer.

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Make sure that the following prerequisites are met: – Heating valves are open.

– A collection container with the necessary capacity is available.

– A suitable drain hose is available, see documentation from the device manufacturer.

– The necessary quantity of coolant is available, see documentation from the device manufacturer.

Operator's manual

Maintenance Cooling system

The necessary quantity of coolant is available, see documentation from the device manufacturer.

Graphic representation

Description

Required number

Identification number

Drain hose

1

12690422

Drain hose 90°

1

12690423

Tab. 21: Special tool WARNING Hot cooler parts and hot coolant!

Serious burns possible.

Make sure that the engine has cooled down to 20 °C or ambient temperature before starting the maintenance activities.

Wear protective gloves and safety goggles.

NOTICE Escaping coolant!

Injuries Avoid skin contact with coolant.

Follow the manufacturer's instructions.

When mixing coolant, wear rubber gloves and safety goggles.

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Wash coolant in the eyes or on the skin off with water immediately.

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Cooling system

2

1

3

Fig. 84: Draining the coolant on the oil cooler Protecting cap Drain valve

3

Drain hose

LMB/01/19.03.2021/enus

1 2

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2

3

1

Fig. 85: Draining the coolant on the coolant manifold 1 2

Protecting cap Drain valve

3

Drain hose

Loosen the end cover on the device side compensation tank slightly.

Excess pressure escapes from the cooling system.

Unscrew protecting cap 1.

Connect drain hose 3 to the drain valve 2.

Let the coolant run into the collection container through the drain hose.

When the coolant has drained completely: Tighten protecting cap 1.

Filling the coolant Fill the coolant via the device side filler neck. (For more information see: Correcting the concentration of the antifreeze agent, page 98.)

Fill cooling system up to maximum.

Place the sealing cap on the compensation tank and close it.

Start the engine.

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Let the engine warm up.

Coolant temperature > 80 °C. Turn off engine. (For more information see: 4.3 Turning off the engine, page 50.)

Let the engine cool down.

Check coolant level. (For more information see: 5.6.2 Checking the coolant level, page 97.)

If the coolant level is too low or too high: Correct the coolant level, see documentation from the device manufacturer.

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Fuel system

5.7 Fuel system 5.7.1 Checking the fuel system for leaks and damage WARNING When the diesel engine is running, the fuel lines are constantly under a fuel pressure of up to 2400 bar Escaping liquids can penetrate the skin and will lead to injuries.

Only work on the fuel and injection system when the diesel engine is turned off.

Reduce pressure to below 20 bar with diagnostics software.

Check the residual pressure with diagnostics software.

Wear suitable protective equipment when working on the fuel and injection system.

Do not open any fuel connections that are under pressure.

Do not remove any fuel lines and hoses that are under pressure.

Protect hands, face and body against escaping liquids when searching for leaks on lines and hoses that are under pressure.

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

4

5

6

3 2

7

Fig. 86: Components 1 2

Fuel high pressure pump Injection lines

5 6

3 4

Fuel fine filter Fuel fine filter console

7

Distributor block Fuel pre-feed pump fuel line - engine control unit Fuel return line

Check components for damage.

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Maintenance Fuel system

Check fuel tank and fastening, see documentation from the device manufacturer.

Check tank lid, see documentation from the device manufacturer.

Check fastening of fuel line to the fuel tank, see documentation from the device manufacturer.

If components are damaged: Do not start engine Replace defective components, see repair manual.

5.7.2 Replacing the fuel prefilter Note The fuel prefilter with water separator is not attached directly to the diesel engine and is installed differently depending on the device design, see documentation from the device manufacturer.

Make sure that the following prerequisites are met: A collection container for escaping fuel is available.

NOTICE Dirt!

Damage to Common Rail System.

Make sure that no dirt comes in contact with fuel-carrying parts.

Do not reuse fuel filter and fuel fine filter.

Observe instructions for work on the Common Rail System.

For procedure to replace the fuel prefilter, see documentation from the device manufacturer.

Ventilate the fuel system. (For more information see: 5.7.5 Ventilating the fuel system, page 106.)

5.7.3 Reducing the pressure in the fuel system If the engine is running: Turn off the engine.

Check pressure reduction with diagnostics software (variables: 6996 - Fuel Pressure High 1/ 6997 - Fuel Pressure High 2). (For more information see: 7.1.3 Diagnostic tools, page 126.)

Pressure below 10 bar

5.7.4 Replacing the fuel fine filter LMB/01/19.03.2021/enus

Removing the fuel fine filter Make sure that the following prerequisites are met: A collection container is available.

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Fuel system

NOTICE Dirt!

Damage to Common Rail System.

Make sure that no dirt comes in contact with fuel-carrying parts.

Do not reuse fuel filter and fuel fine filter.

Observe instructions for work on the Common Rail System.

2

1

Fig. 87: Removing the fuel fine filter 1

Fuel fine filter (2x)

2

Fuel fine filter console

If the engine is running: Turn off engine.

Check pressure reduction with diagnostics software (variables: 6996 - Fuel Pressure High 1/ 6997 - Fuel Pressure High 2). (For more information see: 7.1.3 Diagnostic tools, page 126.)

If the pressure is below 10 bar: Put a collection container under the fuel fine filter.

Close the fuel shut-off valve (device side).

Clean the fuel fine filter console 2 and surrounding area.

Remove old fuel fine filter 1 using a strap wrench or similar tool (e.g. filter cap).

Dispose of old fuel fine filter properly.

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Wait 20 minutes.

Operator's manual

Maintenance Fuel system

Cleaning Clean the thread and sealing surface of the fuel fine filter 1 with a lint-free cloth.

Clean the thread and sealing surface of the fuel fine filter console 2 with a lint-free cloth.

Installing the fuel fine filter NOTICE Dirt!

Damage to Common Rail System.

Make sure that no dirt comes in contact with fuel-carrying parts.

Do not reuse fuel filter and fuel fine filter.

Observe instructions for work on the Common Rail System.

2

1

LMB/01/19.03.2021/enus

Fig. 88: Installing the fuel fine filter 1

Fuel fine filter (2x)

2

Fuel fine filter console

Lubricate sealing surface of the new fuel fine filter 1 with engine oil.

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Fuel system

Tightening instruction for fuel fine filter SW 30 unlocking hex Lubricant

-

Locking agent

-

Part contact surfaces

Engine oil

Screws

-

Stage

Tightening torque

1.

Screw on by hand until the seal is in contact

Stage

Angle of rotation

2.

Tighten by hand 3/4 of a revolution

Tab. 22: Tightening instruction Tighten new fuel fine filter 1 according to the tightening instruction.

Open the fuel shut-off valve (device side).

Ventilate the fuel system. (For more information see: 5.7.5 Ventilating the fuel system, page 106.)

5.7.5 Ventilating the fuel system Note The fuel system is to be vented on the device side and is to be performed differently depending on the device design, see documentation from the device manufacturer.

1

2

3 4

5

LMB/01/19.03.2021/enus

6

Fig. 90: Fuel diagram, external system (example) 1 2 3

Connection to engine Fuel air cooler (optional) Fuel prefilter

4 5 6

Water separator Manual ventilation pump Fuel tank

Turn device side shut-off valve on manual ventilation pump 5 to “manual ventilation” position.

Build up pressure in the fuel system with the manual ventilation pump 5.

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Wait 1 minute.

Pressure escapes through ventilation.

Build up pressure at least three times via the manual ventilation pump 5.

Wait until the pressure has been relieved through ventilation.

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Turn the shut-off valve on the manual ventilation pump 5 to the “operation” position.

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Air filter

5.8 Air filter 5.8.1 Checking the air filter low pressure indicator For procedure to check the air filter low pressure indicator, see documentation from the device manufacturer.

5.8.2 Cleaning the air filter dust discharge valve For procedure to clean the air filter dust discharge valve, see documentation from the device manufacturer.

5.8.3 Replacing the dry air filter main element For procedure to replace the dry air filter main element, see documentation from the device manufacturer.

5.8.4 Replacing the dry air filter safety element

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For procedure to replace the dry air filter safety element, see documentation from the device manufacturer.

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Maintenance Electrical system

5.9 Electrical system 5.9.1 Checking the batteries Check all components for contamination through a visual inspection, see documentation from the device manufacturer.

Check all components for mechanical damage through a visual inspection, see documentation from the device manufacturer.

5.9.2 Checking the cable connections Check all components for contamination through a visual inspection, see documentation from the device manufacturer.

Check all components for mechanical damage through a visual inspection, see documentation from the device manufacturer.

5.9.3 Checking the engine control unit bearings for damage

1

1

1

Fig. 91: Engine control unit mounting LMB/01/19.03.2021/enus

1

Engine control unit bearing Check engine control unit bearings 1 for damage.

Check engine control unit bearings 1 for tight fit.

If bearings are damaged or worn: Do not start the engine.

Replace bearings, see repair manual.

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Electrical system

5.9.4 Checking sensors, actuators, cable holders and plugs NOTICE Disconnected plug connections!

Damage to plug connections.

Leave plug connections plugged in during the visual inspection.

4

5

3

6 2

1 Fig. 92: Sensors 1 2 3

Speed sensor Pressure sensor Pressure sensor

4 5 6

Pressure sensor Temperature sensor Temperature sensor

Check components for tight fit.

Check components for damage.

LMB/01/19.03.2021/enus

Check components for abrasion-free laying.

Check components for proper fastening.

Check components for contamination through oil, fuel, coolant and reducing agent.

If components are damaged: Do not start the diesel engine.

Replace defective components, see repair instruction.

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Maintenance Electrical system

5.9.5 Checking the heating flange Checking resistance in the heating flange Make sure that the following prerequisites are met: Ohmmeter or multimeter is available.

3

2

1

Fig. 93: Checking the heating flange 1 2

Heating flange Ground

3

Positive pole

If a battery master switch is present: Turn off the battery master switch.

Disconnect the negative cable from the battery.

Disconnect the electrical connection cable from the positive pole 3.

LMB/01/19.03.2021/enus

Connect the ohmmeter or multimeter to the positive pole 3 and to ground 2.

Measure the resistance.

If the resistance at 20 °C falls below 230 ±23 mOhm: Check the heating flange for sooting. (For more information see: Checking the heating flange for sooting, page 112.)

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Electrical system

Checking the heating flange for sooting

4

3 5

2

1

Fig. 94: Checking the heating flange for sooting 1 2 3

Air intake pipe (example) Ground Positive pole

4 5

External hex bolt Heating flange

Disconnect the electrical connection cable from the positive pole 3.

Unscrew external hex bolt 4.

Remove heating flange 5.

NOTICE Undiscovered damage on the exhaust gas turbocharger!

Oil residues in the exhaust gas recycling pipe or connection line.

Check the exhaust gas turbocharger for oil loss.

LMB/01/19.03.2021/enus

Check heating flange 5 for sooting.

Check the air intake pipe 1 for sooting.

Check the air intake pipe 1 for oil residues.

If the heating flange is sooted: Clean the heating flange with brake cleaner.

Remove brake cleaner residues from the heating flange.

Install heating flange.

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Maintenance Electrical system

Tightening instruction for ground and positive pole M6 hex bolts Lubricant

-

Locking agent

-

Part contact surfaces

-

Screws

Reusable

Stage

Tightening torque

1.

8.5 +1 Nm

Tab. 23: Tightening instruction 9080927-001 Tighten hex head screws for ground 2 and positive pole 3 according to tightening instruction.

Hold bottom nut in place while doing so.

Connect the ohmmeter or multimeter to the positive pole 3 and to ground 2.

Measure the resistance.

If the resistance at 20 °C falls below 230 ±23 mOhm: Replace the heating flange.

Connect the electrical connection cable to the positive pole 3.

LMB/01/19.03.2021/enus

Connect the negative cable to the battery.

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Electrical system

5.9.6 Replacing the heating flange Removing the heating flange

3

2

4

1

Fig. 96: Replacing the heating flange 1 2

Air intake pipe (example) Positive pole

3 4

External hex bolt Heating flange

Disconnect the electrical line from the positive pole 2.

Unscrew external hex bolt 3.

LMB/01/19.03.2021/enus

Remove heating flange 4.

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Maintenance Electrical system

Installing the heating flange

3

2

4

1

Fig. 97: Replacing the heating flange 1 2

Air intake pipe (example) Positive pole

3 4

External hex bolt Heating flange

Install new heating flange 4.

Screw in external hex bolt 3.

Connect the electrical line to the positive pole 2.

LMB/01/19.03.2021/enus

Connect the ground line to the battery.

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Lubricants and operating fluids

5.10 Lubricants and operating fluids Note Observe corresponding safety data sheets at https://lubricants.liebherr.com.

5.10.1 Fill quantities Name

Quantity

Engine oil

43 l - 47 l (1.5 l per filter)

Coolant (engine) 25 l Tab. 24: Fill quantities for oil change (reference values)

5.10.2 Engine oil for diesel engines without emission type approval Liebherr products When using original Liebherr lubricant products, the longest possible change interval according to the maintenance schedule can be used.

Sulfur content in fuel in ppm

Engine oil change interval

to 15

100% (standard interval according to maintenance schedule)

to 500

50%

500 - 2000

25%

2000 - 5000

13%

Liebherr recommends the use of the following products

Liebherr Motoroil 5W-30 Liebherr Motoroil 10W-40

Lubricating oil specification

LH-00-ENG

Tab. 25: Engine oil change intervals when using Liebherr products

Note When using engine oils from other manufacturers Obtain information on the change intervals from the respective manufacturer or supplier.

Note Engine oils used must correspond to the Liebherr specification LH-00-ENG. Obtain information on this from the respective manufacturer or supplier.

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Third party products

Operator's manual

Maintenance Lubricants and operating fluids

Depending on the oil quality and the fuel used, the following reductions to the oil change interval in comparison to the standard oil change interval will result.

Sulfur content in fuel in ppm

Engine oil change interval

to 15

50%

to 500

25%

500 - 2000

13%

2000 - 5000

6%

Tab. 26: Engine oil change intervals when using non-Liebherr products

5.10.3 Coolant Note It is possible that mixing different anticorrosive and antifreeze agents can cause the properties of the coolant to deteriorate.

Avoid combining different products.

Make sure that silicate-containing and silicate-free coolants are not mixed.

Anticorrosive antifreeze agent Liebherr recommendation Type

Name

PremixA) Liebherr Antifreeze OS Mix Tab. 27: Recommendations for anticorrosive and antifreeze agents A)

Premix = finished mixture (50 % water and 50 % anticorrosive and antifreeze agents)

Minimum requirements for the quality Specification LH-01-COL Tab. 28: Minimum requirement for the quality

Water LMB/01/19.03.2021/enus

Liebherr recommends water having the following qualities Corresponds to the guideline for drinking water from the World Health Organization (WHO) from 2006 Demineralized water (reverse osmosis water) Tab. 29: Minimum requirements for the quality

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Lubricants and operating fluids

5.10.4 Fuel for diesel engines without emission type approval Minimum requirement for the quality Criterion

Limit values

Maximum sulfur content in the fuel

5000 ppm

Lubricity at 60 °C (HFRR)

460 m

Minimum cetane number

45

Tab. 30: Minimum requirement for diesel fuels Specification LH-00-FUEL

LMB/01/19.03.2021/enus

Tab. 31: Specification for diesel fuels

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6 Malfunctions

See Faults - Cause - Remedy table for engine problems and corrective measures. (For more information see: 6.1 Faults - Cause - Remedy, page 119.)

The engine control unit has an error memory. Error entries are stored in the error memory. The remedy for the errors is described in the device documentation.

The following are available for error identification: – Warning lights in the device display – Diagnostics software (For more information see: 7.1.3 Diagnostic tools, page 126.)

6.1 Faults - Cause - Remedy Malfunction / error

Cause

Remedy

Starter does not crank.

Main fuse defective

Replace fuse.

Starter does not crank.

Battery connections loose or corroded

Clean and tighten loose connections.

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Clean contacts.

Starter does not crank.

Battery voltage too low

Charge or replace battery.

Starter does not crank.

Starter circuit interrupted

Contact Liebherr customer service.

Starter does not crank.

Contacts corroded

Clean contacts.

Starter does not crank.

Starter defective

Contact Liebherr customer service.

Starter cranks slowly.

Battery voltage too low

Charge or replace battery.

Starter cranks slowly.

Battery connections loose or corroded

Clean and tighten loose connections.

Starter cranks slowly.

Outside temperature too low

Follow measures for winter operation.

Starter cranks slowly.

Engine under load

Disconnect the unit from the auxiliary output.

Make sure that frictional connection between the engine and transmission is disconnected.

Engine stops immediately after starting.

Fuel tank empty

Engine stops immediately after starting.

Fuel fine filter clogged

Refuel.

Ventilate the fuel system.

Replace the fuel fine filter.

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Faults - Cause - Remedy

Malfunction / error

Cause

Remedy

Engine stops immediately after starting.

Fuel prefilter clogged

Replace the fuel prefilter.

Engine stops immediately after starting.

Fuel line, pre-cleaner or sieve in fuel tank clogged

Clean fuel line, pre-cleaner or sieve in fuel tank.

Ventilate the fuel system.

Engine stops immediately after starting.

Fuel not cold-resistant

Clean the fuel prefilter.

Replace the fuel fine filter.

Use winter fuel.

Engine stops immediately after starting.

Outside temperature too low

Follow measures for winter operation.

Engine stops immediately after starting.

Heating flange defective (at cold temperatures)

Check heating flange, replace if necessary.

Engine stops immediately after starting.

Exhaust gas system dirty

Clean exhaust gas system.

Engine stops immediately after starting.

Engine brake flap closed

Check engine brake flap control.

Engine starts poorly.

Leak or too low pressure in the fuel low pressure circuit

Contact Liebherr customer service.

Perform leak test (visual inspection).

Engine starts poorly.

Engine compression too low

Contact Liebherr customer service.

Engine starts poorly.

Heating flange defective (at cold temperatures)

Check heating flange, replace if necessary.

Engine starts poorly.

Fault of the electronics

Contact Liebherr customer service.

Engine starts poorly.

Rail pressure too low

Inspect rail for leaks.

Engine starts poorly.

Air in fuel system

Ventilate the fuel system.

Engine starts poorly.

Air filter clogged

Check air filter for contamination.

Engine starts poorly.

Inferior fuel quality

Only use fuel recommended by Liebherr.

Engine starts poorly.

Injector defective

Contact Liebherr customer service.

Engine starts poorly.

For engines without hydraulic tappets: Valve clearance not set correctly. For engines with hydraulic tappets: Hydraulic tappet defective.

For engines without hydraulic tappets: Check valve clearance.

If necessary, set valve clearance.

For engines with hydraulic tappets: Contact Liebherr customer service.

Engine turns off inadvertently.

Voltage supply interrupted

Contact Liebherr customer service.

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Contact Liebherr customer service.

Operator's manual

Malfunctions Faults - Cause - Remedy

Malfunction / error

Cause

Engine turns off inadvertently.

Leak or too low pressure in the fuel low pressure circuit

Remedy Perform leak test (visual inspection).

Have checked by Liebherr customer service.

Engine turns off inadvertently.

Fault of the electronics

Contact Liebherr customer service.

Engine turns off inadvertently.

Fuel supply not ensured

Check fuel system.

Power reduction of the engine

Fuel system defective

Perform visual inspection.

Replace filter.

Power reduction of the engine

Charging pressure too low

Check clamps, seals, hoses and air filter.

Power reduction of the engine

Charge air temperature too high

Check charge air cooler, fan and ambient temperature.

Power reduction of the engine

Coolant temperature too high

Check cooler for contamination.

Check fan.

Check thermostat.

LMB/01/19.03.2021/enus

Check coolant level.

Power reduction of the engine

Fuel temperature too high

Contact Liebherr customer service.

Power reduction of the engine

Oxygen content of the air too low since application > 1800 m above sea level

Power reduction of the engine

Injectors stick or do not spray.

Contact Liebherr customer service.

Power reduction of the engine

Engine compression too low

Contact Liebherr customer service.

Power reduction of the engine

Fault of the electronics

Read error memory of the engine control unit.

Power reduction of the engine

Exhaust aftertreatment system clogged

Contact Liebherr customer service.

Power reduction of the engine

For engines without hydraulic tappets: Valve clearance not set correctly. For engines with hydraulic tappets: Hydraulic tappet defective.

For engines without hydraulic tappets: Check valve clearance.

If necessary, set valve clearance.

For engines with hydraulic tappets: Contact Liebherr customer service.

Power reduction of the engine

Too little reducing agent in reducing agent tank

Fill up reducing agent.

Insufficient engine brake power

Engine brake flap without function

Check engine brake flap for function and damage.

No defect, engine power automatically reduced.

Contact Liebherr customer service.

Insufficient engine brake power

Fault of the electronics

Contact Liebherr customer service.

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Faults - Cause - Remedy

Malfunction / error

Cause

Remedy

Hot engine (according to coolant temperature display).

Too little coolant

Refill.

Hot engine (according to coolant temperature display).

Cooler dirty inside or calcified, cooler dirty outside

Clean cooler.

Hot engine (according to coolant temperature display).

Thermostat defective

Check thermostat.

Hot engine (according to coolant temperature display).

Coolant temperature sensor defective

Decalcify cooler.

If necessary, replace thermostat.

Check coolant temperature sensor.

If necessary, replace coolant temperature sensor.

Hot engine (according to coolant temperature display).

Fan speed too low (only hydrostatic fan drive)

Check fan drive.

Hot engine (according to coolant temperature display).

Coolant pump defective

Replace coolant pump.

Hot engine (according to coolant temperature display).

V-ribbed belt tension insufficient

Check V-ribbed belt tension. If necessary, replace tension pulley.

Charging current indicator light illuminates when engine is running.

V-ribbed belt torn

Replace V-ribbed belt.

Charging current indicator light illuminates when engine is running.

Cable connections loose or disconnected

Fasten or replace cable.

Charging current indicator light illuminates when engine is running.

Alternator, rectifier or controller defective

Contact Liebherr customer service.

Charging current indicator light illuminates when engine is running.

Open test circuit

Contact Liebherr customer service.

Engine smokes black.

Exhaust aftertreatment system defective

Contact Liebherr customer service.

Engine smokes black.

Injection system defective

Contact Liebherr customer service.

Engine smokes black.

Charge air pressure sensor defective

Replace charge air pressure sensor.

Exhaust gases are blue.

Oil level in engine too high

Correct oil level.

Exhaust gases are blue.

Engine oil burns in combustion chambers.

Contact Liebherr customer service.

Exhaust gases are blue.

Compressor-side seal on the exhaust gas turbocharger defective

Contact Liebherr customer service.

Exhaust gases are blue.

Exhaust gas-side seal on the exhaust gas turbocharger defective

Contact Liebherr customer service.

Exhaust gases are blue.

Crankcase breather system defective

Check, replace if necessary.

Exhaust gases are blue.

Piston rings defective

Contact Liebherr customer service.

Exhaust gases are blue.

Valve stem seals defective

Contact Liebherr customer service.

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If necessary, replace fan drive.

Operator's manual

Malfunctions Faults - Cause - Remedy

Malfunction / error

Cause

Remedy

Exhaust gases are white.

Injection delayed

Contact Liebherr customer service.

Exhaust gases are white.

Heating flange defective (temperature < -10 °C)

Check heating flange. If necessary, replace heating flange.

Exhaust gases are white.

Coolant in combustion chamber

Contact Liebherr customer service.

Engine rattles.

Combustion faults

Contact Liebherr customer service.

Engine knocks.

Injection nozzles damaged or coked

Contact Liebherr customer service.

Engine knocks.

Bearing damage

Contact Liebherr customer service.

Engine knocks.

Piston rings worn, piston rings broken, piston scuffed

Contact Liebherr customer service.

Abnormal noises

Leaks on suction lines and exhaust pipes cause whistling noises.

Eliminate leak. If necessary, replace seal.

Abnormal noises

Foreign object in compressor or turbine

Contact Liebherr customer service.

Abnormal noises

Turbine wheel or compressor wheel rubbing against housing

Contact Liebherr customer service.

Abnormal noises

Seized bearings on rotating parts

Contact Liebherr customer service.

Lubricating oil pressure too low

Oil level in the oil pan too low

Correct oil level.

Lubricating oil pressure too low

Engine oil too thin

Drain oil.

Fill the oil.

Determine cause of the oil dilution and rectify.

Lubricating oil pressure too low

Oil pressure sensor defective

Check engine oil system.

LMB/01/19.03.2021/enus

Replace damaged oil pressure sensor.

Lubricating oil pressure too low

End control valve defective

Contact Liebherr customer service.

Lubricating oil pressure too low

End control valve dirty

Contact Liebherr customer service.

Lubricating oil pressure too low

Bearing play due to wear too great or bearing damage

Contact Liebherr customer service.

Lubricating oil pressure too low

Oil pump defective

Check oil pump.

Replace oil pump, if necessary.

Lubricating oil pressure too low

Oil filter clogged

Replace oil filter.

Lubricating oil pressure too low

Oil pressure regulating valve defective

Contact Liebherr customer service.

Engine oil in cooling system

Oil cooler or oil cooler plate is leaking

Contact Liebherr customer service.

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Operator's manual

Faults - Cause - Remedy

Cause

Remedy

Coolant in engine oil

O-rings on cylinder liners are leaking

Contact Liebherr customer service.

Coolant in engine oil

Oil cooler or oil cooler plate is leaking

Contact Liebherr customer service.

LMB/01/19.03.2021/enus

Malfunction / error

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7 Tools and devices

7.1 Tools 7.1.1 Special tool

LMB/01/19.03.2021/enus

Graphic representation

Description

Required number

Identification number

Turning device

1

0524045

Turning device

1

10118801

Turning device

1

10116805

Drain hose

1

12690422

Drain hose 90°

1

12690423

Tab. 32: Special tool

7.1.2 Assembly agents Use the following locking agent, sealant and greases for repair and maintenance work. Refer to the respective work description for the application.

Locking agent Designation Part number Quantity Manufacturer information

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Tools

Locking agent Loctite® 243 811205708

50 ml

https://www.henkel-adhesives.com

Loctite® 278 811200908

50 ml

https://www.henkel-adhesives.com

Loctite® 572 870001914

50 ml

https://www.henkel-adhesives.com

Loctite® 577 811201314

50 ml

https://www.henkel-adhesives.com

Tab. 33: Locking agent Sealant Designation

Part number Quantity Manufacturer information

Loctite® 5910 10354595

300 ml

https://www.henkel-adhesives.com

Tab. 34: Sealant Lubricants Designation

Part number Quantity Manufacturer information

NBU 30 grease

10285708

1 kg

https://www.klueber.com

Motorex 14

10002552

850 g

https://www.motorex.com

Altemp QNB 50

10490569

80 g

https://www.klueber.com

Klüberplus S 06-100 12694669

1 kg

https://www.klueber.com

Ceramic grease

11830242

200 ml

https://www.techno-ag.ch/de/home.cfm

Loctite® 577

811201314

50 ml

https://www.henkel-adhesives.com

Tab. 35: Lubricants

7.1.3 Diagnostic tools

LMB/01/19.03.2021/enus

For information on diagnostic tools, see diagnostics software operating instructions.

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Tools and devices Devices

7.2 Devices 7.2.1 Lifting traverse with two-point-raising (basic version) DANGER Pulling out of the lifting devices on the engine and falling of the engine!

Will lead to death or serious injuries due to crushing.

Make sure that no one is standing or walking under suspended loads. Maintain safety distance.

Observe maximum weight for lifting points.

Maintain a maximum of a 10° deviation from the vertical to the engine axis.

Use a Liebherr lifting traverse. (For more information see: 7.2.1 Lifting traverse with two-pointraising (basic version), page 127.)

Take safety instructions / warning signs from the operator's manual of the lifting traverse into account.

Observe national and international guidelines for lifting heavy loads.

Make sure that no persons reside in the danger zone (see safety chapter).

Remove the gear box or other attachments before lifting the engine. max.10°

max.10°

4 1

4 5

3

4

5

3

3

5

1

1

1

2

B

2

2

D

C

A

LMB/01/19.03.2021/enus

max.6° max.6° 5

2 E

F

Fig. 103: Lifting the engine A

Transport device detail view

1

Tolerance for maximum deviation of motor axis

See next page for continuation of the image legend

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Tools and devices

Operator's manual

Devices

B

2

Crankcase

C D

Front / rear view of two lateral transport devices Side engine view Front / rear view of lateral transport device

3 4

E

Lifting traverse lifting point detail view

5

Lifting traverse Engine lifting traverse lifting point (observe maximum total load) Tolerance for maximum horizontal deviation

F

Take lifting traverse warning signs, lifting traverse operator's manual into account.

Note Before commissioning the lifting traverse, carefully read and follow the description included in the scope of delivery and the safety instructions included therein.

7.2.2 Lifting traverse with two-point-raising 2

3

1

LMB/01/19.03.2021/enus

4

Fig. 104: Lifting traverse with two-point-raising 1 2

Slide piece Attachment point sign

3 4

Reception tube Chain suspension

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Tools and devices Devices

Fig. 105: Attachment point sign

7.2.3 Engine assembly stand 2

3

5

1

4

Fig. 106: Engine assembly stand LMB/01/19.03.2021/enus

1 2 3

Universal mount Engine assembly stand Height

4 5

Length Width

Engine assembly stand

10471324

12696052

Load bearing capacity

2500 kg

2500 kg

Drive

mechanical

electric

Universal mount

10467810 2500 kg

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Devices

Engine assembly stand

10471324

12696052

mobile

Yes

Yes

Oil drip pan

Yes

Yes

Height adjustment with compressed air

Yes, 350 mm

No

Dimensions Width Length Height

1730 mm 1730 mm 2240 mm 2240 mm 1365 mm - 1715 mm 1510 mm

Own weight

approx. 1250 kg

Universal mount

10467810

approx. 1100 kg

Tab. 36: Technical data

7.2.4 Transport device DANGER Pulling out of the lifting devices on the engine and falling of the engine!

Will lead to death or serious injuries due to crushing.

Make sure that no one is standing or walking under suspended loads. Maintain safety distance.

Observe maximum weight for lifting points.

Maintain a maximum of a 10° deviation from the vertical to the engine axis.

Use a Liebherr lifting traverse. (For more information see: 7.2.1 Lifting traverse with two-pointraising (basic version), page 127.)

Take safety instructions / warning signs from the operator's manual of the lifting traverse into account.

Observe national and international guidelines for lifting heavy loads.

Make sure that no persons reside in the danger zone (see safety chapter).

Remove the gear box or other attachments before lifting the engine.

Tightening instruction for M10x30 10.9 FLZN hex bolt -

Locking agent

Loctite 243

Part contact surfaces

-

Screws

Reusable

Stage

Tightening torque

1.

Standard torque

Tightening sequence

1

4 2

3

Tab. 37: Tightening instruction

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Lubricant

Operator's manual

Tools and devices Devices

Tightening instruction for M16x50 8.8 FLZN hex bolt Lubricant

-

Locking agent

-

Part contact surfaces

-

Screws

Reusable

Stage

Tightening torque

1.

Standard torque

Tightening sequence

1 2

Tab. 38: Tightening instruction Tightening instruction for M16x35 10.9 FLZN hex bolt Lubricant

-

Locking agent

-

Part contact surfaces

-

Screws

Reusable

Stage

Tightening torque

1.

Standard torque

LMB/01/19.03.2021/enus

Tab. 39: Tightening instruction

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Operator's manual

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Devices

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8 Appendix

8.1 Tightening torques 8.1.1 For hex bolts / cylinder screws / external hex bolts For hex bolts according to: – – – –

ISO 4014 ISO 4017 ISO 8765 ISO 8676

For cylinder screws according to: DIN EN ISO 4762 (formerly DIN 912) For external hex bolts according to: DIN 34800.

Values for an average coefficient of friction of

= 0.12

Tightening torques valid for the following screw coatings: – A2K (coating material= zinc; thickness= 5 µm; chromate coating= silver, bluish) – bare (black) – A3C/A2C (coating material= zinc; thickness= 8 µm; chromate coating= yellowish) Standard thread

Nm

LMB/01/19.03.2021/enus

Strength class

ft/lb

Nm

8.8

ft/lb

Nm

10.9

ft/lb 12.9

M4

3

2

4

3

5

4

M5

6

4

8

6

10

7

M6

10

7

14

10

17

13

M7

16

12

23

17

27

20

M8

23

17

34

25

40

30

M10

46

34

68

50

79

58

M12

79

58

117

86

135

100

M14

125

92

185

136

215

159

M16

195

144

280

207

330

243

M18

280

207

390

288

460

339

M20

390

288

560

413

650

479

M22

530

391

750

553

880

649

M24

670

494

960

708

1120

826

M27

1000

738

1400

1033

1650

1217

M30

1350

996

1900

1401

2250

1660

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Appendix

Operator's manual

Tightening torques

Standard thread

Nm

ft/lb

Nm

ft/lb

Nm

ft/lb

M33

1850

1364

2600

1918

3000

2213

M36

2350

1733

3300

2434

3900

2876

M39

3000

2213

4300

3172

5100

3762

ft/lb

Nm

ft/lb

Tab. 40: Tightening torques for metric standard thread Nm

Strength class

ft/lb

Nm

8.8

10.9

12.9

M8x1

25

18

36

27

43

32

M9x1

36

27

53

39

62

46

M 10 x 1

52

38

76

56

89

66

M 10 x 1.25

49

36

72

53

84

62

M 12 x 1.25

87

64

125

92

150

111

M 12 x 1.5

83

61

122

90

145

107

M 14 x 1.5

135

100

200

148

235

173

M 16 x 1.5

205

151

300

221

360

266

M 18 x 1.5

310

229

440

325

520

384

M 18 x 2

290

214

420

310

490

361

M 20 x 1.5

430

317

620

457

720

531

M 22 x 1.5

580

428

820

605

960

708

M 24 x 1.5

760

561

1090

804

1270

937

M 24 x 2

730

538

1040

767

1220

900

M 27 x 1.5

1110

819

1580

1165

1850

1364

M 27 x 2

1070

789

1500

1106

1800

1328

M 30 x 1.5

1540

1136

2190

1615

2560

1888

M 30 x 2

1490

1099

2120

1564

2480

1829

M 33 x 1.5

2050

1512

2920

2154

3420

2522

M 33 x 2

2000

1475

2800

2065

3300

2434

M 36 x 1.5

2680

1977

3820

2817

4470

3297

M 36 x 3

2500

1844

3500

2581

4100

3024

M 39 x 1.5

3430

2530

4890

3607

5720

4219

M 39 x 3

3200

2360

4600

3393

5300

3909

Tab. 41: Tightening torques for metric fine thread For hex bolts according to: – DIN 6921 – DIN EN 1665 For cylinder screws according to: DIN EN ISO 4762 (formerly DIN 912) Values for an average coefficient of friction of

= 0.12

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Standard thread

Operator's manual

Appendix Tightening torques

Tightening torques valid for the following screw coatings: – PHR (phosphated/black) – flZn (zinc flake coating/gray) – 480H (galvanized according to DIN 50979/zinc flake coating according to ISO10683/silver) Standard thread

Nm

Nm

Strength class

8.8

10.9

M4

2.2

3.3

M5

4.5

7

M6

8

12

M7

13

19

M8

19

28

M10

38

55

M12

65

95

M14

104

150

M16

158

234

M18

230

326

M20

320

450

Tab. 42: Tightening torques for metric standard thread

LMB/01/19.03.2021/enus

Standard thread

Nm

Nm

Strength class

8.8

10.9

M8x1

20

29

M9x1

29

42

M 10 x 1

40

59

M 10 x 1.25

39

57

M 12 x 1.25

69

102

M 12 x 1.5

67

99

M 14 x 1.5

109

160

M 16 x 1.5

165

240

M 18 x 1.5

245

350

M 18 x 2

238

335

M 20 x 1.5

340

480

Tab. 43: Tightening torques for metric fine thread

8.1.2 For locking screws and banjo bolts Banjo bolts according to DIN 7643.

Locking screws according to DIN 910.

Locking screws according to DIN 908.

With copper seal according to DIN 7603:

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Appendix

Operator's manual

Tightening torques

Standard thread

Nm

ft/lb

Standard thread

Nm

ft/lb

M6x1

7

5

M 20 x 1.5

47

35

M8x1

7.5

6

M 22 x 1.5

57

42

M 8 x 1.5

7.5

6

M 24 x 1.5

68

50

M 10 x 1

15

11

M 26 x 1.5

75

55

M 10 x 1.25

15

11

M 27 x 2

87

64

M 12 x 1.5

20

15

M 30 x 1.5

115

85

M 14 x 1.5

27

20

M 30 x 2

115

85

M 16 x 1.5

37

27

M 33 x 2

120

89

M 18 x 1.5

40

30

M 36 x 1.5

155

114

M 36 x 2

155

114

M 52 x 1.5

380

280

M 38 x 1.5

171

126

M 52 x 2

380

280

M 39 x 2

215

159

M 56 x 2

430

317

M 42 x 1.5

240

177

M 60 x 2

510

376

M 42 x 2

240

177

M 64 x 2

570

420

M 45 x 1.5

270

199

M 65 x 2

620

457

M 45 x 2

270

199

M 48 x 1.5

300

221

M 48 x 2

300

221

Tab. 44: Tightening torques for locking screws and banjo bolts

LMB/01/19.03.2021/enus

8.1.3 Standard torques for metric flange connections

Fig. 110: Overview of flange connections

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Operator's manual

Appendix Tightening torques

Note Tightening torques apply for mating material: Steel.

Tolerance for the tightening torques stated in the table: + 10 %.

Lubricate the screw-in thread with engine oil before screwing it in.

8.1.4 Metric screw connection series L (light) (up to 500 bar/7252 Psi) Pipe diameter X

Thread Y

Form A with sealing ring

Form B with sealing edge

6

Form E with flat (ED) seal

Form F with oring

Nm

ft/lb

Nm

ft/lb

Nm

ft/lb

Nm

ft/lb

M 10 x 1.0

9

7

18

13

18

13

15

11

8

M 12 x 1.5

20

15

30

22

25

18

25

18

10

M 14 x 1.5

35

26

45

33

45

33

35

26

12

M 16 x 1.5

45

33

65

48

55

41

40

30

15

M 18 x 1.5

55

41

80

59

70

52

45

33

18

M 22 x 1.5

65

48

140

103

125

92

60

44

22

M 26 x 1.5

90

66

190

140

180

133

100

74

28

M 33 x 2.0

150

111

340

251

310

229

160

118

35

M 42 x 2.0

240

177

500

369

450

332

210

155

42

M 48 x 2.0

290

214

630

465

540

398

260

192

Tab. 45: Metric screw connection series L (light), part 1

LMB/01/19.03.2021/enus

Pipe diameter X

Thread Y

WH

TH

SWVE

Nm

ft/lb

Nm

ft/lb

Nm

ft/lb

6

M 10 x 1.0

18

13

18

13

18

13

8

M 12 x 1.5

45

33

45

33

35

26

10

M 14 x 1.5

55

41

55

41

50

37

12

M 16 x 1.5

80

59

80

59

60

44

15

M 18 x 1.5

100

74

100

74

80

59

18

M 22 x 1.5

140

103

140

103

120

89

22

M 26 x 1.5

320

236

320

236

130

96

28

M 33 x 2.0

360

266

360

266

35

M 42 x 2.0

540

398

540

398

42

M 48 x 2.0

700

516

700

516

Tab. 46: Metric screw connection series L (light), part 2

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Appendix

Operator's manual

Tightening torques

8.1.5 Metric screw connection series S (heavy) (up to 800 bar/11603 Psi) Pipe diameter X

Thread Y

Form A with sealing ring

Form B with sealing edge

Form E with flat (ED) seal

Nm

ft/lb

Nm

ft/lb

Nm

ft/lb

6

M 12 x 1.5

20

15

35

26

40

30

8

M 14 x 1.5

35

26

55

41

40

30

10

M 16 x 1.5

45

33

70

52

70

52

12

M 18 x 1.5

55

41

110

81

90

66

14

M 20 x 1.5

55

41

150

111

125

92

16

M 22 x 1.5

65

48

170

125

135

100

20

M 27 x 2.0

90

66

270

199

180

133

25

M 33 x 2.0

150

111

410

302

310

229

30

M 42 x 2.0

240

177

540

398

450

332

38

M 48 x 2.0

290

214

700

516

540

398

Tab. 47: Metric screw connection series S (heavy), part 1 Pipe diameter X

Thread Y

WH

TH

SWVE

Nm

ft/lb

Nm

ft/lb

Nm

ft/lb

6

M 12 x 1.5

45

33

45

33

35

26

8

M 14 x 1.5

55

41

55

41

50

37

10

M 16 x 1.5

80

59

80

59

60

44

12

M 18 x 1.5

100

74

100

74

80

59

14

M 20 x 1.5

125

92

125

92

110

81

16

M 22 x 1.5

135

100

135

100

120

89

20

M 27 x 2.0

320

236

320

236

135

100

25

M 33 x 2.0

360

266

360

266

30

M 42 x 2.0

540

398

540

398

38

M 48 x 2.0

700

516

700

516

8.1.6 Inch screw connection series L (light) (up to 500 bar/7252 Psi) Pipe diameter X

Thread Y Form A with sealing ring

Form B with sealing edge

Form E with flat (ED) seal

Nm

ft/lb

Nm

ft/lb

Nm

ft/lb

6

G 1/8A

9

7

18

13

18

13

8

G 1/4A

35

26

35

26

35

26

10

G 1/4A

35

26

35

26

35

26

copyright © Liebherr Machines Bulle SA 2021

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LMB/01/19.03.2021/enus

Tab. 48: Metric screw connection series S (heavy), part 2

Operator's manual

Appendix Tightening torques

Pipe diameter X

Thread Y Form A with sealing ring

Form B with sealing edge

Form E with flat (ED) seal

Nm

ft/lb

Nm

ft/lb

Nm

ft/lb

12

G 3/8A

45

33

70

52

70

52

15

G 1/2A

65

48

140

103

90

66

18

G 1/2A

65

48

100

74

90

66

22

G 3/4A

90

66

180

133

180

133

28

G 1A

150

111

330

243

310

229

35

G 1 1/4A

240

177

540

398

450

332

42

G 1 1/2A

290

214

630

465

540

398

Tab. 49: Inch screw connection series S (light) - part 1 Pipe diameter X

Thread Y

WH

TH

SWVE

Nm

ft/lb

Nm

ft/lb

Nm

ft/lb

6

G 1/8A

18

13

18

13

18

13

8

G 1/4A

45

33

45

33

40

30

10

G 1/4A

45

33

45

33

40

30

12

G 3/8A

70

52

70

52

65

48

15

G 1/2A

120

89

120

89

90

66

18

G 1/2A

120

89

120

89

90

66

22

G 3/4A

230

170

230

170

125

92

28

G 1A

320

236

320

236

35

G 1 1/4A

540

398

540

398

42

G 1 1/2A

700

516

700

516

Tab. 50: Inch screw connection series S (light) - part 2

8.1.7 Inch screw connection series S (heavy) (up to 800 bar/11603 Psi)

LMB/01/19.03.2021/enus

Pipe diameter X

Thread Y Form A with sealing ring

Form B with sealing edge

Form E with flat (ED) seal

Nm

ft/lb

Nm

ft/lb

Nm

ft/lb

6

G 1/4A

35

26

55

41

40

30

8

G 1/4A

35

26

55

41

40

30

10

G 3/8A

45

33

90

66

80

59

12

G 3/8A

45

33

90

66

80

59

14

G 1/2A

65

48

150

111

115

85

16

G 1/2A

65

48

130

96

115

85

20

G 3/4A

90

66

270

199

180

133

25

G 1A

150

111

340

251

310

229

30

G 1 1/4A

240

177

540

398

450

332

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Appendix

Operator's manual

Tightening torques

Pipe diameter X 38

Thread Y Form A with sealing ring G 1 1/2A

Form B with sealing edge

Form E with flat (ED) seal

Nm

ft/lb

Nm

ft/lb

Nm

ft/lb

290

214

700

516

540

398

Tab. 51: Inch screw connection series S (heavy) - part 1 Pipe diameter X

Thread Y

WH

TH

SWVE

Nm

ft/lb

Nm

ft/lb

Nm

ft/lb

6

G 1/4A

45

33

45

33

40

30

8

G 1/4A

45

33

45

33

40

30

10

G 3/8A

70

52

70

52

65

48

12

G 3/8A

70

52

70

52

65

48

14

G 1/2A

120

89

120

89

90

66

16

G 1/2A

120

89

120

89

90

66

20

G 3/4A

230

170

230

170

125

92

25

G 1A

320

236

320

236

30

G 1 1/4A

540

398

540

398

38

G 1 1/2A

700

516

700

516

Tab. 52: Inch screw connection series S (heavy) - part 2

8.1.8 Metric thread unit series L (light) (up to 500 bar/7252 Psi) for aluminum Pipe diameter X Thread Y

Form A with sealing ring Nm

ft/lb

15

Form B with sealing edge Nm

ft/lb

Form E with flat (ED) seal Nm

ft/lb

11

12

9

30

22

40

30

M 10 x 1.0

8

M 12 x 1.5

10

M 14 x 1.5

30

22

12

M 16 x 1.5

40

30

15

M 18 x 1.5

18

M 22 x 1.5

80

59

80

59

22

M 26 x 1.5

80

59

150

111

28

M 33 x 2.0

35

M 42 x 2.0

42

M 48 x 2.0

40

30

LMB/01/19.03.2021/enus

6

Tab. 53: Metric thread unit series L (up to 500 bar/7252 Psi) for aluminum Standard torques for cutting ring screw connections

copyright © Liebherr Machines Bulle SA 2021

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Operator's manual

Appendix Tightening torques

Fig. 111: Cutting ring flange connections Series

Pipe diameter X

Standard thread Z

LL

6

M 10 × 1

14

10

L

6

M 12 × 1.5

14

10

8

M 14 × 1.5

20

15

10

M 16 × 1.5

27–30

20 - 22

12

M 18 × 1.5

60

44

15

M 22 × 1.5

105

77

18

M 26 × 1.5

150

111

22

M 30 × 2

200

148

28

M 36 × 2

250

184

35

M 45 × 2

450

332

42

M 52 × 2

600

443

16

M 24 × 1.5

150

111

20

M 30 × 2

250

184

25

M 36 × 2

450

332

30

M 45 × 2

600

443

38

M 52 × 2

750

553

S

Nm

ft/lb

Tab. 54: Standard torques for cutting ring screw connections Note Tighten screw connections with the prescribed tightening torque.

Hold the screw connection in place.

Screw on the box nut up until a clearly noticeable increase in force (without spanner extension).

Tighten the box nut with the above-mentioned tightening torque.

LMB/01/19.03.2021/enus

Standard torques for Triple Lok® screw connections

Fig. 112: Triple lock flange connections

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141

Appendix

Operator's manual

Tightening torques

Series

Pipe diameter X mm

Standard thread Z

inch

Nm

UN/UNF

ft/lb Steel

Nm

ft/lb

Stainless steel

4

6

1/4

7/17-20

15

11

30

22

5

8

5/16

1/2-20

20

15

40

30

6

10

3/8

9/16-18

30

22

60

44

8

12

1/2

3/4-16

60

44

115

85

10

14, 15, 16

5/8

7/8-14

75

55

145

107

12

18, 20

3/4

1 1/16-12

110

81

180

133

16

22

7/8

1 5/16-12

135

100

225

166

25

1

1 5/16-12

175

129

255

188

1 5/8-12

260

192

295

218

1 5/8-12

260

192

295

218

1 7/8-12

340

251

345

254

1 7/8-12

340

251

345

254

2 1/4-12

380

280

400

295

2 1/2-12

450

332

470

347

28 20

30, 32

1 1/4

35 24

38

28

42

32

50

1 1/2

2

Tab. 55: Standard torques for Triple Lok® screw connections Note Screw tight the screw connections with the prescribed tightening torque.

Hold the screw connection in place.

Screw on the box nut up until a clearly noticeable increase in force (without spanner extension).

Tighten the box nut with the above-mentioned tightening torque.

Fig. 113: VSTI screw plugs Standard thread

Nm

ft/lb

Standard thread

Nm

ft/lb

M 10 x 1

10

7

M 26 x 1.5

100

74

M 12 x 1.5

20

15

M 27 x 2

120

89

M 14 x 1.5

30

22

R 3/4”

120

89

M 16 x 1.5

40

30

M 30 x 1.5

120

89

M 18 x 1.5

50

37

M 33 x 2

200

148

copyright © Liebherr Machines Bulle SA 2021

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LMB/01/19.03.2021/enus

Standard torques for VSTI screw plugs

Operator's manual

Appendix Tightening torques

Standard thread

Nm

ft/lb

Standard thread

Nm

ft/lb

M 20 x 1.5

60

44

M 38 x 1.5

280

207

M 22 x 1.5

80

59

M 42 x 2

350

258

M 24 x 1.5

90

66

M 48 x 2

400

295

LMB/01/19.03.2021/enus

Tab. 56: Standard torques for VSTI screw plugs

copyright © Liebherr Machines Bulle SA 2021

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143

Appendix

Operator's manual

LMB/01/19.03.2021/enus

Tightening torques

copyright © Liebherr Machines Bulle SA 2021

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